Infrared detector automatic assembly control method and control system

Abstract

This invention relates to the field of automated assembly control technology, specifically to an automated assembly control method and system for infrared detectors. The method includes: designing an assembly production line for assembling and packaging infrared detectors; establishing a communication protocol to enable communication between the PLC and equipment, and between the serial number recording terminal and the PIR inspection machine, and transmitting relevant information to the production line database; defining objectives and states based on assembly tasks and database information, and generating an optimized assembly strategy using dynamic programming through state transition equations and boundary conditions to minimize total production time and maximize resource utilization; and updating tasks and information in real time until all assembly tasks are completed. This invention maximizes resource utilization, shortens production time, thereby improving production efficiency and reducing assembly costs.

Description

Technical Field

[0001] This invention relates to the field of automatic assembly control technology, specifically to an automated assembly control method and control system for infrared detectors. Background Technology

[0002] In modern industrial production, infrared detectors, with their unique advantages, have been widely used in many fields such as security, medical care, and military. With the continuous increase in market demand, the production scale of infrared detectors is also constantly expanding, making automated assembly lines for infrared detectors a key means to improve production efficiency and quality. To ensure the high efficiency and precision of the production process, the control system must be able to guarantee the precise operation of each process and achieve smooth transitions between them.

[0003] Currently, automated assembly control systems for infrared detectors generally employ traditional distributed control methods. Each process within the system relies on independent control, leading to poor coordination between processes and potential production line halts or improper process connections. While capable of fulfilling their individual functions, these systems are susceptible to external factors such as environmental changes and equipment malfunctions during production, resulting in reduced production efficiency or unstable product quality. Furthermore, these systems cannot respond promptly to abnormal situations during production, causing production stoppages and highlighting the need for further improvements in production efficiency.

[0004] To address this, an automated assembly control method and control system for infrared detectors are proposed. Summary of the Invention

[0005] The purpose of this invention is to provide an automated assembly control method and control system for infrared detectors. This system involves designing an assembly production line to complete the assembly and packaging of infrared detectors; establishing a communication protocol to enable communication between the PLC and the equipment, and between the serial number recording terminal and the PIR inspection machine, and transmitting relevant information to the production line database; defining objectives and states based on assembly tasks and database information; and using dynamic programming to generate an optimized assembly strategy through state transition equations and boundary conditions to minimize total production time and maximize resource utilization; and updating tasks and information in real time until all assembly tasks are completed, thereby maximizing resource utilization, shortening production time, improving production efficiency, and reducing assembly costs.

[0006] To achieve the above objectives, the present invention provides the following technical solution:

[0007] An automated assembly control method for an infrared detector includes:

[0008] Step S10: Design an assembly line for assembling and packaging infrared detectors to obtain packaged finished products;

[0009] 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 terminal; the third communication protocol is used for communication between the PIR inspection machine and the control machine; transmit the information content of the communication protocol to the production line database;

[0010] Step S30: Obtain assembly tasks and retrieve the information content from the production line database; define an assembly objective based on the assembly tasks and the information content to minimize total production time and maximize resource utilization; define an assembly state, which includes the set of completed assembly tasks, the state of the assembly machine type, 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 dynamic programming based on the assembly objective, the assembly state, the state transition equation, and the boundary conditions.

[0011] Step S40: Update the assembly task and the information content. If the assembly task has been completed, end the assembly; otherwise, continue with step S30.

[0012] Furthermore, the assembly line includes:

[0013] Start the assembly machine and load the assembly task and the assembly strategy;

[0014] The PIR inspection machine is used to perform PIR inspection on the components output by the board mounting machine and the board splitting machine through a threshold adjustment mechanism, and outputs the first inspection information; the face cover is inspected and the second inspection information is output; the control machine receives the first inspection information and the second inspection information, screens qualified products and sends them to the assembly machine; the assembly machine performs the final assembly inspection, screens the qualified products and sends them to the laser machine, and outputs the third inspection information to obtain the finished infrared detector;

[0015] Packaging materials are provided according to the assembly task, and the finished product of the infrared detector is sensed using a leak detection mechanism to obtain the packaged finished product.

