Production line control method and device, computer equipment and storage medium

Abstract

The invention discloses a production line control method and device, computer equipment and a storage medium. The method comprises the steps of obtaining preset area data of a transported object on a production line; determining a plurality of target lamp beads in the plurality of lamp beads based on the preset area data; based on at least two of the first photoelectric sensor, the second photoelectric sensor and the target lamp bead, the advancing direction of the transported object on the production line is judged; based on the target lamp beads, the exceeding area of the transported objects on the production line is judged; and performing control processing on the production line based on the exceeding area and the advancing direction. According to the safety optical grating, the first photoelectric sensor and the second photoelectric sensor, the exceeding area and the advancing direction of the transported objects are effectively judged, then the production line is accurately controlled and processed according to the exceeding area and the advancing direction, it is effectively guaranteed that when personnel enter, an alarm can be accurately given for shutdown, and meanwhile false triggering shutdown caused by goods passing is avoided.

Description

TECHNICAL FIELD

[0001] The present application relates to the field of sensors, in particular to a production line control method and device, computer equipment and storage medium. BACKGROUND

[0002] In the field of industrial manufacturing, assembly lines are widely used in large-scale continuous production of products. In order to realize the quantity statistics, size measurement and position recognition of the transported objects, the production line is usually equipped with various sensors, among which the safety grating is a commonly used non-contact detection device. The safety grating is composed of an array of infrared beams composed of a transmitting end and a receiving end, which is used to detect whether an object has crossed the light curtain area formed thereby. When an obstruction is detected, the system will consider it as a risk factor and immediately output a stop signal to make the assembly line or work equipment enter a shutdown state.

[0003] However, in actual application, the safety grating will not only respond to the intrusion of personnel, but also frequently trigger shutdown due to the normal passing of goods, which seriously affects the efficiency of the production line. Especially in high-speed or continuous feeding scenarios, the system has difficulty in effectively distinguishing between "goods allowed to pass" and "personnel that should be intercepted", thereby forming a contradiction between ensuring personal safety and maintaining production efficiency.

[0004] Therefore, how to ensure that personnel entering can accurately alarm shutdown while avoiding mis-triggering shutdown caused by the passing of goods has become a technical problem that needs to be solved in the field. SUMMARY

[0005] Therefore, it is necessary to provide a production line control method and device, computer equipment and storage medium, which can effectively distinguish between normal transported objects and abnormal intruding objects, reduce the misjudgment rate, and improve the running efficiency and safety of the production line.

[0006] A production line control method, the method is applied to a safety grating, the safety grating includes a plurality of lamp beads, the production line includes a dangerous area and a safe area, the safety grating is deployed at the junction of the dangerous area and the safe area, the dangerous area is provided with a first photoelectric sensor and a second photoelectric sensor, and the method comprises: acquiring preset area data of transported objects on the production line; based on the preset area data, determining a plurality of target lamp beads from the plurality of lamp beads; judging the direction of travel of the transported objects on the production line based on at least two of the first photoelectric sensor, the second photoelectric sensor and the target lamp beads; judging the exceeding area of the transported objects on the production line based on the target lamp beads; controlling the production line based on the exceeding area and the direction of travel.

[0007] Optionally, determining a plurality of target lamp beads from the plurality of lamp beads based on the preset area data includes: Obtaining an arrangement matrix of deployment positions of the plurality of lamp beads in the safety grating; In the arrangement matrix, the target lamp beads are extracted based on the preset area data.

[0008] Optionally, extracting the target lamp beads in the arrangement matrix based on the preset area data includes: Obtaining historical occlusion data of the safety grating; Filtering out occlusion records matching the preset area data from the historical occlusion data as target occlusion data; Based on the target occlusion data, counting the occlusion frequency of each lamp bead in the arrangement matrix and the corresponding system response state when occluded, the system response state including a non-safe response; Based on the shading frequency and the correlation relationship with the non-safety response, target lamp beads that meet the cross-border determination requirements are determined in the arrangement matrix.

[0009] Optionally, the controlling the production line based on the excess area and the traveling direction includes: Performing a comparison process based on the exceeded area and a preset area threshold to obtain a first comparison result; Performing a comparison process based on the traveling direction and a preset traveling direction to obtain a second comparison result; Based on at least one of the first comparison result and the second comparison result, control processing is performed on the production line.

[0010] Optionally, the controlling the production line based on at least one of the first comparison result and the second comparison result includes: Obtaining the duration of occlusion of the transported object when the target lamp bead determines the excess area of ​​the transported object on the production line; When the shielding duration meets a preset duration threshold, the production line is controlled based on at least one of the first comparison result and the second comparison result.

[0011] Optionally, the controlling the production line based on at least one of the first comparison result and the second comparison result includes: When the first comparison result shows that the excess area is greater than or equal to the preset area threshold, controlling the production line to stop; when the second comparison result is that the traveling direction does not conform to the preset traveling direction, controlling the production line to stop; when the first comparison result is that the exceeding area is less than the preset area threshold value, and the second comparison result is that the traveling direction conforms to the preset traveling direction, controlling the production line to normally operate.

