Infrared detector automatic assembly control method and control system

Abstract

The invention relates to the technical field of automatic assembly control, in particular to an infrared detector automatic assembly control method and system, and the method comprises the steps: designing an assembly production line which is used for completing the assembly and packaging of an infrared detector; a communication protocol is established, communication between the PLC and the equipment and communication between the serial number recording end and the PIR checking machine are achieved, and related information is transmitted to a production line database; defining a target and a state on the basis of an assembly task and database information, and generating an optimal assembly strategy by utilizing dynamic planning through a state transition equation and a boundary condition so as to minimize total production time and maximize a resource utilization rate; and updating the tasks and the information in real time until all the assembly tasks are completed. According to the invention, the maximum resource utilization rate is realized, and the production time is shortened, so that the production efficiency is improved, and the assembly cost is reduced.

Description

Technical Field

[0001] The present invention relates to the technical field of automatic assembly control, in particular to an automatic assembly control method and control system for infrared detectors. Background Art

[0002] In modern industrial production, infrared detectors, due to their unique advantages, are widely used in fields such as security, healthcare, and the military. As market demand continues to rise, the scale of infrared detector production is also expanding, making automated infrared detector assembly lines a key means of improving production efficiency and quality. To ensure efficient and accurate production processes, control systems must be able to guarantee precise operation of each process and ensure smooth transitions between them.

[0003] Currently, automated infrared detector assembly control systems generally utilize traditional decentralized control methods. Each process within the system relies on independent control, resulting in poor coordination between processes and the potential for production line stalls or misaligned process connections. While capable of fulfilling their respective functions, these systems are susceptible to external factors such as environmental changes and equipment failures during the production process, leading to reduced production efficiency and unstable product quality. Furthermore, when abnormalities arise during production, these systems are unable to respond promptly, resulting in production halts and a need for further efficiency improvement.

[0004] Therefore, an automatic assembly control method and control system for infrared detectors are proposed. Summary of the Invention

[0005] The purpose of the present invention is to provide an automatic assembly control method and control system for infrared detectors, which are used to complete the assembly and packaging of infrared detectors by designing an assembly production line; establish a communication protocol to realize communication between PLC and equipment, and between serial number recording terminal and PIR inspection machine, and transmit relevant information to the production line database; define goals and states based on assembly tasks and database information, and use dynamic programming to generate an optimized assembly strategy through state transition equations and boundary conditions to minimize total production time and maximize resource utilization; update tasks and information in real time until all assembly tasks are completed, thereby maximizing resource utilization, shortening production time, and thus improving production efficiency and reducing assembly costs.

[0006] To achieve the above object, the present invention provides the following technical solutions: An automatic assembly control method for an infrared detector, comprising: Step S10: Designing an assembly production line for assembling and packaging infrared detectors to obtain packaged finished products; Step S20: Establishing a communication protocol for the assembly line, the communication protocol including a first communication protocol, a second communication protocol, and a third communication protocol; the first communication protocol is used for communication between the PLC and the assembly machine; the second communication protocol is used for communication between the PLC and the serial number recording terminal; and the third communication protocol is used for communication between the PIR inspection machine and the control machine; and the information content of the communication protocol is transmitted to the production line database; Step S30: Obtaining an assembly task and obtaining the information content from the production line database; defining an assembly goal based on the assembly task and the information content to minimize total production time and maximize resource utilization; defining an assembly state, wherein the assembly state includes a set of completed assembly tasks, a state of the assembly machine model, and a processing state of the assembly task; determining a state transition equation to describe the transition from the current assembly state to the assembly state at the next moment; determining boundary conditions to describe the initial assembly state; and generating an assembly strategy using a dynamic programming method based on the assembly goal, the assembly state, the state transition equation, and the boundary conditions. Step S40: updating the assembly task and the information content. If the assembly task has been completed, the assembly is ended; otherwise, the step S30 is continued.

[0007] Furthermore, the assembly line includes: Starting the assembly machine and loading the assembly task and the assembly strategy; The components output by the board loading machine and the board depaneling machine are subjected to PIR inspection by the PIR inspection machine through a threshold adjustment mechanism, and first inspection information is output; the cover is inspected and second inspection information is output; the control machine receives the first and second inspection information, selects qualified products, and sends them to the assembly machine; the assembly machine performs final assembly inspection, selects qualified products, sends them to the laser machine, and outputs third inspection information, thereby obtaining a finished infrared detector; Packaging materials are provided according to the assembly task, and the finished infrared detector is sensed using a leakage sensing mechanism to obtain the packaged finished product.