[0016] Furthermore, the threshold adjustment mechanism includes:

[0017] The PIR inspection machine is used to collect reference test data, which includes current, temperature, and vibration signals; the average value and standard deviation of the current, temperature, and vibration signals are calculated to obtain reference data;

[0018] Acquire historical PIR data, classify the historical PIR data into normal data and abnormal data based on the benchmark data and expert experience, and use the historical PIR data to train the base model to obtain the trained SVM model.

[0019] The PIR inspection machine is used to perform the PIR inspection through the SVM model, and the first inspection information is output.

[0020] Furthermore, the assembly equipment includes: automatic assembly line operation and manual operation. The automatic assembly line operation includes front cover engraving, front 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 affixing, INCERT sticker affixing, NF certification sticker affixing, and outer box sticker printing and affixing.

[0021] Furthermore, the specific process of the first communication protocol includes:

[0022] The PLC sends communication content to the assembly machine according to the assembly task; the communication content includes order number, machine model number, LOT number, production quantity, spare bytes, and end character;

[0023] 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 message is displayed.

[0024] Furthermore, the second communication protocol specifically includes:

[0025] The PLC sends communication content to the serial number record 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.

[0026] During the production process, the PLC receives the execution result of the assembly model 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.

[0027] If the assembly type corresponding to the assembly task does not exist in the serial number record terminal, then the assembly task is created and the serial number is initialized to 1.

[0028] Furthermore, the third communication protocol specifically includes:

[0029] The controller sends a start signal to the PIR inspection machine; after receiving the start signal, the PIR inspection machine performs a PIR inspection through a threshold adjustment mechanism, outputs first inspection information, and feeds it back to the controller.

[0030] Furthermore, the state transition equation is expressed as:

[0031] ;

[0032] ;

[0033] ;

[0034] in, This refers to the assembly state at the next moment. The set of completed assembly tasks for the next time step. This refers to the set of assembly tasks that have been completed so far. For the current assembly task, The assembly machine type to perform the assembly task at the next moment. For the next time step, For the current time step, For the current assembly task in the assembly machine type On the processing time, This is the sequence number of the assembly task. The serial number of the assembled machine model. The union symbol;

[0035] Among them, if If execution fails, then ,and .

[0036] The second part, an automated assembly and control system for an infrared detector, includes:

[0037] Assembly line design module, used to assemble and package infrared detectors to obtain packaged finished products;

[0038] A communication protocol establishment module, comprising 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; the third communication protocol is used for communication between the PIR inspection machine and the control machine; and the information content of the communication protocols is transmitted to the production line database;

[0039] An assembly strategy generation module is used to acquire assembly tasks and obtain information from the production line database; define an assembly objective based on the assembly tasks and the information, which minimizes total production time and maximizes resource utilization; define an assembly state, which includes the set of completed assembly tasks, the state of the assembly machine type, 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 objective, the assembly state, the state transition equation, and the boundary conditions.

[0040] The assembly task update module is used to update the assembly task and the information content.

[0041] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0042] This invention designs an infrared detector assembly production line, covering key steps such as assembly, testing, and packaging, and effectively connects the control steps of each process. In the PIR testing stage, the accuracy and efficiency of testing are improved by collecting reference test data and combining it with an SVM model for precise analysis. In the packaging stage, a missed-pick sensing mechanism is used to improve the integrity of the packaging process. Furthermore, an assembly machine is designed into the production line, integrating the advantages of automated equipment and manual operation, achieving efficient assembly and packaging of infrared detectors. This 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.

[0043] This invention constructs three communication protocols. The first protocol is used for task issuance and execution result feedback, ensuring accurate transmission and timely response of task instructions. The second protocol 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 protocol is used to initiate inspection tasks and provide inspection information feedback. Combined with a threshold adjustment mechanism, it accurately screens qualified products, improving the precision and reliability of quality control. Through the implementation of multi-layered communication protocols, this invention enhances the coordination between devices and the accuracy of information transmission, avoiding production problems caused by data delays or errors, and improving the overall stability and production efficiency of the system.

