Remote control system and method applied to waste line

Abstract

The invention relates to the technical field of automation control, and discloses a remote control system and method applied to a waste line, and the system comprises signal collection groups which are disposed on branch line processing equipment, and are used for detecting the production state of production line equipment and a waste generation signal in real time; the distributed remote I / O module is connected with the signal acquisition groups through an industrial bus and is used for acquiring real-time data of each branch signal acquisition group; the PLC is integrated with an intelligent control module and is in communication connection with the remote I / O module through an industrial Ethernet; the intelligent control module comprises a state analysis unit used for decoding real-time data collected by a local sensor group; the logic judgment unit is used for judging the waste generation condition of each branch line based on the real-time data; and the branch control unit generates a corresponding waste line start-stop instruction according to the judgment result. Remote control and efficient management of the waste line can be achieved, the automation level of waste treatment can be improved, and production energy consumption is reduced.

Description

Technical Field

[0001] The present invention relates to the field of automation control technology, and in particular to a remote control system and method applied to a scrap line. Background Art

[0002] In industrial production systems, scrap lines are a core component of material transportation and recycling, and their control efficiency is directly related to production energy consumption, equipment lifespan, and operating costs. Traditional scrap line control generally uses PLC programs based on fixed logic, triggering equipment start and stop based on preset timing or conditions.

[0003] However, this control approach has significant drawbacks: the system cannot dynamically adjust to the actual operating status of branch line equipment. For example, when some branch lines are not producing, traditional PLCs will continue to operate all equipment along the entire line according to a fixed program. This results in wasted energy (such as motors continuously idling), excessive wear on mechanical components (such as unnecessary wear on conveyor belts and bearings), and increased failure rates and maintenance costs. Statistics show that approximately 30% of energy waste in the industrial sector stems from this non-intelligent equipment control model. Furthermore, with stricter environmental regulations and the advancement of the "dual carbon" goals, companies are increasingly demanding refined energy management.

[0004] Therefore, developing a remote control system that can perceive working conditions in real time and dynamically adjust operating strategies has become an inevitable choice to improve the energy efficiency of scrap lines, reduce operation and maintenance costs, and meet the needs of sustainable development. Summary of the Invention

[0005] The present invention aims to provide a remote control system and method for a waste line, which can realize remote control and efficient management of the waste line, help to improve the automation level of waste processing and reduce production energy consumption.

[0006] To achieve the above objectives, the present invention provides the following basic solutions.

[0007] Option 1 A remote control system for a waste material production line, comprising: The signal acquisition group installed on each branch processing equipment is used to detect the production status of the production line equipment and the waste generation signal in real time; Distributed remote I / O modules are connected to the signal acquisition group via the industrial bus and are used to collect real-time data from each branch signal acquisition group; the real-time data includes production line operation status signals and waste generation signals; PLC controller, integrated with intelligent control module, establishes communication connection with remote I / O module through industrial Ethernet; The intelligent control module includes: a state analysis unit for decoding real-time data collected by the local sensor group; a logic judgment unit for judging the waste generation status of each branch line based on the real-time data; and a branch control unit for generating corresponding waste line start and stop instructions according to the judgment results.

[0008] Furthermore, the signal acquisition group includes: a signal collector, which is arranged in the operating cabinet chassis of the first press equipment of each branch line, and is used to detect equipment start-up signals and equipment shutdown signals; the equipment start-up signals and equipment shutdown signals belong to production line operation status signals.

[0009] Furthermore, the signal acquisition group also includes: a pressure sensor group, installed at the waste collection point, for detecting the amount of waste accumulation; an infrared sensing device, set at the production line transmission node, for monitoring the material flow status; the waste accumulation amount and material flow status belong to waste generation signals.

[0010] Furthermore, when judging the waste generation situation of each branch line, the following steps are included: if a branch line has both an equipment start-up signal and a waste generation signal, it is determined that the branch line has waste generation and the waste line needs to be activated; if a branch line has an equipment shutdown signal and the waste generation signal is eliminated, it is determined that the branch line has no waste generation and the waste line needs to be deactivated.

[0011] Furthermore, the processing equipment of the scrap line is provided with a forced start-stop button for forcibly starting or stopping the scrap line.

[0012] Furthermore, the intelligent control module also includes: a dynamic priority adjustment unit, which is used to automatically assign the scrap line control priority according to the process parameters of each branch line processing equipment.

[0013] Furthermore, the intelligent control module also includes: an energy consumption statistics unit for recording the operating energy consumption data of each branch device in real time.

[0014] Furthermore, the intelligent control module also includes: a predictive maintenance unit, which is used to generate maintenance prompts based on the equipment's operating time and the number of starts and stops.