[0008] Furthermore, the threshold adjustment mechanism includes: Collecting benchmark test data using the PIR inspection machine, the benchmark test data including current, temperature, and vibration signals; calculating an average value and a standard deviation of the current, temperature, and vibration signals to obtain benchmark data; Acquire historical PIR data, classify the historical PIR data into normal data and abnormal data according to the benchmark data and expert experience, and use the historical PIR data to train a basic model to obtain a trained SVM model; The PIR inspection machine is used to perform the PIR inspection through the SVM model, and the first inspection information is output.

[0009] Furthermore, the assembly machine includes: automatic assembly line operation and manual operation, the automatic assembly line operation includes face cover engraving, face cover inspection, PIR inspection, bottom cover engraving, final assembly inspection, color box feeding, color box engraving and color box inspection; the manual operation includes instruction manual preparation, bracket and accessory component installation, 3C sticker pasting, INCERT sticker pasting, NF certification sticker pasting and outer box sticker printing and pasting.

[0010] Furthermore, the specific process of the first communication protocol includes: The PLC sends communication content to the assembly machine model according to the assembly task; the communication content includes the order number, machine model number, LOT number, production quantity, spare bytes and terminator; The assembly machine executes the task according to the communication content and returns the execution result to the PLC; if the execution result is consistent with the assembly task, the execution is successful; otherwise, the execution fails and an error reminder is given.

[0011] Furthermore, the second communication protocol specifically includes: The PLC sends communication content to the serial number recording terminal according to the assembly task and requests to obtain the serial number; if the PLC does not receive the serial number within N seconds, it issues a timeout alarm; The PLC receives the execution result of the assembly machine during the production process and feeds it back to the serial number recording terminal; if the execution result is consistent with the assembly task, the execution is successful, and the serial number recording terminal increments the serial number corresponding to the assembly task by 1; otherwise, the serial number remains unchanged; If the assembly machine model corresponding to the assembly task does not exist in the serial number recording end, a new assembly task is created and the serial number is initialized to 1.

[0012] Furthermore, the third communication protocol specifically includes: The control machine sends a start signal to the PIR inspection machine; after receiving the start signal, the PIR inspection machine performs PIR inspection through a threshold adjustment mechanism, outputs first inspection information and feeds it back to the control machine.

[0013] Furthermore, the state transfer equation is expressed as: ; ; ; in, is the assembly state at the next moment, is the set of completed assembly tasks at the next moment, is the set of completed assembly tasks currently described, For the current assembly task, The assembly machine model that will execute the assembly task at the next moment, is the time step of the next moment, is the current time step, For the current assembly task on the assembly machine The processing time on is the serial number of the assembly task, is the serial number of the assembled model, is the union symbol; Among them, if If the execution fails, ,and .

[0014] The second part is an automatic assembly control system for infrared detectors, including: An assembly line design module is used to assemble and package infrared detectors to obtain packaged finished products; A communication protocol establishment module, wherein the communication protocols include a first communication protocol, a second communication protocol, and a third communication protocol; the first communication protocol is used for communication between the PLC and the assembly machine; the second communication protocol is used for communication between the PLC and the serial number recording terminal; and the third communication protocol is used for communication between the PIR inspection machine and the control machine; and information content of the communication protocols is transmitted to the production line database; An assembly strategy generation module is configured to obtain assembly tasks and the information content from the production line database; define assembly goals based on the assembly tasks and the information content to minimize total production time and maximize resource utilization; define assembly states, which include a set of completed assembly tasks, the state of the assembly machine model, and the processing state of the assembly tasks; determine a state transition equation to describe the transition from the current assembly state to the assembly state at the next moment; determine boundary conditions to describe the initial assembly state; and generate an assembly strategy using a dynamic programming method based on the assembly goals, the assembly state, the state transition equation, and the boundary conditions. The assembly task updating module is used to update the assembly task and the information content.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The present invention designs an infrared detector assembly production line that covers key steps such as assembly, testing, and packaging, achieving effective integration of the control steps of each process. Specifically, in the PIR detection process, the accuracy and efficiency of detection are improved by collecting benchmark test data and combining it with the SVM model for precise analysis. In the packaging process, a leak detection mechanism is used to improve the integrity of the packaging process. In addition, an assembly machine is designed into the production line, combining the advantages of automated equipment and manual operations to achieve efficient assembly and packaging of infrared detectors. The present invention not only increases production speed but also effectively ensures product consistency and quality, thereby improving the assembly efficiency and production reliability of infrared detectors.