[0012] Optionally, the controlling the production line to stop comprises: sending a shutdown instruction to a driving device of the production line to make the production line shutdown; and alarming and prompting through an audible and visual alarming device.

[0013] A control device of a production line, the device is applied to a safety light barrier, the safety light barrier comprises a plurality of lamp beads, the production line comprises a dangerous area and a safe area, the safety light barrier is arranged at a boundary between the dangerous area and the safe area, the dangerous area is provided with a first photoelectric sensor and a second photoelectric sensor, and the device comprises: a first acquisition module configured to acquire preset area data of a transported object on the production line; a first determination module configured to determine a plurality of target lamp beads from the plurality of lamp beads based on the preset area data; a first judgment module configured to judge a traveling direction of the transported object on the production line based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target lamp beads; a second judgment module configured to judge an exceeding area of the transported object on the production line based on the target lamp beads; a control module configured to control the production line based on the exceeding area and the traveling direction.

[0014] A computer device, comprising a memory, a processor, and computer readable instructions stored in the memory and executable on the processor, when the processor executes the computer readable instructions, the production line control method is realized.

[0015] A readable storage medium, having computer readable instructions stored thereon, when the computer readable instructions are executed by a processor, the production line control method is realized.

[0016] The control method, device, computer device and storage medium of the production line obtain preset area data of a transported object on the production line; based on the preset area data, a plurality of target lamp beads are determined from the plurality of lamp beads; based on at least two of the first photoelectric sensor, the second photoelectric sensor and the target lamp beads, a running direction of the transported object on the production line is judged; based on the target lamp beads, an exceeding area of the transported object on the production line is judged; and based on the exceeding area and the running direction, the production line is controlled. By deploying the safety grating at the junction of the dangerous area and the safe area, and arranging the first photoelectric sensor and the second photoelectric sensor in the dangerous area, the exceeding area and the running direction of the transported object can be effectively judged according to the safety grating, the first photoelectric sensor and the second photoelectric sensor, and the production line can be accurately controlled according to the exceeding area and the running direction, so that the personnel can be accurately alarmed to stop while the goods are prevented from triggering the stop by mistake. BRIEF DESCRIPTION OF DRAWINGS

[0017] In order to more clearly illustrate the technical solutions of the embodiments of the present application, the following will briefly introduce the drawings needed to be used in the description of the embodiments of the present application. Obviously, the drawings in the following description are only some embodiments of the present application, and other drawings can be obtained by those skilled in the art without creative labor.

[0018] Figure 1 is a flowchart of a control method of a production line in an embodiment of the present application; Figure 2 is a structural schematic diagram of a production line in an embodiment of the present application; Figure 3 is a structural schematic diagram of another production line in an embodiment of the present application; Figure 4 is a structural schematic diagram of a control device of a production line in an embodiment of the present application; Figure 5 is a schematic diagram of a computer device in an embodiment of the present application. DETAILED DESCRIPTION

[0019] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some embodiments of the present application, not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor are within the protection scope of the present application.

[0020] In an embodiment, as shown in Figure 1As shown, a production line control method is provided. The method is applied to a safety light barrier. The safety light barrier includes multiple lamp beads. The production line includes a dangerous area and a safe area. The safety light barrier is deployed at the junction of the dangerous area and the safe area. The dangerous area is provided with a first photoelectric sensor and a second photoelectric sensor, including the following steps: 101. Obtain the preset area data of the transported objects on the production line.

[0021] In an embodiment of the present invention, the above production line can be Figure 2 The schematic diagram of a production line further illustrates this. The AOPD represents a safety light curtain, D1 represents the first photoelectric sensor, D2 represents the second photoelectric sensor, and x1 and x2 represent the gaps between the cargo and the safety light curtain. In practical applications, the safety light curtain (AOPD) can be a Type 4 through-beam infrared light curtain device with high resolution and fast response. The first and second photoelectric sensors D1 and D2 are preferably through-beam photoelectric switches, which can determine the direction of movement based on the order in which the target obstructs them.

[0022] The control method of the above-mentioned production line can be applied to the control system, and the above-mentioned control system can be deployed in the above-mentioned safety light curtain. It can be understood that when the safety light curtain is a beam-type infrared light curtain device, that is, it can include a transmitting end and a receiving end, usually the transmitting end and the receiving end are respectively provided with a processing chip. The above-mentioned control system (or understood as the control method) can be deployed in the processing chip of the above-mentioned transmitting end, or it can also be deployed in the processing chip of the receiving end, or an additional safety controller can be set up and deployed in the safety controller, and the above-mentioned safety light curtain and the photoelectric sensor are electrically connected by the above-mentioned safety controller to implement the control method of the above-mentioned production line.