[0044] This invention defines an assembly objective aimed at minimizing total production time and maximizing resource utilization, thereby optimizing the overall efficiency of the assembly process. By defining assembly states, the production progress and the status of the assembled machine are reflected in real time, providing real-time data support for decision-making. State transition equations describe task allocation, time progression, 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, a dynamic programming method is used to adjust the assembly strategy, especially in the event of machine failure or task changes, achieving optimal resource allocation and maximizing efficiency, thus improving the assembly efficiency and production reliability of infrared detectors. Attached Figure Description

[0045] Figure 1 This invention provides a flowchart illustrating an automated assembly and control method for an infrared detector.

[0046] Figure 2 A flowchart illustrating the threshold adjustment mechanism provided by this invention;

[0047] Figure 3 This invention provides a schematic diagram of the structure of an automated assembly and control system for infrared detectors;

[0048] Figure 4 A schematic diagram illustrating the production line database provided for this invention;

[0049] Figure 5 A schematic diagram of the serial number recording terminal is provided for this invention. Detailed Implementation

[0050] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0051] Please see Figures 1 to 5 This invention provides an automated assembly control method and control system for infrared detectors, the technical solution of which is as follows:

[0052] With the continuous rise in market demand, a certain company, a veteran in the research and development and production of infrared detectors, is also steadily expanding its production scale. However, under the traditional assembly model, due to the increasingly complex production tasks involving numerous processes, each with different requirements for time, space, and equipment, the traditional production management model is difficult to flexibly adapt to the complex and ever-changing production needs. The company has adopted an automated assembly control method for infrared detectors, aiming to improve the efficiency of infrared detector assembly control. Example 1 is as follows:

[0053] Figure 1 This invention provides a flowchart illustrating an automated assembly and control method for an infrared detector.

[0054] like Figure 1 As shown, an automated assembly control method for an infrared detector includes:

[0055] An automated assembly control method for an infrared detector includes:

[0056] refer to Figure 1 Step S10: Design an assembly line for assembling and packaging infrared detectors to obtain packaged finished products.

[0057] Furthermore, the assembly line includes:

[0058] Start the assembly machine and load the assembly task and assembly strategy;

[0059] The passive infrared (PIR) inspection machine is used to inspect the components output by the board mounting machine and the board splitting machine through a threshold adjustment mechanism, and outputs the first inspection information; the face cover is inspected, and the second inspection information is output; the control machine receives the first inspection information and the second inspection information, selects qualified products and sends them to the assembly machine; the assembly machine performs the final assembly inspection, selects the qualified products and sends them to the laser machine, and outputs the third inspection information to obtain the finished infrared detector;

[0060] Packaging materials are provided according to the assembly task, and the finished product of the infrared detector is sensed using a leak detection mechanism to obtain the packaged finished product.

[0061] Specifically, when the production line starts, the corresponding assembly strategy is automatically selected according to the requirements of different assembly machine types. For example, assembly machine type 01 executes production batch (LOT) 01 to ensure smooth and efficient production. When the components output by the board loading machine and the board splitting machine are completed and ready to enter the next process, the PIR inspection machine will perform infrared detection on the components through a threshold adjustment mechanism and output the first inspection information, including whether the component is qualified or unqualified. The cover operator performs cover welding and uses a laser machine to engrave the cover. During the cover production process, automated inspection equipment is used to inspect each cover to ensure that there are no defects. After the inspection is completed, the system outputs the second inspection information, including whether the cover is qualified or unqualified. Insect-proof sponge is added to qualified covers, the inspection results are recorded and transmitted to the control machine (rotary table / robotic arm A). The control machine receives and processes the first and second inspection information from the PIR inspection machine and the cover inspection, automatically filters out qualified products that meet the quality standards, and decides to send these qualified products to the assembly machine (rotary table / robotic arm B). The assembly machine further inspects the components, selects qualified products, and outputs third-party inspection information, including whether the detector is qualified or not. Qualified products are sent to a laser machine for bottom cover engraving, preparing the finished infrared detectors for packaging.