[0016] This invention establishes three communication protocols. The first is used for task issuance and execution result feedback, ensuring accurate transmission of task instructions and timely response. The second is responsible for the generation and updating of serial numbers, ensuring that each batch of products has a unique identifier, improving traceability and management efficiency. The third is used to initiate inspection tasks and feedback inspection information. Combined with a threshold adjustment mechanism, it accurately screens qualified products, improving the accuracy and reliability of quality control. By implementing multiple layers of communication protocols, this invention enhances coordination between devices and the accuracy of information transmission, avoids production problems caused by data delays or errors, and improves the overall stability and production efficiency of the system.

[0017] The present invention defines assembly goals, aiming to minimize total production time and maximize resource utilization, thereby optimizing the overall efficiency of the assembly process. By defining the assembly state, the production progress and assembly machine status are reflected in real time, providing real-time data support for decision-making. The state transition equation describes task allocation, time advancement, and execution result feedback, ensuring the continuity of the production process. The setting of boundary conditions ensures the accuracy and rationality of the initial state. Finally, the dynamic programming method is used to adjust the assembly strategy, especially when the assembly machine fails or the task changes, to achieve optimal resource allocation and efficiency maximization, thereby improving the assembly efficiency and production reliability of the infrared detector. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1 The present invention provides a flow chart of an automatic assembly control method for infrared detectors; Figure 2 A flow chart of a threshold adjustment mechanism is provided for the present invention; Figure 3 The present invention provides a structural schematic diagram of an automatic assembly control system for infrared detectors; Figure 4 A schematic diagram of a production line database is provided for the present invention; Figure 5 A schematic diagram of a serial number recording terminal is provided for the present invention. DETAILED DESCRIPTION

[0019] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making creative efforts are within the scope of protection of the present invention.

[0020] See also Figures 1 to 5 The present invention provides an infrared detector automatic assembly control method and control system, the technical solution is as follows: As market demand continues to rise, a certain company, a veteran in the R&D and production of infrared detectors, has steadily expanded its production scale. However, under the traditional assembly model, due to the increasing complexity of production tasks, involving numerous processes, and each process having different requirements for time, space, equipment, etc., the traditional production management model is difficult to flexibly adapt to complex and changing production needs. The company uses an automated assembly control method for infrared detectors to improve the efficiency of infrared detector assembly control. Example 1 is as follows: Figure 1 The present invention provides a flow chart of an automatic assembly control method for infrared detectors.

[0021] like Figure 1 As shown, a method for controlling the automatic assembly of an infrared detector includes: An automatic assembly control method for an infrared detector, comprising: refer to Figure 1 Step S10: designing an assembly production line for assembling and packaging infrared detectors to obtain packaged finished products.

[0022] Furthermore, the assembly line includes: Start the assembly machine and load the assembly tasks and assembly strategies; The passive infrared (PIR) inspection machine performs PIR inspection on the components output by the board loader and the board separator using a threshold adjustment mechanism, outputting first inspection information. The cover is inspected and second inspection information is output. The control machine receives the first and second inspection information, selects qualified products, and sends them to the assembly machine. The assembly machine performs final assembly inspection, selects qualified products, sends them to the laser machine, and outputs third inspection information, thereby obtaining the finished infrared detector. Packaging materials are provided according to the assembly task, and the infrared detector product is sensed using a leakage sensing mechanism to obtain the packaged product.

[0023] Specifically, when the production line starts up, the appropriate assembly strategy is automatically selected based on the requirements of each assembly machine type. For example, assembly machine type 01 executes production lot (LOT) 01, ensuring a smooth and efficient production process. When the components output by the loader and depaneler are completed and ready to enter the next process, the PIR inspection machine uses a threshold adjustment mechanism to perform infrared inspection on the components, outputting primary inspection information, including whether the components are qualified or unqualified. The cover operator welds the cover, and a laser machine engraves the cover. During the cover production process, automated inspection equipment inspects each cover to ensure there are no defects. After inspection, the system outputs secondary inspection information, including whether the cover is qualified or unqualified. Insect repellent sponge is applied to qualified cover, and the inspection results are recorded and transmitted to the control machine (turntable / robot A). The control machine receives and processes the primary and secondary inspection information from the PIR inspection machine and the cover inspection machine, automatically screening out qualified products that meet quality standards and determining which of these products will be sent to the assembly machine (turntable / robot B). The assembly machine further inspects the components, screens qualified products, and outputs third-inspection information, including qualified and unqualified detectors. Qualified products are then sent to the laser machine for bottom cover engraving, and the finished infrared detectors are ready for packaging.