[0023] The aforementioned preset area data can refer to the standard dimensions of objects transported on the production line, which can be obtained through various methods. This data can be used to determine whether the objects are exceeding the area limit or experiencing occlusion, and to determine whether to trigger a safety response.

[0024] Specifically, the preset area data can be derived from historical statistical data. This involves sampling the length, width, and height of different batches of transported items multiple times during the initial stages of production or operation. The system then calculates the typical size range (e.g., mean ± standard deviation) to generate a reference area parameter for this type of transported item. This statistical result can be categorized and managed by batch, material number, product model, and other factors for quick matching and recall.

[0025] Alternatively, the preset area data can also be a set value directly read from the process parameters or production orders, such as product specification data issued by the MES system in a partially automated production line, or the geometric boundary size of the transported object predefined in the process recipe table. After obtaining, the size parameter is converted into area data and used as a reference for subsequent quick matching calls.

[0026] The preset area data obtained by any of the above methods can be associated with the arrangement structure of the grating lamp beads, thereby providing a basis for subsequent target lamp bead screening, abnormal area judgment, and other operations.

[0027] 102. Based on the preset area data, a plurality of target lamp beads are determined from the plurality of lamp beads.

[0028] In the embodiments of the present application, based on the preset area data of the transported object, a target lamp bead set for area out-of-limit judgment can be determined from the plurality of lamp beads included in the safety grating. The target lamp bead can be understood as an unshieldable lamp bead, i.e., a light beam channel that should not be shielded during the normal passing process of the transported object.

[0029] The preset area data of the transported object usually corresponds to a standard shielding area of the transported object on the projection plane of the safety grating, which can be determined by the boundary size of the transported object and the installation direction of the grating. For example, in the case of vertical installation of the grating, the transported object may shield a continuous number of lamp bead regions when passing. To identify the area out-of-limit risk, a certain number of lamp bead numbers can be further expanded upward, downward, or outward from the standard shielding area in the arrangement direction of the grating lamp beads, as a boundary determination area, and the above-mentioned expanded area constitutes an initial target lamp bead candidate set.

[0030] Further, to enhance adaptability and robustness, historical operation data can be combined to statistically analyze the shielding frequency of each lamp bead in a plurality of previous passing periods and the associated system response state. If the shielding frequency of a certain lamp bead is low, but once shielded, it is significantly associated with a non-safety response event (such as false stop, personnel misentry, cargo stacking, etc.), then the lamp bead can be classified as an unshieldable lamp bead. The number set composed of a plurality of such lamp beads constitutes the target lamp bead set (i.e., a plurality of target lamp beads) for subsequent area out-of-limit judgment and safety control decision.

[0031] In the above manner, dynamic identification and accurate definition of the key light curtain area can be achieved, thereby effectively enhancing the identification ability of the transported object out-of-bound behavior and the protection response efficiency of abnormal events without interfering with the normal logistics passing.

[0032] 103. Based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target lamp bead, the direction of travel of the transported object on the production line is determined.

[0033] In the embodiment of the present application, the running direction of the transported object on the production line can be determined based on at least two of the first photoelectric sensor, the second photoelectric sensor and the target lamp bead, and the normal transportation and abnormal reverse crossing behavior can be distinguished.

[0034] The first photoelectric sensor and the second photoelectric sensor are arranged on one side of the dangerous area and arranged in front and back along the direction of the transportation path, and are used to sense the moving track of the transported object before approaching the safety grating. When the transported object successively blocks the first photoelectric sensor and the second photoelectric sensor, and further triggers the blocking event of the target lamp bead, it can be determined that the transported object moves from the dangerous area to the safe area, which belongs to the normal running direction.

[0035] If the blocking sequence is reversed, that is, the second photoelectric sensor is triggered first and then the first photoelectric sensor is triggered, or the target lamp bead is directly blocked without triggering the two photoelectric sensors in sequence, the system can identify that the transported object enters in reverse or there is abnormal blocking, such as reverse crossing of personnel, reverse sliding of lost objects and other abnormal operation behaviors.

[0036] 104. Based on the target lamp bead, the exceeding area of the transported object on the production line is determined.

[0037] In the embodiment of the present application, the safety grating is usually composed of a plurality of infrared emission and receiving pairs, which are arranged at equal intervals in the vertical direction (i.e. the height direction). Each pair of emission / receiving units is defined as a “lamp bead”. These lamp beads form a sequence according to the number, and different numbers correspond to specific vertical height positions in the physical space. The blocking state of each lamp bead can be obtained in real time, and a blocking data set at the current time is formed.

[0038] When the transported object enters the safety grating detection area, the number set of the blocked lamp beads can be periodically obtained and compared with the preset target lamp bead set. The preset target lamp bead set is an unblockable lamp bead interval calculated based on the preset area data of the transported object, which represents the light beam area that should not be touched by the transported object in the normal posture and standard volume. Once it is detected that a target lamp bead is blocked, it is initially considered that the transported object may have exceeded the boundary.