[0062] The packaging machine automatically selects and provides the appropriate packaging materials, and a laser machine engraves the packaging 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 and forming operation, stretching the flat packaging material into shape using automated equipment to ensure that the shape and size of the boxes meet production requirements. Finally, operators package the infrared detector finished products using the packaging boxes. During the packaging process, a missing item sensing mechanism is used to detect the completed infrared detector finished products. This mechanism ensures that each product is correctly packaged; if a product is not correctly packaged or a packaging material (such as an instruction manual) is missing, an alarm will be automatically triggered.

[0063] By implementing an automated assembly line, efficient integration of task scheduling, equipment coordination, quality inspection, and packaging was successfully achieved, effectively ensuring smooth production process flow and avoiding equipment overload or idleness. Furthermore, automated assembly control reduced rework, thereby improving production efficiency and product quality.

[0064] Furthermore, the threshold adjustment mechanism includes:

[0065] The PIR inspection machine is used to collect reference test data, which includes current, temperature, and vibration signals; the average value and standard deviation of the current, temperature, and vibration signals are calculated to obtain reference data;

[0066] Acquire historical PIR data, classify the historical PIR data into normal data and abnormal data based on the benchmark data and expert experience, and use the historical PIR data to train the base model to obtain the trained SVM model.

[0067] The PIR inspection machine is used to perform the PIR inspection through the SVM model, and the first inspection information is output.

[0068] Figure 2 A flowchart illustrating the threshold adjustment mechanism provided by this invention.

[0069] Specifically, such as Figure 2 As shown, the reference unit provides a known standard signal, such as the value of infrared radiation at a specific temperature. First, a PIR inspection machine is used to collect current, temperature, and vibration signals through the reference unit. For each test result, the standard deviation of the sensor output is calculated; the product's output signal should be within ±30% of the average value and ±5% of the standard deviation. Historical PIR data includes historical current, temperature, and vibration signals. Based on expert experience and calculations, historical PIR data is finely divided into normal and abnormal data. Next, this data is used to train an 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.

[0070] Comparing the threshold adjustment mechanism with the traditional method (fixed threshold), the false detection rate of the threshold adjustment mechanism is 2%, the false negative rate is 3%, and the overall accuracy is 95%, while the false detection rate of the traditional method is 5%, the false negative rate is 8%, and the overall accuracy is 87%. Comparative experimental data shows that using an SVM model to dynamically adjust the PIR inspection threshold, combined with PIR current, temperature, and vibration signals, improves the quality control accuracy and intelligence level of infrared detector assembly. Furthermore, by combining historical and real-time data, environmental changes and equipment status can be assessed, thereby improving production efficiency and product quality.

[0071] Furthermore, the assembly equipment includes: automatic assembly line operation and manual operation. The automatic assembly line operation includes front cover engraving, front 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 affixing, INCERT sticker affixing, NF certification sticker affixing, and outer box sticker printing and affixing.

[0072] Specifically, the assembly machine types are shown in Tables 1 and 2, which respectively illustrate the specific settings for automatic and manual assembly line operations. "〇" indicates that the operation is available, and "×" indicates that the operation is not available. In this embodiment, expansion space for 20 assembly machine types is also reserved, meaning the production line can be flexibly adjusted to support the production needs of different machine types.

[0073] Table 1. Examples of automated assembly line operations for assembly machine models

[0074]

[0075] Table 2 Examples of manual operation for assembly models

[0076]

[0077] Automated operations ensure high precision and efficiency, while manual operations guarantee production flexibility and adaptability. Combining automated 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 it to respond quickly to market changes and further enhance production efficiency and product quality.

[0078] refer to Figure 1 In 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 terminal; the third communication protocol is used for communication between the PIR inspection machine and the control machine; and transmit the information content of the communication protocol to the production line database.