[0024] The packaging machine automatically selects and provides the appropriate packaging materials, and a laser machine engraves the boxes. After engraving, the boxes undergo an AOI-3 color box inspection process, using high-precision optical scanning technology to inspect the surface of the boxes for scratches, stains, misprints, and poor barcode scanning. For some packaging materials, the packaging machine performs a color box stretching operation, stretching the flat box material through automated equipment to ensure that the shape and size of the box meet production requirements. Finally, operators package the finished infrared detectors in boxes. During the packaging process, a missing detection mechanism monitors the finished infrared detectors. This mechanism ensures that each product is correctly packaged. If a product is not packaged correctly or if any packaging material (such as the instruction manual) is missing, an alarm will be automatically issued.

[0025] By implementing an automated assembly line, we successfully integrated task scheduling, equipment coordination, quality inspection, and packaging. This effectively ensured a smooth transition between production processes and avoided equipment overload or idleness. Furthermore, automated assembly control reduced rework, thereby improving production efficiency and product quality.

[0026] Furthermore, the threshold adjustment mechanism includes: Collecting benchmark test data using the PIR inspection machine, the benchmark test data including current, temperature, and vibration signals; calculating an average value and a standard deviation of the current, temperature, and vibration signals to obtain benchmark data; Acquire historical PIR data, classify the historical PIR data into normal data and abnormal data according to the benchmark data and expert experience, and use the historical PIR data to train a basic model to obtain a trained SVM model; The PIR inspection machine is used to perform the PIR inspection through the SVM model, and the first inspection information is output.

[0027] Figure 2 A flow chart of a threshold adjustment mechanism is provided for the present invention.

[0028] Specifically, if Figure 2 As shown, the reference device provides a known standard signal, such as the value of infrared radiation at a specific temperature. First, a PIR inspection machine collects current, temperature, and vibration signals through the reference device. For each test result, the standard deviation of the sensor output is calculated. The product's output signal should be within ±30% of the mean value and ±5% of the standard deviation. Historical PIR data includes historical current, temperature, and vibration signals. Based on expert experience and calculation results, this historical PIR data is finely divided into normal and abnormal data. This data is then used to train a support vector machine (SVM) model. The SVM model can accurately determine whether the current PIR inspection is normal based on factors such as current, temperature, and vibration signals, and then adjust the PIR inspection threshold, achieving more precise quality control.

[0029] Comparing the threshold adjustment mechanism with the traditional method (fixed threshold), the threshold adjustment mechanism achieved a false detection rate of 2%, a missed detection rate of 3%, and an overall accuracy of 95%. The traditional method achieved a false detection rate of 5%, a missed detection rate of 8%, and an overall accuracy of 87%. This comparison of test data shows that by using the SVM model to dynamically adjust the PIR inspection threshold and combining PIR current, temperature, and vibration signals, the quality control accuracy and intelligence level of infrared detector assembly are improved. Furthermore, by combining historical and real-time data, environmental changes and equipment status can be determined, thereby improving production efficiency and product quality.

[0030] Furthermore, the assembly machine includes: automatic assembly line operation and manual operation, the automatic assembly line operation includes face cover engraving, face cover inspection, PIR inspection, bottom cover engraving, final assembly inspection, color box feeding, color box engraving and color box inspection; the manual operation includes instruction manual preparation, bracket and accessory component installation, 3C sticker pasting, INCERT sticker pasting, NF certification sticker pasting and outer box sticker printing and pasting.

[0031] Specifically, the assembly machine types are shown in Tables 1 and 2, which illustrate the specific settings for automatic assembly line operations and manual operations, respectively. "O" indicates that this operation is available, and "X" indicates that this operation is not available. In this embodiment, expansion space is reserved for 20 assembly machine types, meaning that the production line can be flexibly adjusted to support the production needs of different machine types.

[0032] Table 1 Example of automatic assembly line operation for assembly machines

[0033] Table 2 Manual work examples for assembly models

[0034] Automated operations ensure high precision and efficiency, while manual operations guarantee production flexibility and adaptability. Combining automatic assembly line operations with manual operations not only optimizes production efficiency, product quality and resource utilization, but also improves the overall performance of the production line, enabling the production line to respond quickly to market changes, further improving production efficiency and product quality.