[0039] In order to realize the quantitative judgment of the exceeding area, the following method can be used for area estimation: assuming that the vertical interval between the safety grating lamp beads is d (for example, 10 mm), the sensing width of the grating is w (for example, 500 mm), and the number of target lamp beads blocked is n, then the blocked area S = n x d x w can be calculated. The area value represents the unblockable area actually blocked by the current transported object, that is, the “exceeding area”.

[0040] 105. Based on the exceeding area and the running direction, the production line is controlled and processed.

[0041] In the embodiment of the present application, the above exceeding area is compared with a preset area threshold to determine whether the transport object exceeds the safety boundary. The area threshold can be set based on the preset area data of the transport object, for example, set as 110% of the standard area as the upper limit of tolerance, and the preset area threshold is 10%, so as to improve the fault tolerance capability for abnormal state. When the judgment result is that the actual shielding area is greater than or equal to the set threshold, it is determined that the current transport object exceeds the specified detection range.

[0042] Meanwhile, the actual moving direction of the transport object can also be determined based on at least two of the first photoelectric sensor, the second photoelectric sensor and the target lamp bead. If the judgment result is that the transport object moves from the dangerous area to the safe area, it is considered as normal transport behavior; if the judgment result is that the transport object enters in the opposite direction or the shielding sequence is abnormal, it is considered as direction abnormality or illegal intrusion event.

[0043] When any one of the exceeding area determination result and the moving direction determination result is abnormal (i.e. area exceeding limit or direction abnormality), the production line is switched from the current safe working state to the non-safe working state, and corresponding control processing operation is performed, such as outputting stop control instruction, triggering sound and light alarm, cutting off power supply of the equipment, so as to ensure the safety of personnel and equipment.

[0044] In the above manner, the safety control logic based on the joint determination of area and direction can be realized, so as to effectively avoid the risk of production line safety caused by the out-of-bound transport object, reverse intrusion or other irregular operation. The processing manner not only improves the accuracy and timeliness of safety response, but also improves the adaptability of intelligent production line to complex operation state.

[0045] In the embodiment of the present application, the preset area data of the transport object on the production line is obtained; based on the preset area data, a plurality of target lamp beads are determined from the plurality of lamp beads; based on at least two of the first photoelectric sensor, the second photoelectric sensor and the target lamp bead, the moving direction of the transport object on the production line is determined; based on the target lamp bead, the exceeding area of the transport object on the production line is determined; and based on the exceeding area and the moving direction, the production line is controlled and processed. By deploying the safety grating at the junction of the dangerous area and the safe area, and setting the first photoelectric sensor and the second photoelectric sensor in the dangerous area, the exceeding area and the moving direction of the transport object can be effectively determined according to the safety grating, the first photoelectric sensor and the second photoelectric sensor, and then the production line is accurately controlled and processed according to the exceeding area and the moving direction, so as to effectively ensure that personnel can accurately alarm stop while avoiding false triggering of stop caused by goods passing.

[0046] It can be understood that in the specific embodiments of the present application, related data such as area data, historical shielding data, and shielding duration are involved. When the embodiments in the present application are applied to specific products or technologies, user permission or consent is required, and the collection, use, and processing of related data, as well as the construction and use of the production line, safety grating, and photoelectric sensor, need to comply with relevant laws, regulations, and standards of the country and region.

[0047] Optionally, in the step of determining the target light beads from the plurality of light beads based on the preset area data, a matrix of arrangement of the plurality of light beads in the deployment position of the safety grating can also be obtained; and in the matrix of arrangement, the target light beads are extracted based on the preset area data.

[0048] In the embodiments of the present application, the plurality of light beads in the safety grating can be uniformly arranged in a vertical or two-dimensional matrix form to form a spatial distribution structure for detecting shielding. To achieve more accurate detection range determination, a matrix of arrangement of the light beads in the grating can be established first, which is used to describe the correspondence between the numbering and position of each light bead in space.

[0049] In combination with the preset area data of the transported object, the numbering range of the light beads that should be shielded in the grating area can be calculated according to the height, width, and other parameters of the transported object. For example, if the height of the transported object is 300 mm, the width is 400 mm, and the spacing between the light beads is 10 mm, then the light bead numbering block in the range of 30 consecutive rows from the bottom and 40 columns horizontally in the matrix of arrangement can be located as the preliminary shielding area.

[0050] On the basis of the preliminary area, the shielding boundary can be further expanded upward, downward, or laterally in combination with the deployment position of the grating, risk control requirements, or historical out-of-bound situations. Finally, the set of light bead numbers corresponding to the expanded area is extracted from the matrix of arrangement to form a set of target light beads for out-of-bound judgment, which serves as the basis for subsequent judgment of events such as shielding abnormality and area out-of-limit of the transported object.

[0051] By introducing the mapping relationship between the light bead arrangement matrix and the preset area, the detection area can be finely demarcated, which helps to improve the sensitivity of out-of-bound judgment and the accuracy of safety control.