[0079] Furthermore, the specific process of the first communication protocol includes:

[0080] The PLC sends communication content to the assembly machine according to the assembly task; the communication content includes order number, machine model number, LOT number, production quantity, spare bytes, and end character;

[0081] 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 message is displayed.

[0082] Specifically, in this embodiment, the PLC and the assembly machine communicate using a wireless protocol. Specifically, for communication between the PLC and the various devices within the assembly machine, the PLC sends the received assembly task to each device. The communication content is as follows: 111555666, 19178, 200, 0000, CR, and LF, representing the order number, machine model number, LOT number, production quantity, spare bytes, and end character, respectively. If each device returns the original information after receiving the assembly task, it indicates successful reception.

[0083] When switching between different assembly models, the PLC will send data twice to each device in the assembly model. The first time is the communication content, and the second time is the execution result code. The second data will be sent within 4 seconds after the first transmission. If the execution result code is not received within 4 seconds, the main PLC should report an error.

[0084] The execution result code is shown in Table 3. By establishing the first communication protocol for the infrared detector assembly production line, the system achieves full-process management of automated task scheduling, quality control, and production information traceability. This not only significantly improves production efficiency but also enhances the accuracy of assembly tasks and the coordination between equipment. Simultaneously, the system can quickly locate and resolve problems that arise during production, ensuring efficient collaboration and real-time data feedback at each production stage, thereby improving both production efficiency and product quality.

[0085] Table 3 Execution Result Code Example

[0086]

[0087] Furthermore, the second communication protocol specifically includes:

[0088] The PLC sends communication content to the serial number record 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.

[0089] During the production process, the PLC receives the execution result of the assembly model 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.

[0090] If the assembly type corresponding to the assembly task does not exist in the serial number record terminal, then the assembly task is created and the serial number is initialized to 1.

[0091] Specifically, the PLC and the serial number record terminal use the TPC protocol. Each time an assembly task is scanned, the PLC sends communication content to the serial number record terminal. Upon receiving the communication content, the serial number record terminal returns the same communication content to the PLC. Next, the PLC requests the corresponding serial number. If the serial number record terminal has a corresponding task, it returns the serial number; if the task does not exist or during a switch of assembly models, it creates a new task, initializes the serial number to 1, and returns it to the PLC. If the PLC fails to receive the serial number returned by the serial number record terminal within a specified time, it triggers a timeout alarm. During production, the PLC feeds back the task execution results to the serial number record terminal. If production is confirmed to be complete, the task is successful, and the serial number is incremented by 1; if production fails, the serial number remains unchanged. The serial number record terminal records task information and serial number status through file management, ensuring the traceability of production data. Table 4 shows the initial production record, where the LOT number is the production batch number corresponding to the order number. Table 5 shows the final production record after organizing this production record.

[0092] The second communication protocol enables full automation of serial number generation, serial number updating, and task linkage, ensuring the uniqueness of product identification during the production process, improving the flexibility and stability of production tasks, and simplifying management processes, thereby enhancing the efficiency and reliability of the infrared detector production line.

[0093] Table 4 Example of Initial Production Record

[0094]

[0095] Table 5 Example of Final Production Record

[0096]

[0097] Furthermore, the third communication protocol specifically includes:

[0098] The controller sends a start signal to the PIR inspection machine; after receiving the start signal, the PIR inspection machine performs a PIR inspection through a threshold adjustment mechanism, outputs first inspection information, and feeds it back to the controller.

[0099] Specifically, suppose the controller sends a start signal to the PIR inspection machine, requesting a PIR inspection of 10 components. The PIR inspection machine checks each component one by one according to the threshold adjustment mechanism, finding 8 qualified and 2 unqualified. The first inspection information is fed back to the controller, which sends the 8 qualified products to the assembly machine, while marking the 2 unqualified products and transferring them to the rework area.