[0015] Option 2 A remote control method for a scrap line, using a remote control system for a scrap line as described in Solution 1 to start and stop the scrap line, comprising the following steps: S1. The signal collection group installed on each branch processing equipment collects the production status signal and waste generation signal of the production line equipment in real time; S2. Using a distributed remote I / O module to obtain real-time data from the signal acquisition group via an industrial bus, the real-time data including a production line operation status signal and a waste generation signal; S3, transmitting the real-time data to the intelligent control module of the PLC controller via industrial Ethernet; S4, the intelligent control module executes the following processing flow: Status analysis: Decode and process the received real-time data to extract the characteristic parameters of the production line operation status and the waste generation parameters; Logical judgment: judge the waste generation situation of each branch line based on real-time data; Branch control: Generate corresponding scrap line start and stop instructions based on scrap generation conditions, and send them to the processing equipment of each scrap line through the remote I / O module.

[0016] The working principle and advantages of the present invention are: The present invention provides a remote control system and method for a waste processing line, which can achieve remote control and efficient management of the waste processing line, helping to improve the automation level of waste processing and reduce production energy consumption. This solution achieves precise and intelligent management of scrap lines through the collaborative design of a multi-level sensor network and an intelligent control architecture. By establishing a precise mapping relationship between equipment status and scrap generation, the system achieves precise synchronization between scrap line operation and production rhythm, avoiding both the energy waste caused by the traditional continuous operation mode and the operational delays that may be caused by manual control. In addition, the intelligent control module of the PLC controller has a three-level processing architecture of state analysis, logical judgment, and branch control. It can perform time-series correlation analysis between equipment operating status and scrap generation signals, ensuring that the triggering of scrap line start and stop commands strictly complies with the actual production rhythm, avoiding energy waste or response lag caused by traditional timing control or single threshold control. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a schematic diagram of the system structure of a first embodiment of a remote control system and method for a scrap line according to the present invention. DETAILED DESCRIPTION

[0018] The following is a further detailed description through specific implementation methods: Example 1 The embodiment is basically as shown in the attached Figure 1 Shown: A remote control system for a scrap line, comprising: The signal acquisition group installed on each branch processing equipment is used to detect the production status of the production line equipment and the waste generation signal in real time.

[0019] The signal acquisition group includes a signal collector, located in the operating cabinet of the first press machine on each branch line, for detecting equipment startup and shutdown signals; these signals represent production line operating status signals. In this embodiment, the signal collector uses the KZ-04AL signal collector from Huacheng Intelligent Control.

[0020] Preferably, the signal acquisition group further comprises: a pressure sensor group installed at the waste collection point for detecting the amount of waste accumulation. In this embodiment, the pressure sensor group is a 3*8 meter high-precision floor scale that can weigh 50 tons.

[0021] Infrared sensors are installed at transmission nodes on the production line to monitor material flow. The waste accumulation and material flow status represent waste generation signals. In this embodiment, the infrared sensors can be E3F-5DN1 (NPN normally open) with a range of 5 meters or E3F-5DP1 (PNP normally open) with a range of 5 meters. In actual applications, the choice of NPN or PNP infrared sensors can be determined based on the type of PLC.

[0022] Through the dual configuration of a pressure sensor group and an infrared sensing device, this system can further form a three-dimensional perception system for waste detection: the pressure sensor group monitors the physical quantity changes of waste accumulation from a static dimension, while the infrared device tracks the material flow status from a dynamic dimension. This combined dynamic and static monitoring mode effectively solves the defects of a single sensor that is susceptible to environmental interference or status misinterpretation. In conjunction with a signal collector, it can identify the production line status more comprehensively and accurately.

[0023] The distributed remote I / O module is connected to the signal acquisition group via the industrial bus and is used to collect real-time data from each branch signal acquisition group; the real-time data includes production line operation status signals and waste generation signals.

[0024] The PLC controller integrates an intelligent control module and establishes a communication connection with the remote I / O module via industrial Ethernet.

[0025] The intelligent control module includes: a state analysis unit for decoding real-time data collected by the local sensor group; a logic judgment unit for judging the waste generation status of each branch line based on the real-time data; and a branch control unit for generating corresponding waste line start and stop instructions according to the judgment results.

[0026] Specifically, when judging the waste generation situation of each branch line, the following steps are included: if a branch line has both an equipment start-up signal and a waste generation signal, it is determined that the branch line has waste generation and the waste line needs to be activated; if a branch line has an equipment shutdown signal and the waste generation signal is eliminated, it is determined that the branch line has no waste generation and the waste line needs to be deactivated.