[0052] Optionally, in the step of extracting the target light beads based on the preset area data in the matrix of arrangement, the historical shielding data of the safety grating can also be obtained; in the historical shielding data, the shielding records matching the preset area data are filtered out as target shielding data; based on the target shielding data, the shielding frequency of each light bead in the matrix of arrangement and the corresponding system response state when shielding are counted, the system response state including a non-safety response; and based on the association between the shielding frequency and the non-safety response, the target light beads meeting the out-of-bound judgment requirements are determined in the matrix of arrangement.

[0053] In the embodiments of the present application, in order to further improve the screening accuracy of the target lamp bead, in addition to directly positioning the shielding area based on the preset area data, the historical shielding data of the safety grating can also be introduced for auxiliary judgment. The historical shielding data usually records the state change process of each lamp bead being shielded during the passing of the safety grating by the plurality of transported objects, and the event record of whether a non-safety response is triggered.

[0054] By screening the historical shielding record matched with the current preset area data, a set of target shielding data can be formed, which reflects the actual shielding situation of the grating by similar transported objects under normal operation or abnormal state.

[0055] Further, based on the target shielding data, the shielding frequency of each lamp bead in the arrangement matrix can be counted, and the corresponding system response state when it is shielded, such as whether it triggers line shutdown, alarm prompt or other non-safety response behavior, is extracted. For those lamp beads that are almost never shielded in most normal shielding records, or once shielded, are highly related to non-safety response events, it can be determined that they have higher out-of-bound risk sensitivity.

[0056] Based on the above association between the shielding frequency and the non-safety response, the target lamp bead meeting the out-of-bound judgment requirement in the arrangement matrix is screened out, which is used as the key detection point for subsequent out-of-area judgment, alarm triggering and control response.

[0057] Through the target lamp bead screening strategy based on historical data, higher discrimination accuracy and safety control robustness can be achieved, which is especially suitable for production line scenes with diverse transported object specifications, compact operation rhythm or complex environmental interference factors.

[0058] Optionally, in the step of controlling the production line based on the out-of-area and the direction of travel, the out-of-area and the preset area threshold can also be compared to obtain a first comparison result; the direction of travel and the preset direction of travel can be compared to obtain a second comparison result; and the production line can be controlled based on at least one of the first comparison result and the second comparison result.

[0059] In the embodiments of the present application, when controlling the production line based on the out-of-area and the direction of travel, a comparison mechanism can be introduced to make a more accurate judgment on the state of the transported object. Specifically, the actual out-of-area calculated by shielding the target lamp bead can be compared with the preset area threshold to determine whether it exceeds the allowed range, thereby generating a first comparison result. If the out-of-area is greater than or equal to the threshold, it is considered as area out-of-bound; otherwise, it is considered as fluctuating within a reasonable range.

[0060] At the same time, the currently detected direction of the transported object can be compared with the preset compliance direction to generate a second comparison result. For example, on a one-way production line, if the direction detection result indicates that the transported object is entering in the opposite direction or in an abnormal direction, it can be determined that the operation does not meet the requirements.

[0061] Either of these two comparison results can be used to determine whether to implement control measures on the production line. Specifically, if the first comparison result indicates an area out-of-bounds, or the second comparison result indicates an abnormal direction, a safety control mechanism should be triggered, such as suspending the production line or issuing an audible or visual alarm. If both comparison results are normal, the production line maintains normal operation.

[0062] By introducing a dual judgment mechanism of area and direction, the ability to identify abnormal transportation behavior can be significantly enhanced, and the overall safety protection level of the system and the accuracy of production line response can be improved.

[0063] Optionally, in the step of controlling the production line based on at least one of the first comparison result and the second comparison result, the occlusion duration of the transported object when the target lamp bead judges the excess area of ​​the transported object on the production line can also be obtained; when the occlusion duration meets the preset duration threshold, the production line is controlled based on at least one of the first comparison result and the second comparison result.

[0064] To further enhance judgment accuracy and system robustness, in this embodiment of the present invention, in addition to the control processing based on the first and second comparison results, an occlusion duration analysis mechanism can be introduced. Specifically, when determining whether a transported object is occluding a target LED, the start and end times of the occlusion can be recorded in real time, and the corresponding occlusion duration can be calculated.

[0065] If a target LED is blocked for a duration exceeding a preset threshold, the blockage is considered stable and persistent, not a fleeting nuisance or temporary interruption. In this case, combining at least one of the first comparison result (area out-of-bounds) and the second comparison result (direction abnormality) can more reliably trigger production line control measures.

[0066] For example, if the target LED is continuously blocked for more than 500ms and the area is judged to be out of bounds, even if the direction of travel is normal, it can be determined that there is an abnormal height or offset of the transported object, and the production line should be stopped immediately; if the blockage time is short and only momentary, it can be ignored to avoid misjudgment and false stop.

[0067] By introducing the occlusion duration dimension as an auxiliary judgment basis, the misjudgment caused by occasional occlusion can be effectively filtered out, the system's ability to identify real abnormal conditions can be enhanced, and the timeliness and rationality of control processing can be ensured.