[0100] By implementing the third communication protocol, automated startup, real-time feedback, and quality control of PIR detection in the production line were achieved, ensuring the efficiency and reliability of the detection work, thereby improving the efficiency and reliability of the infrared detector production line.

[0101] refer to Figure 1 Step S30: Obtain assembly tasks and retrieve the information content from the production line database; define an assembly objective based on the assembly tasks and the information content to minimize total production time and maximize resource utilization; define an assembly state, which includes the set of completed assembly tasks, the state of the assembly machine type, 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 dynamic programming based on the assembly objective, the assembly state, the state transition equation, and the boundary conditions.

[0102] The minimum total production time can be expressed as:

[0103] ;

[0104] in, It is a minimization function. This is the total completion time for the assembly task. It is an assembly task. End time, It is an assembly task The start time, This represents the total number of assembly tasks.

[0105] Maximizing resource utilization can be expressed as:

[0106] ;

[0107] in, It is a maximization function. It is the overall utilization rate of assembled models. It is an assembled model The actual processing time It is an assembled model Available time, This refers to the total number of assembled models. This is the serial number of the assembled model.

[0108] The assembly target is obtained by adding the minimum total production time to the maximum resource utilization. The status of the assembly machine indicates whether it is busy, idle, or malfunctioning, and the processing status of the assembly task indicates whether the assembly task was successfully processed, failed, or not processed.

[0109] In the boundary conditions, the initial assembly state can be represented as follows: the set of completed assembly tasks is empty, the state of all assembly machines is idle, and the processing state of all assembly tasks is "assembly task not processed." Furthermore, the final assembly state can also be represented as follows: the set of completed assembly tasks is all assembly tasks, the state of all assembly machines is idle, and the processing state of all assembly tasks indicates that the assembly task has been successfully processed.

[0110] Furthermore, the state transition equation is expressed as:

[0111] ;

[0112] ;

[0113] ;

[0114] in, This refers to the assembly state at the next moment. The set of completed assembly tasks for the next time step. This refers to the set of assembly tasks that have been completed so far. For the current assembly task, The assembly machine type to perform the assembly task at the next moment. For the next time step, For the current time step, For the current assembly task in the assembly machine type On the processing time, This is the sequence number of the assembly task. The serial number of the assembled machine model. The union symbol;

[0115] Among them, if If execution fails, then ,and .

[0116] Specifically, the dynamic programming method supports efficient allocation of multiple tasks and can adapt to changes in assembly tasks and equipment failures in assembly models. This enables the production line to achieve optimal allocation and efficient execution of assembly tasks. In particular, 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.

[0117] refer to Figure 1 In step S40: Update the assembly task and the information content. If the assembly task has been completed, end the assembly; otherwise, continue with step S30.

[0118] In summary, by designing the assembly line, the execution sequence of assembly tasks can be optimized, thereby significantly shortening the total production time and improving overall production efficiency. Simultaneously, the introduction of first, second, and third communication protocols enables efficient transmission and real-time updates of information content, achieving not only full-process monitoring and data sharing but also improving the efficiency of information flow and the accuracy of data management. Furthermore, by clearly defining assembly goals and states, and combining state transition equations and boundary conditions, dynamic programming methods enable the rational allocation and efficient scheduling of resources, effectively avoiding resource waste. Finally, the dynamic programming method can flexibly adjust assembly strategies based on real-time updates of assembly tasks and information content, allowing it to adapt to changes in different assembly tasks. This invention demonstrates advantages in improving production efficiency, reducing production costs, and ensuring product quality, providing strong support for the sustainable development of enterprises.

[0119] Example 2 is as follows:

[0120] Figure 3 This invention provides a schematic diagram of the structure of an automated assembly and control system for infrared detectors.

[0121] Based on Example 1, such as Figure 3 As shown, this embodiment further proposes an automated assembly and control system for infrared detectors, including:

[0122] refer to Figure 3 The assembly line design module in the middle is used to assemble and package infrared detectors to obtain packaged finished products;

[0123] 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. The third communication protocol is used for communication between the PIR inspection machine and the control machine. The information content of the communication protocol is transmitted to the production line database.