[0035] refer to Figure 1 Step S20: Establish a communication protocol for the assembly line, the communication protocol including a first communication protocol, a second communication protocol and a third communication protocol; the first communication protocol is used for communication between the PLC and the assembly machine; the second communication protocol is used for communication between the PLC and the serial number recording end; the third communication protocol is used for communication between the PIR inspection machine and the control machine; and the information content of the communication protocol is transmitted to the production line database.

[0036] Furthermore, the specific process of the first communication protocol includes: The PLC sends communication content to the assembly machine model according to the assembly task; the communication content includes the order number, machine model number, LOT number, production quantity, spare bytes and terminator; The assembly machine executes the task according to the communication content and returns the execution result to the PLC; if the execution result is consistent with the assembly task, the execution is successful; otherwise, the execution fails and an error reminder is given.

[0037] Specifically, in this embodiment, a wireless protocol is used to communicate between the PLC and the assembly machine. The PLC sends received assembly tasks to each device within the assembly machine. Communication content, such as 111555666, 19178, 200, 0000, CR, and LF, represent the order number, machine model number, LOT number, production quantity, spare byte, and terminator, respectively. After receiving the assembly task, each device successfully responds by returning the original message.

[0038] When switching assembly models, the PLC sends data twice to each device in the assembly model: the first is the communication content, and the second is the execution result code. The second data is sent within 4 seconds of the first transmission. If the execution result code is not received within 4 seconds, the main PLC should report an error.

[0039] The execution result code is shown in Table 3. By establishing the first communication protocol for the infrared detector assembly line, we achieved full-process management of automated task scheduling, quality control, and production information traceability. This not only significantly improved production efficiency but also enhanced the accuracy of assembly tasks and the coordination between equipment. Furthermore, the system can quickly locate and resolve problems that arise during the production process, ensuring efficient collaboration and real-time data feedback at every stage of the production process, thereby improving production efficiency and product quality.

[0040] Table 3 Execution result code example

[0041] Furthermore, the second communication protocol specifically includes: The PLC sends communication content to the serial number recording terminal according to the assembly task and requests to obtain the serial number; if the PLC does not receive the serial number within N seconds, it issues a timeout alarm; The PLC receives the execution result of the assembly machine during the production process and feeds it back to the serial number recording terminal; if the execution result is consistent with the assembly task, the execution is successful, and the serial number recording terminal increments the serial number corresponding to the assembly task by 1; otherwise, the serial number remains unchanged; If the assembly machine model corresponding to the assembly task does not exist in the serial number recording end, a new assembly task is created and the serial number is initialized to 1.

[0042] Specifically, the PLC and the serial number recorder use the TPC protocol. Each time an assembly task is scanned, the PLC sends a communication message to the serial number recorder. Upon receiving the message, the serial number recorder returns the same message to the PLC. The PLC then requests the corresponding serial number. If the corresponding task exists, the serial number recorder returns the serial number. If the task does not exist, or when switching assembly machine models, a new task is created, the serial number is initialized to 1, and returned to the PLC. If the PLC fails to receive the serial number from the serial number recorder within the specified time, a timeout alarm is triggered. During the production process, the PLC sends feedback on the task execution results to the serial number recorder. If production is confirmed to be complete, the task is considered successful, and the serial number is incremented by 1. If production fails, the serial number remains unchanged. The serial number recorder records task information and serial number status through file management, ensuring traceability of production data. Table 4 shows the initial production record obtained, where the LOT number is the production batch number corresponding to the order number. After organizing this production record, the final production record is shown in Table 5.

[0043] Through the second communication protocol, full automation of serial number generation, serial number update and task linkage is achieved, ensuring the uniqueness of product identification during the production process, improving the flexibility and stability of production tasks, and simplifying the management process, thereby improving the efficiency and reliability of the infrared detector production line.

[0044] Table 4 Example of initial production records

[0045] Table 5 Example of final production record

[0046] Furthermore, the third communication protocol specifically includes: The control machine sends a start signal to the PIR inspection machine; after receiving the start signal, the PIR inspection machine performs PIR inspection through a threshold adjustment mechanism, outputs first inspection information and feeds it back to the control machine.

[0047] Specifically, suppose the control machine sends a start signal to the PIR inspection machine, requesting PIR inspection of 10 components. The PIR inspection machine detects them one by one according to the threshold adjustment mechanism and finds that 8 are qualified and 2 are unqualified. The first inspection information is fed back to the control machine, and the control machine sends the 8 qualified products to the assembly machine, while marking the 2 unqualified products and transferring them to the rework area.