[0068] Optionally, in the step of controlling the production line based on at least one of the first comparison result and the second comparison result, when the first comparison result is that the exceeding area is greater than or equal to the preset area threshold, the production line is controlled to stop; when the second comparison result is that the advancing direction does not conform to the preset advancing direction, the production line is controlled to stop; and when the first comparison result is that the exceeding area is less than the preset area threshold and the second comparison result is that the advancing direction conforms to the preset advancing direction, the production line is controlled to normally operate.

[0069] In the embodiment of the present application, in order to achieve more refined production line operation control, different control strategies can be executed based on the joint situation of the first comparison result and the second comparison result. When the first comparison result indicates that the exceeding area of the transported object is greater than or equal to the set area threshold, it can be determined that the size of the current transported object is abnormal, and there may be hidden dangers such as overheight, stacking, and deviation. At this time, the production line should be immediately controlled to stop to prevent equipment from being stuck, colliding, or personnel from being injured during transportation.

[0070] When the second comparison result judges that the advancing direction of the transported object does not conform to the preset normal direction (such as detecting reverse entry or lateral interference), it is also regarded as an abnormal situation, and the production line is also triggered to stop to prevent dangerous events caused by misoperation or personnel intrusion.

[0071] Conversely, when the first comparison result judges that the area of the transported object is not over-limited, and the second comparison result judges that the advancing direction is normal, that is, the transported object is in a controllable and safe state, the production line is allowed to maintain normal operation, and no alarm or intervention is triggered.

[0072] By setting the control logic of the above three different situations, not only can safety measures be taken in time when the size or direction of the transported object is abnormal, but also unnecessary shutdown caused by slight errors or occasional events can be effectively avoided, thereby ensuring the safety and continuity of the production line operation.

[0073] Optionally, in the step of controlling the production line to stop, a shutdown instruction can also be sent to the driving device of the production line to make the production line stop, and an audible and visual alarm device is used for alarm prompting.

[0074] In the embodiment of the present application, in order to ensure that the production line can respond in time and remind the operator when a non-safe state is identified, the following specific operations can be performed in the process of controlling the production line to stop: First, a shutdown control signal is generated according to the aforementioned judgment logic, and the signal is transmitted to the driving device linked with the production line through wired or wireless mode. After the driving device receives the shutdown instruction, it will interrupt the control of the conveying motor or the actuator, so that the production line immediately stops running, preventing the transported object from continuing to advance and causing greater safety risks.

[0075] Secondly, after the stop command is issued, the sound and light alarm device such as the buzzer and the warning light can be triggered synchronously to send the alarm signal at the preset alarm rhythm. The sound and light prompt can effectively remind the on-site personnel to pay attention to the current abnormal state, and timely investigate the cause and handle the safety hazard.

[0076] By combining the electrical control and the physical prompt, not only the rapid response and the stop control can be realized, but also the warning ability of the system to the sudden risk can be enhanced, and the overall production line safety protection level can be improved.

[0077] In a possible embodiment, the above production line can also be another production line structure schematic diagram as shown in Figure 3 As shown in Figure 3 , the AOPD is a safety grating, which is deployed at the junction of the safe area and the dangerous area, D1 is a first photoelectric sensor, D2 is a second photoelectric sensor, a and b are the gaps between the goods and the safety grating, and L is the length of the workpiece. It should be noted that the intersection position of the first sensor and the second sensor is arranged on the dangerous area side, and the intersection position and the workpiece movement direction are not on the same central axis. Through the above production line arrangement, the production line control during the bidirectional passage detection of the equipment can be realized.

[0078] In the production line, the logic value of the safety curtain has a corresponding relationship with the system safety state: Initial state: the safety curtain logic value is 1, the system safety output is 1, and it is indicated that if the curtain is blocked, the system will be directly stopped; When D1 is blocked or D2 is blocked: the safety curtain is still 1, the safety output is 1, and the function state is “at this time, the curtain is blocked and the system is directly stopped”; When D2 is continuously blocked for more than 2s: the safety curtain remains 1, but the safety state is set to 1, at this time, even if the curtain is blocked, the system will not be immediately stopped, and only when the preset time (such as 5 minutes) is exceeded and the curtain is not restored, the system will be forced to stop; When the safety curtain is blocked: the safety curtain value becomes 0, the safety output is 1, and the system function state is “at this time, the curtain is blocked and the system is not stopped”, and if the preset time is exceeded, the system will be directly stopped; When the safety curtain is restored: the safety curtain returns to 1, the safety state remains 1, and the system continues to allow the goods to pass, and if the total time exceeds 5 minutes, the system will be stopped; When D1 is restored, or D1 is restored for 1s, or D2 is restored: the safety curtain value gradually returns to 1, the safety state is cleared, and the system reenters the initial safety state.