[0027] When a scrap line needs to be activated, the branch control unit generates a corresponding scrap line activation instruction and sends it to the processing equipment of each scrap line through the remote I / O module. When a scrap line needs to be deactivated, the branch control unit generates a corresponding scrap line deactivation instruction and sends it to the processing equipment of each scrap line through the remote I / O module.

[0028] Furthermore, the scrap line's processing equipment is equipped with forced start / stop buttons for forcibly starting or stopping the scrap line. This feature helps maintain the flexibility of manual intervention in the production line, ensuring a quick response in emergency situations without disrupting the normal operation of the automatic control logic.

[0029] This embodiment further provides a remote control method for a scrap line, which uses the remote control system for a scrap line as described above to start and stop the scrap line, including the following steps: S1. The signal collection group installed on each branch processing equipment collects the production status signal and waste generation signal of the production line equipment in real time; S2. Using a distributed remote I / O module to obtain real-time data from the signal acquisition group via an industrial bus, the real-time data including a production line operation status signal and a waste generation signal; S3, transmitting the real-time data to the intelligent control module of the PLC controller via industrial Ethernet; S4, the intelligent control module executes the following processing flow: Status analysis: Decode and process the received real-time data to extract the characteristic parameters of the production line operation status and the waste generation parameters; Logical judgment: judge the waste generation situation of each branch line based on real-time data; Branch control: Generate corresponding scrap line start and stop instructions based on scrap generation conditions, and send them to the processing equipment of each scrap line through the remote I / O module.

[0030] The present embodiment provides a remote control system and method for a scrap line, which can realize remote control and efficient management of the scrap line, and contribute to improving the automation level of scrap processing and reducing production energy consumption. Compared with the traditional on-site hard-wired control method, the traditional method requires multiple wiring locations, which is costly and prone to flying wire problems, posing a safety hazard. In addition, the signal transmission distance through the line is long, there is a significant signal delay, and it is easily interfered with by the surrounding environment, resulting in poor signal acquisition and control effects. However, the remote control system provided by this solution does not have such problems. Signal transmission is not affected by the transmission distance, and it is free of current for life. Since the line does not run through the foundation pit, it will not be interfered with by strong electricity or strong magnetism, and the signal delay can be controlled within 20ms, with high control accuracy and efficiency.

[0031] Example 2 A remote control system for a scrap production line is provided, with the following adjustments made on the basis of the first embodiment.

[0032] The intelligent control module further comprises: a dynamic priority adjustment unit for automatically allocating the control priority of the scrap line according to the process parameters of each branch line processing equipment.

[0033] In this embodiment, the dynamic priority adjustment unit, during operation, first collects or sets the process parameters of each branch processing equipment in real time, including the remaining order delivery time, scrap generation rate, equipment health (here measured by the equipment vibration spectrum), energy consumption per ton of scrap, and scrap type diversity coefficient. It then constructs a multidimensional evaluation matrix, normalizes each parameter, and assigns weight coefficients, where the remaining order delivery time is weighted at 0.25, the scrap generation rate at 0.30, the equipment health at 0.20, the energy consumption per ton of scrap at 0.15, and the scrap type diversity at 0.10.

[0034] Then, the improved TOPSIS decision algorithm is applied to calculate the priority score of each branch line, and hierarchical control instructions are generated based on the priority score: The priority is level 1, and the scrap line is immediately started at full speed; The priority is level 2, and the scrap line is started after a delay of 5 seconds and runs at 80% speed; The priority is level 3, and the scrap line waits to start after the current production cycle ends.

[0035] The energy consumption statistics unit is used to record the operating energy consumption data of each branch line device in real time. In this embodiment, the energy consumption statistics unit collects meter data and combines it with the total equipment power, operating hours, and total waste volume to calculate energy consumption and generate a visual energy consumption report, including the total energy consumption of each branch line, energy consumption per ton of waste, and energy efficiency ranking. It also periodically performs abnormal energy consumption detection, triggering an alarm if energy consumption exceeds the historical average by 20% for three consecutive periods.

[0036] A predictive maintenance unit is used to generate maintenance reminders based on the equipment's operating hours and the number of starts and stops.

[0037] In this embodiment, the predictive maintenance unit collects real-time equipment operating data, including cumulative operating time, number of starts and stops, and action delay time. It also calculates the remaining life of the equipment based on a Weibull distribution model. When the remaining life of the equipment falls below a corresponding threshold, a maintenance reminder is generated.