[0048] By implementing the third communication protocol, the automated start-up, real-time feedback, and quality control of PIR detection in the production line are achieved, ensuring the efficiency and reliability of the detection work, thereby improving the efficiency and reliability of the infrared detector production line.

[0049] refer to Figure 1 Step S30: obtain the assembly task and obtain the information content from the production line database; define the assembly goal based on the assembly task and the information content to minimize the total production time and maximize resource utilization; define the assembly state, the assembly state includes a set of completed assembly tasks, the state of the assembly machine model and the processing state of the assembly task; determine the state transition equation to describe the transfer of the current assembly state to the assembly state at the next moment; determine the boundary conditions to describe the initial assembly state; generate the assembly strategy using the dynamic programming method based on the assembly goal, the assembly state, the state transition equation and the boundary conditions.

[0050] Among them, minimizing the total production time can be expressed as: ; in, is the minimization function, is the total completion time of the assembly task, It is an assembly task The end time, It is an assembly task The start time, is the total number of assembly tasks.

[0051] Maximizing resource utilization can be expressed as: ; in, is the maximization function, is the total utilization rate of the assembled machines, It is an assembled model The actual processing time, It is an assembled model Available time, is the total number of assembled models, The serial number of the assembled model.

[0052] The assembly target is obtained by adding the minimization of total production time and the maximization of resource utilization. The status of the assembly machine indicates whether the assembly machine is busy, idle, or faulty, and the processing status of the assembly task indicates whether the assembly task is successfully processed, failed, or not processed.

[0053] In the boundary conditions, the initial assembly state can be represented as follows: the set of completed assembly tasks is empty, the status of all assembly machines is idle, and the processing status of all assembly tasks is unprocessed. Furthermore, the final assembly state can also be represented as follows: the set of completed assembly tasks is all assembly tasks, the status of all assembly machines is idle, and the processing status of all assembly tasks indicates that the assembly tasks have been successfully processed.

[0054] Furthermore, the state transfer equation is expressed as: ; ; ; in, is the assembly state at the next moment, is the set of completed assembly tasks at the next moment, is the set of completed assembly tasks currently described, For the current assembly task, The assembly machine model that will execute the assembly task at the next moment, is the time step of the next moment, is the current time step, For the current assembly task on the assembly machine The processing time on is the serial number of the assembly task, is the serial number of the assembled model, is the union symbol; Among them, if If the execution fails, ,and .

[0055] Specifically, the dynamic programming method supports efficient multi-task allocation and can adapt to changes in assembly tasks and equipment failures in assembly machines, enabling the production line to achieve optimal allocation and efficient execution of assembly tasks. Especially when tasks change or equipment fails, it ensures the continuity and flexibility of the production plan, thereby improving the assembly efficiency and production reliability of infrared detectors.

[0056] refer to Figure 1 In step S40 , the assembly task and the information content are updated. If the assembly task has been completed, the assembly is ended; otherwise, the step S30 is continued.

[0057] In short, through the design of the assembly production line, the execution order of the assembly tasks can be optimized, thereby significantly shortening the total production time and improving overall production efficiency. At the same time, the introduction of the first, second, and third communication protocols realizes the efficient transmission and real-time updating of information content, which not only realizes the full monitoring and data sharing of the production process, but also improves the efficiency of information flow and the accuracy of data management. In addition, by clarifying the assembly goals and assembly states, and combining the state transition equations and boundary conditions, the use of dynamic programming methods can achieve reasonable allocation and efficient scheduling of resources, effectively avoiding waste of resources. Finally, the dynamic programming method can flexibly adjust the assembly strategy based on the real-time updated assembly tasks and information content, so that it can calmly cope with changes in different assembly tasks. The present invention has demonstrated advantages in improving production efficiency, reducing production costs, and ensuring product quality, providing strong support for the sustainable development of enterprises.

[0058] The second embodiment is as follows: Figure 3 The present invention provides a structural schematic diagram of an automatic assembly control system for infrared detectors.