[0079] Through the logic setting, when personnel accidentally enter a dangerous area and block the light curtain, the system will immediately trigger shutdown, thereby ensuring personal safety; while in the normal passing of goods, the system allows the goods to pass without triggering shutdown through the judgment of the sequence of D1 and D2, the blocking time and the recovery of the light curtain, combined with the safety delay control, avoiding the false shutdown caused by material blocking, and balancing the safety and the continuity of the production line.

[0080] It should be understood that the size of the serial number of each step in the above embodiment does not mean the order of execution, and the execution order of each process should be determined according to its function and internal logic, and should not constitute any limitation on the implementation process of the embodiment of the present application.

[0081] In an embodiment, a production line control device is provided, which corresponds to the production line control method in the above embodiment. As shown in the figure, the production line control device includes a first acquisition module 401, a first determination module 402, a first judgment module 403, a second judgment module 404, and a control module 405. The function modules are described in detail as follows: Figure 4 The first acquisition module 401 is configured to acquire preset area data of a transported object on the production line. The first determination module 402 is configured to determine a plurality of target light beads from the plurality of light beads based on the preset area data. The first judgment module 403 is configured to judge the direction of travel of the transported object on the production line based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target light beads. The second judgment module 404 is configured to judge the exceeding area of the transported object on the production line based on the target light beads. The control module 405 is configured to control the production line based on the exceeding area and the direction of travel.

[0082] Optionally, the first determination module 402 is further configured to: acquire an arrangement matrix of the deployment positions of the plurality of light beads in the safety grating; extract the target light beads in the arrangement matrix based on the preset area data.

[0083] Optionally, the first determination module 402 is further configured to: acquire historical blocking data of the safety grating; filter out the blocking records matched with the preset area data from the historical blocking data as target blocking data; ​Based on the target shielding data, the shielding frequency of each lamp bead in the arrangement matrix and the corresponding system response state when shielding are counted, and the system response state includes a non-safe response; Based on the association between the shielding frequency and the non-safe response, a target lamp bead meeting the out-of-boundary judgment requirement is determined in the arrangement matrix.

[0084] Optionally, the control module 405 is further configured to: Based on the comparison between the exceeding area and the preset area threshold, a first comparison result is obtained; Based on the comparison between the advancing direction and the preset advancing direction, a second comparison result is obtained; Based on at least one of the first comparison result and the second comparison result, the production line is controlled.

[0085] Optionally, the control module 405 is further configured to: When the target lamp bead judges the exceeding area of the transported object on the production line, the shielding duration of the transported object is obtained; When the shielding duration meets the preset duration threshold, based on at least one of the first comparison result and the second comparison result, the production line is controlled.

[0086] Optionally, the control module 405 is further configured to: When the first comparison result is that the exceeding area is greater than or equal to the preset area threshold, the production line is controlled to stop; When the second comparison result is that the advancing direction does not meet the preset advancing direction, the production line is controlled to stop; When the first comparison result is that the exceeding area is less than the preset area threshold, and the second comparison result is that the advancing direction meets the preset advancing direction, the production line is controlled to normally operate.

[0087] Optionally, the control module 405 is further configured to: A shutdown instruction is sent to a driving device of the production line, so that the production line is shut down; And an audible and visual alarm device is used for alarm prompt.

[0088] Each module in the control device of the production line can be realized by software, hardware and their combinations in whole or in part. Each module can be embedded in or independent of the processor in the computer device in hardware form, or can be stored in the memory in the computer device in software form, so as to be called and executed by the processor to perform the operations corresponding to each module.

[0089] In one embodiment, a computer device is provided. The computer device may be a terminal device, and its internal structure diagram may be as follows: Figure 5 As shown. The computer device includes a processor, a memory, and a network interface connected via a system bus. The processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a readable storage medium. The readable storage medium stores computer-readable instructions. The network interface of the computer device is used to communicate with an external terminal via a network connection. When the computer-readable instructions are executed by the processor, a production line control method is implemented. The readable storage medium provided in this embodiment includes a non-volatile readable storage medium and a volatile readable storage medium.

[0090] In an embodiment of the present application, a computer device is provided, including a memory, a processor, and computer-readable instructions stored in the memory and executable on the processor. When the processor executes the computer-readable instructions, the steps of the control method for the production line described above are implemented.

[0091] In an embodiment of the application, a readable storage medium is provided, which stores computer-readable instructions. When the computer-readable instructions are executed by a processor, the steps of the control method of the production line as described above are implemented.

[0092] Those skilled in the art will understand that all or part of the processes in the above-mentioned embodiments can be implemented by instructing related hardware through computer-readable instructions. The computer-readable instructions can be stored in a non-volatile readable storage medium or a volatile readable storage medium. When the computer-readable instructions are executed, they can include the processes of the embodiments of the above-mentioned methods. Among them, any reference to memory, storage, database or other media used in the embodiments provided in this application may include non-volatile and / or volatile memory. Non-volatile memory may include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM) or flash memory. Volatile memory may include random access memory (RAM) or external cache memory. By way of illustration and not limitation, RAM is available in many forms such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), Synchronous Link DRAM (SLDRAM), Rambus direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM), etc.