[0124] The PLC and the production line database use the TCP protocol, and the production line database is as follows: Figure 4 As shown, the interface includes communication content, data update status, and prompts. After scanning the production task, the production line database retrieves the production information and then sends it to the assembly line. The assembly line provides feedback information after completing the task. Additionally, the interface includes a prompt indicating that the production line's production data update failed, possibly due to incomplete production information retrieval or communication errors.

[0125] Additionally, for the serial number record end in the second communication protocol, such as Figure 5As shown, it provides file, operation, and help function options for managing and configuring serial numbers. When the current assembly model is opened, the serial number corresponding to that assembly model and LOT is read. When the assembly production line requests a serial number, the serial number recorder will transmit the serial number corresponding to the current serial number. If the production result is successful, the serial number is incremented by 1; if it fails, the serial number remains unchanged. Furthermore, Figure 5 It also displays the current communication content, including the current model, serial number information, communication status, and serial number communication records. For the serial number communication record, assuming the production line requests a serial number, the system returns the current serial number as 1897. The production result is successful, the serial number increments by 1, and the increment process is clearly visible, from 1897 to 1898.

[0126] refer to Figure 3 The assembly strategy generation module is used to obtain assembly tasks and information from the production line database; define an assembly objective based on the assembly tasks and information to minimize total production time and maximize resource utilization; define an assembly state, which includes the set of completed assembly tasks, the state of the assembly machine type, and the processing state of the assembly tasks; determine a state transition equation to describe the transition from the current assembly state to the next assembly state; determine boundary conditions to describe the initial assembly state; and generate an assembly strategy using dynamic programming based on the assembly objective, the assembly state, the state transition equation, and the boundary conditions.

[0127] refer to Figure 3 The assembly task update module is used to update the assembly task and the information content.

[0128] Specifically, the total latency from task issuance to feedback on the production line equipment is only 200ms. If a task fails, the assembly machine returns a detailed error code, which helps to quickly identify and resolve problems, reducing downtime. Furthermore, the communication protocol supports flexible configuration of parameters such as production quantity and machine number to adapt to different order requirements. For example, if a batch of tasks requires adjusting the production quantity from 200 to 150, the task plan can be quickly adjusted by modifying the communication content. Through real-time feedback and task confirmation mechanisms, production intervals are reduced, resulting in a 9% increase in production efficiency compared to a company's traditional methods.

[0129] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. An infrared detector automated assembly control method, characterized by, The application relates to an infrared detector assembly line communication protocol and an infrared detector assembly line communication protocol information content updating method. Step S10: an assembly production line is designed for assembling and packaging infrared detectors to obtain packaged products; Step S20: a communication protocol is established for the assembly production line, the communication protocol comprises a first communication protocol, a second communication protocol and a third communication protocol; the first communication protocol is used for communication between a PLC and an assembly machine; the second communication protocol is used for communication between the PLC and a serial number recording terminal; and the third communication protocol is used for communication between a PIR inspection machine and a control machine; Information content of the communication protocol is transmitted to a production line database; The second communication protocol specifically comprises: The PLC sends communication content to the serial number recording terminal according to an assembly task and requests to obtain a serial number; if the PLC does not receive the serial number within N seconds, a timeout alarm is sent; The PLC receives an execution result of the assembly machine in a production process and feeds 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 increases a serial number corresponding to the assembly task by 1; otherwise, the serial number remains unchanged; If the assembly machine corresponding to the assembly task does not exist in the serial number recording terminal, the assembly task is newly created, and the serial number is initialized as 1; Step S30: an assembly task is obtained, and the information content is obtained from the production line database; according to the assembly task and the information content, an assembly target is defined for minimizing total production time and maximizing resource utilization; an assembly state is defined, the assembly state comprises a completed assembly task set, a state of the assembly machine and a processing state of the assembly task; a state transition equation is determined for describing that the current assembly state is transferred to the assembly state at the next moment; a boundary condition is determined for describing the initial assembly state; according to the assembly target, the assembly state, the state transition equation and the boundary condition, a dynamic programming method is used to generate an assembly strategy; Step S40: the assembly task and the information content are updated; if the assembly task is completed, the assembly is ended; otherwise, the step S30 is continuously executed.