[0059] Based on the first embodiment, Figure 3 As shown, this embodiment further proposes an infrared detector automatic assembly control system, including: refer to Figure 3 The assembly line design module in the package is used to assemble and package infrared detectors to obtain packaged finished products; refer to Figure 3 The communication protocol establishment module includes a first communication protocol, a second communication protocol, and a third communication protocol; the first communication protocol is used for communication between the PLC and the assembly machine; the second communication protocol is used for communication between the PLC and the serial number recording terminal; and the third communication protocol is used for communication between the PIR inspection machine and the control machine; and the information content of the communication protocol is transmitted to the production line database; Among them, the TCP protocol is used between PLC and production line database. The production line database is as follows: Figure 4 The interface displays the communication details, data update status, and prompts. After scanning a production task, the production line database retrieves the production information and sends it to the assembly line. The assembly line then provides feedback upon completing the task. Additionally, a prompt appears on the interface indicating that the production data update failed, possibly due to incomplete production information or communication anomalies.

[0060] In addition, for the serial number recording end in the second communication protocol, such as Figure 5As shown, it provides file, operation, help and other functional options for managing and configuring serial numbers. When the current assembly model is opened, the serial number corresponding to the assembly model and LOT is read. When the assembly production line applies for the serial number, the serial number recording end will transmit the serial number corresponding to the current serial number. If the production result is successful, the serial number will be increased by 1; if it is a failure, the serial number remains unchanged. In addition, Figure 5 The current communication content is also displayed, including the current machine model, serial number information, communication status, and serial number communication history. Regarding the serial number communication history, suppose a production line requests a serial number, and the system returns the current serial number as 1897. The production result is successful, and the serial number increases by 1. The serial number increment process is clearly visible, from 1897 to 1898.

[0061] refer to Figure 3 The assembly strategy generation module in the production line is used to obtain assembly tasks and obtain the information content from the production line database; define assembly goals based on the assembly tasks and the information content to minimize total production time and maximize resource utilization; define assembly states, which include a set of completed assembly tasks, the state of the assembly machine model, and the processing state of the assembly tasks; determine a state transition equation to describe the transition from the current assembly state to the assembly state at the next moment; determine boundary conditions to describe the initial assembly state; and generate an assembly strategy using a dynamic programming method based on the assembly goals, the assembly state, the state transition equation, and the boundary conditions. refer to Figure 3 The assembly task update module in is used to update the assembly task and the information content.

[0062] Specifically, the total delay between task issuance and feedback from production line equipment is only 200ms. If a task fails, the assembly machine returns a detailed error code, helping to quickly identify and resolve the issue and reduce downtime. Furthermore, the communication protocol supports flexible configuration of parameters such as production quantity and machine model number to accommodate different order requirements. For example, if a batch task requires the production quantity to be adjusted from 200 to 150, the task plan can be quickly adjusted by modifying the communication content. This real-time feedback and task confirmation mechanism reduces production intervals and improves production efficiency by 9% compared to one company's traditional methods.

[0063] While embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that various changes, modifications, substitutions, and variations may be made to these embodiments without departing from the principles and spirit of the invention, and that the scope of the invention is defined by the appended claims and their equivalents.

Claims

1. A method for controlling the automatic assembly of an infrared detector, characterized in that: include: Step S10: Designing an assembly production line for assembling and packaging infrared detectors to obtain packaged finished products; Step S20: Establishing a communication protocol for the assembly line, the communication protocol including a first communication protocol, a second communication protocol, and a third communication protocol; the first communication protocol is used for communication between the PLC and the assembly machine; the second communication protocol is used for communication between the PLC and the serial number recording terminal; and the third communication protocol is used for communication between the PIR inspection machine and the control machine; and the information content of the communication protocol is transmitted to the production line database; Step S30: Obtaining an assembly task and obtaining the information content from the production line database; defining an assembly target based on the assembly task and the information content to minimize total production time and maximize resource utilization; Defining an assembly status, wherein the assembly status includes a set of completed assembly tasks, a status of the assembly machine model, and a processing status of the assembly task; Determine a state transition equation for describing the transition from the current assembly state to the assembly state at the next moment; determining boundary conditions for describing the initial assembly state; generating an assembly strategy using a dynamic programming method according to the assembly goal, the assembly state, the state transition equation, and the boundary conditions; Step S40: updating the assembly task and the information content. If the assembly task has been completed, the assembly is ended; otherwise, the step S30 is continued.

2. The infrared detector automatic assembly control method according to claim 1, characterized in that: The assembly line comprises: Starting the assembly machine and loading the assembly task and the assembly strategy; The components output by the board loading machine and the board depaneling machine are subjected to PIR inspection by the PIR inspection machine through a threshold adjustment mechanism, and first inspection information is output; the cover is inspected and second inspection information is output; the control machine receives the first and second inspection information, selects qualified products, and sends them to the assembly machine; the assembly machine performs final assembly inspection, selects qualified products, sends them to the laser machine, and outputs third inspection information, thereby obtaining a finished infrared detector; Packaging materials are provided according to the assembly task, and the finished infrared detector is sensed using a leakage sensing mechanism to obtain the packaged finished product.