[0093] Those skilled in the art can clearly understand that, for the convenience and brevity of description, only the above-mentioned division of each functional unit and module is exemplified, and in actual application, the above-mentioned functions can be completed by different functional units and modules according to needs, that is, the internal structure of the device is divided into different functional units or modules to complete all or part of the functions described above.

[0094] The above examples are only used to illustrate the technical solutions of the present application, but not to limit them; although the present application has been described in detail with reference to the foregoing examples, those skilled in the art should understand that the technical solutions recorded in the foregoing examples can still be modified, or some technical features can be replaced by equivalents; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the spirit and scope of the technical solutions of the embodiments of the present application, and should be included in the protection scope of the present application.

Claims

1. A production line control method, characterized in that: The method is applied to a safety light grating, wherein the safety light grating includes a plurality of lamp beads, the production line includes a dangerous area and a safe area, the safety light grating is deployed at the junction of the dangerous area and the safe area, and the dangerous area is provided with a first photoelectric sensor and a second photoelectric sensor. The method includes: Obtaining preset area data of the transported objects on the production line; Based on the preset area data, determining a plurality of target lamp beads from the plurality of lamp beads; Determine the direction of travel of the transported object on the production line based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target lamp bead; Based on the target lamp beads, determining the excess area of ​​the transported objects on the production line; The production line is controlled based on the excess area and the traveling direction.

2. The production line control method according to claim 1, wherein: The step of determining a plurality of target lamp beads from the plurality of lamp beads based on the preset area data comprises: Obtaining an arrangement matrix of deployment positions of the plurality of lamp beads in the safety grating; In the arrangement matrix, the target lamp beads are extracted based on the preset area data.

3. The production line control method according to claim 2, characterized in that: The step of extracting the target lamp beads in the arrangement matrix based on the preset area data includes: Obtaining historical occlusion data of the safety grating; Filtering out occlusion records matching the preset area data from the historical occlusion data as target occlusion data; Based on the target occlusion data, counting the occlusion frequency of each lamp bead in the arrangement matrix and the corresponding system response state when occluded, the system response state including a non-safe response; Based on the shading frequency and the correlation relationship with the non-safety response, target lamp beads that meet the cross-border determination requirements are determined in the arrangement matrix.

4. The production line control method according to claim 1, wherein: The controlling process of the production line based on the excess area and the moving direction includes: Performing a comparison process based on the exceeded area and a preset area threshold to obtain a first comparison result; Performing a comparison process based on the traveling direction and a preset traveling direction to obtain a second comparison result; Based on at least one of the first comparison result and the second comparison result, control processing is performed on the production line.

5. The production line control method according to claim 4, characterized in that: The controlling process of the production line based on at least one of the first comparison result and the second comparison result includes: Obtaining the duration of occlusion of the transported object when the target lamp bead determines the excess area of ​​the transported object on the production line; When the shielding duration meets a preset duration threshold, the production line is controlled based on at least one of the first comparison result and the second comparison result.

6. The production line control method according to claim 4 or 5, characterized in that: The controlling process of the production line based on at least one of the first comparison result and the second comparison result includes: When the first comparison result shows that the excess area is greater than or equal to the preset area threshold, controlling the production line to stop; When the second comparison result shows that the moving direction does not conform to the preset moving direction, controlling the production line to stop; When the first comparison result is that the excess area is smaller than the preset area threshold, and the second comparison result is that the moving direction conforms to the preset moving direction, the production line is controlled to operate normally.

7. The production line control method according to claim 6, characterized in that: The controlling the production line to stop includes: Sending a stop command to a drive device of the production line to stop the production line; And alarm prompts are given through sound and light alarm devices.

8. A control device for a production line, characterized in that: The device is applied to a safety grating, the safety grating includes a plurality of lamp beads, the production line includes a dangerous area and a safe area, the safety grating is deployed at the junction of the dangerous area and the safe area, the dangerous area is provided with a first photoelectric sensor and a second photoelectric sensor, and the device includes: A first acquisition module is used to obtain preset area data of the transported objects on the production line; A first determining module is configured to determine a plurality of target lamp beads from the plurality of lamp beads based on the preset area data; a first determination module, configured to determine a direction of travel of the transported object on the production line based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target lamp bead; A second judgment module is used to judge the excess area of ​​the transported objects on the production line based on the target lamp beads; A control module is used to control the production line based on the excess area and the moving direction.

9. A computer device comprising a memory, a processor, and computer-readable instructions stored in the memory and executed on the processor, wherein: When the processor executes the computer-readable instructions, the production line control method according to any one of claims 1 to 7 is implemented.

10. A computer-readable storage medium having computer-readable instructions stored thereon, characterized in that: When the computer-readable instructions are executed by a processor, the production line control method according to any one of claims 1 to 7 is implemented.

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