2. The method of claim 1, wherein, The assembly production line comprises: The assembly machine is started, and the assembly task and the assembly strategy are loaded; The PIR inspection machine is used to perform PIR inspection on components output by a board feeding machine and a board separating machine through a threshold adjustment mechanism, first inspection information is output; face cover inspection is performed on a face cover, second inspection information is output; the control machine receives the first inspection information and the second inspection information, screens qualified products and sends the qualified products to a component assembling machine; the component assembling machine performs final assembly inspection, screens the qualified products and sends the qualified products to a laser machine, and third inspection information is output, thereby obtaining infrared detector products; Packaging materials are provided according to the assembly task, and the infrared detector products are sensed by using a missing sensing mechanism, thereby obtaining the packaged products.

3. The method of claim 2, wherein the method further comprises: The threshold adjustment mechanism comprises: The PIR inspection machine is used to collect reference instrument test data, including current, temperature and vibration signals; the average value and standard deviation of the current, temperature and vibration signals are calculated to obtain reference data; Historical PIR data is obtained, the historical PIR data is divided into normal data and abnormal data according to the reference data and expert experience, and a basic model is trained using the historical PIR data to obtain a trained SVM model; The PIR inspection machine is used to perform the PIR inspection through the SVM model, and output the first inspection information.

4. The method of claim 2, wherein the method further comprises: The assembly machine type includes automatic assembly line operation and manual operation, the automatic assembly line operation includes face cover marking, face cover inspection, PIR inspection, bottom cover marking, final assembly inspection, color box feeding, color box marking and color box inspection; the manual operation includes instruction preparation, support and accessory installation, 3C sticker pasting, INCERT sticker pasting, NF certification sticker pasting and outer box sticker printing and pasting.

5. The method of claim 1, wherein The first communication protocol specific process includes: The PLC sends communication content to the assembly machine type according to the assembly task; the communication content includes order number, machine type number, LOT number, production quantity, spare byte and end symbol; The assembly machine type 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 is reported.

6. The method of claim 1, wherein, 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 back to the control machine.

7. The method of claim 1, wherein the method further comprises: The state transition equation is represented as: S' = (T' done M' current t') ; T' done = T done ∪ {T i}; wherein S' is the assembly status at the next time step, T' done is the set of completed assembly tasks at the next time step, T done is the set of completed assembly tasks at the current time step, T i is the assembly task at the current time step, M' current is the assembly machine type that performs the assembly task at the next time step, t' is the time step at the next time step, t is the time step at the current time step, is the processing time of the assembly task at the current time step on the assembly machine type M j , i is the serial number of the assembly task, j is the serial number of the assembly machine type, and ∪ is the union symbol. wherein, if T i If the execution fails, T' done = T done , and t' = t.

8. An infrared detector automated assembly control system, characterized by, An infrared detector automatic assembly control method according to any one of claims 1 to 7, comprising: An assembly production line design module for assembling and packaging infrared detectors to obtain packaged finished products; A communication protocol establishment module, the communication protocol 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 type; 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; the information content of the communication protocol is transmitted to the production line database; An assembly strategy generation module is configured to acquire an assembly task and information content from the production line database, define an assembly target based on the assembly task and the information content, the assembly target being configured to minimize total production time and maximize resource utilization, define an assembly state, the assembly state including a completed assembly task set, a state of the assembly machine type, and a processing state of the assembly task, determine a state transition equation configured to describe a current assembly state transition to a next assembly state, determine a boundary condition configured to describe an initial assembly state, and generate an assembly strategy based on the assembly target, the assembly state, the state transition equation, and the boundary condition using a dynamic programming method. An assembly task update module is configured to update the assembly task and the information content.

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