3. The infrared detector automatic assembly control method according to claim 2, characterized in that: The threshold adjustment mechanism includes: Collecting benchmark test data using the PIR inspection machine, the benchmark test data including current, temperature, and vibration signals; calculating an average value and a standard deviation of the current, temperature, and vibration signals to obtain benchmark data; Acquire historical PIR data, classify the historical PIR data into normal data and abnormal data according to the benchmark data and expert experience, and use the historical PIR data to train a basic model to obtain a trained SVM model; The PIR inspection machine is used to perform the PIR inspection through the SVM model, and the first inspection information is output.

4. The infrared detector automatic assembly control method according to claim 2, characterized in that: The assembly machine includes: automatic assembly line operation and manual operation. The automatic assembly line operation includes face cover engraving, face cover inspection, PIR inspection, bottom cover engraving, final assembly inspection, color box feeding, color box engraving and color box inspection; the manual operation includes instruction manual preparation, bracket and accessory component installation, 3C sticker pasting, INCERT sticker pasting, NF certification sticker pasting and outer box sticker printing and pasting.

5. The infrared detector automatic assembly control method according to claim 1, characterized in that: The specific process of the first communication protocol includes: The PLC sends communication content to the assembly machine model according to the assembly task; the communication content includes the order number, machine model number, LOT number, production quantity, spare bytes and terminator; The assembly machine executes the task according to the communication content and returns the execution result to the PLC; if the execution result is consistent with the assembly task, the execution is successful; otherwise, the execution fails and an error reminder is given.

6. The infrared detector automatic assembly control method according to claim 1, characterized in that: The second communication protocol specifically includes: The PLC sends communication content to the serial number recording terminal according to the assembly task and requests to obtain the serial number; if the PLC does not receive the serial number within N seconds, it issues a timeout alarm; The PLC receives the execution result of the assembly machine during the production process and feeds it back to the serial number recording terminal; if the execution result is consistent with the assembly task, the execution is successful, and the serial number recording terminal increments the serial number corresponding to the assembly task by 1; otherwise, the serial number remains unchanged; If the assembly machine model corresponding to the assembly task does not exist in the serial number recording end, a new assembly task is created and the serial number is initialized to 1.

7. The infrared detector automatic assembly control method according to claim 1, characterized in that: The third communication protocol specifically includes: The control machine sends a start signal to the PIR inspection machine; after receiving the start signal, the PIR inspection machine performs PIR inspection through a threshold adjustment mechanism, outputs first inspection information and feeds it back to the control machine.

8. The infrared detector automatic assembly control method according to claim 1, characterized in that: The state transfer equation is expressed as: ； ； ； in, is the assembly state at the next moment, is the set of completed assembly tasks at the next moment, is the set of completed assembly tasks currently described, For the current assembly task, The assembly machine model that will execute the assembly task at the next moment, is the time step of the next moment, is the current time step, For the current assembly task on the assembly machine The processing time on is the serial number of the assembly task, is the serial number of the assembled model, is the union symbol; Among them, if If the execution fails, ,and .

9. An automatic assembly control system for infrared detectors, characterized in that: include: An assembly line design module is used to assemble and package infrared detectors to obtain packaged finished products; A communication protocol establishment module, wherein the communication protocols include a first communication protocol, a second communication protocol, and a third communication protocol; the first communication protocol is used for communication between the PLC and the assembly machine; the second communication protocol is used for communication between the PLC and the serial number recording terminal; and the third communication protocol is used for communication between the PIR inspection machine and the control machine; and information content of the communication protocols is transmitted to the production line database; An assembly strategy generation module is configured to obtain assembly tasks and the information content from the production line database; define assembly goals based on the assembly tasks and the information content to minimize total production time and maximize resource utilization; Defining an assembly status, wherein the assembly status includes a set of completed assembly tasks, a status of the assembly machine model, and a processing status of the assembly task; Determine a state transition equation for describing the transition from the current assembly state to the assembly state at the next moment; Determining boundary conditions for describing the initial assembly state; generating an assembly strategy using a dynamic programming method according to the assembly goal, the assembly state, the state transition equation, and the boundary conditions; The assembly task updating module is used to update the assembly task and the information content.

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