[0038] This embodiment provides a remote control system and method for a scrap production line, offering enhanced functionality compared to the first embodiment. The dynamic priority adjustment module, through multi-dimensional parameter evaluation and the TOPSIS algorithm, flexibly allocates resources, improves equipment utilization, and reduces response time. The energy consumption statistics unit effectively monitors energy consumption, helping to identify waste points on the production line and reduce costs. The predictive maintenance module uses the Weibull model to predict equipment lifespan, enabling proactive maintenance and reducing downtime.

[0039] The above is only an embodiment of the present invention. Common knowledge such as the specific structure and characteristics of the scheme is not described in detail here. Ordinary technicians in the relevant field are aware of all common technical knowledge in the technical field of the invention before the application date or priority date, can obtain all existing technologies in the field, and have the ability to apply conventional experimental means before that date. Ordinary technicians in the relevant field can improve and implement this scheme in combination with their own abilities under the guidance of this application. Some typical well-known structures or well-known methods should not become obstacles for ordinary technicians in the relevant field to implement this application. It should be pointed out that for those skilled in the art, without departing from the structure of the present invention, several variations and improvements can be made, which should also be regarded as the scope of protection of the present invention. These will not affect the effect of the implementation of the present invention and the practicality of the patent.

Claims

1. A remote control system for a scrap line, characterized in that: include: The signal acquisition group installed on each branch processing equipment is used to detect the production status of the production line equipment and the waste generation signal in real time; Distributed remote I / O modules are connected to the signal acquisition group via the industrial bus and are used to collect real-time data from each branch signal acquisition group; the real-time data includes production line operation status signals and waste generation signals; PLC controller, integrated with intelligent control module, establishes communication connection with remote I / O module through industrial Ethernet; The intelligent control module includes: a state analysis unit for decoding real-time data collected by the local sensor group; a logic judgment unit for judging the waste generation status of each branch line based on the real-time data; and a branch control unit for generating corresponding waste line start and stop instructions according to the judgment results.

2. A remote control system for a scrap line according to claim 1, characterized in that: The signal acquisition group includes: a signal collector, which is arranged in the operating cabinet chassis of the first press equipment of each branch line, and is used to detect equipment start-up signals and equipment stop signals; the equipment start-up signals and equipment stop signals are production line operation status signals.

3. A remote control system for a scrap line according to claim 2, characterized in that: The signal acquisition group also includes: a pressure sensor group, installed at the waste collection point, for detecting the amount of waste accumulation; an infrared sensing device, set at the production line transmission node, for monitoring the material flow status; the waste accumulation amount and material flow status belong to waste generation signals.

4. A remote control system for a scrap line according to claim 2, characterized in that: When judging the waste generation situation of each branch line, the following steps are included: if a branch line has both an equipment start-up signal and a waste generation signal, it is determined that the branch line has waste generation and the waste line needs to be activated; if a branch line has an equipment shutdown signal and the waste generation signal is eliminated, it is determined that the branch line has no waste generation and the waste line needs to be deactivated.

5. The remote control system for a scrap line according to claim 1, characterized in that: The processing equipment of the scrap line is provided with a forced start and stop button for forcibly starting or stopping the scrap line.

6. The remote control system for a scrap line according to claim 1, characterized in that: The intelligent control module further comprises: a dynamic priority adjustment unit for automatically allocating the control priority of the scrap line according to the process parameters of each branch line processing equipment.

7. The remote control system for a scrap line according to claim 1, characterized in that: The intelligent control module also includes: an energy consumption statistics unit, which is used to record the operating energy consumption data of each branch device in real time.

8. The remote control system for a scrap line according to claim 1, characterized in that: The intelligent control module further includes: a predictive maintenance unit for generating maintenance prompts based on the equipment's operating time and the number of starts and stops.

9. A remote control method for a waste line, characterized in that: Using a remote control system for a scrap line as claimed in any one of claims 1 to 8 to control the start and stop of the scrap line, the method comprises the following steps: S1. The signal collection group installed on each branch processing equipment collects the production status signal and waste generation signal of the production line equipment in real time; S2. Using a distributed remote I / O module to obtain real-time data from the signal acquisition group via an industrial bus, the real-time data including a production line operation status signal and a waste generation signal; S3, transmitting the real-time data to the intelligent control module of the PLC controller via industrial Ethernet; S4, the intelligent control module executes the following processing flow: Status analysis: Decode and process the received real-time data to extract the characteristic parameters of the production line operation status and the waste generation parameters; Logical judgment: judge the waste generation situation of each branch line based on real-time data; Branch control: Generate corresponding scrap line start and stop instructions based on scrap generation conditions, and send them to the processing equipment of each scrap line through the remote I / O module.

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