Production line control methods, devices, computer equipment, and storage media

Abstract

This invention discloses a production line control method, device, computer equipment, and storage medium. The method includes: acquiring preset area data of transported items on the production line; identifying multiple target LEDs from among multiple LEDs based on the preset area data; determining the direction of travel of the transported items on the production line based on at least two of a first photoelectric sensor, a second photoelectric sensor, and the target LEDs; determining the area of ​​the transported items exceeding the permitted area based on the target LEDs; and controlling the production line based on the area exceeding the permitted area and the direction of travel. By effectively determining the area exceeding the permitted area and the direction of travel of the transported items using a safety light curtain, the first photoelectric sensor, and the second photoelectric sensor, and then accurately controlling the production line based on the area exceeding the permitted area and the direction of travel, the method effectively ensures accurate alarm and shutdown when personnel enter, while preventing accidental shutdown caused by goods passing through.

Description

Technical Field

[0001] This invention relates to the field of sensors, and more particularly to a control method, apparatus, computer equipment, and storage medium for a production line. Background Technology

[0002] In industrial manufacturing, assembly lines are widely used for large-scale continuous production. To achieve quantity counting, size measurement, and position identification of transported goods, production lines are typically equipped with various sensors, among which safety light curtains are a commonly used non-contact detection device. A safety light curtain consists of an infrared beam array composed of a transmitter and a receiver, used to detect whether an object crosses the light curtain area. When an obstruction is detected, the system considers it a risk factor and immediately outputs a stop signal, halting the assembly line or operating equipment.

[0003] However, in practical applications, safety light curtains not only respond to personnel intrusions but also frequently trigger shutdowns due to the normal passage of goods, severely impacting production line efficiency. Especially in high-speed or continuous feeding scenarios, the system struggles to effectively distinguish between "goods allowed to pass" and "personnel that should be stopped," thus creating a conflict between ensuring personal safety and maintaining production efficiency.

[0004] Therefore, how to ensure accurate alarm and shutdown when personnel enter, while avoiding accidental shutdown caused by goods passing through, has become a technical problem that urgently needs to be solved in this field. Summary of the Invention

[0005] Therefore, it is necessary to provide a production line control method, device, computer equipment, and storage medium to address the above-mentioned technical problems. This method and device can effectively distinguish between normal transported goods and abnormal intruders, reduce the misjudgment rate, and improve the efficiency and safety of production line operation.

[0006] A production line control method is applied to a safety light curtain, the safety light curtain comprising multiple LEDs, the production line comprising a hazardous area and a safe area, the safety light curtain being deployed at the boundary between the hazardous area and the safe area, the hazardous area being equipped with a first photoelectric sensor and a second photoelectric sensor, the method comprising:

[0007] Obtain the preset area data of the transported items on the production line;

[0008] Based on the preset area data, multiple target LED beads are identified from among the multiple LED beads;

[0009] Based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target LED bead, the direction of travel of the transported items on the production line is determined.

[0010] Based on the target LED bead, determine the area of ​​the transported items on the production line that exceeds the permitted area;

[0011] The production line is controlled based on the excess area and the direction of travel.

[0012] Optionally, determining multiple target LEDs from among the multiple LEDs based on the preset area data includes:

[0013] Obtain the arrangement matrix of the deployment positions of the multiple LED beads in the safety light curtain;

[0014] In the arrangement matrix, the target LED bead is extracted based on the preset area data.

[0015] Optionally, extracting the target LED bead from the permutation matrix based on the preset area data includes:

[0016] Obtain the historical occlusion data of the safety light curtain;

[0017] In the historical occlusion data, occlusion records that match the preset area data are selected as target occlusion data;

[0018] Based on the target occlusion data, the occlusion frequency of each LED in the permutation matrix and its corresponding system response state when occluded are statistically analyzed, and the system response state includes unsafe responses.

[0019] Based on the occlusion frequency and its correlation with unsafe responses, target LED beads that meet the boundary judgment requirements are determined in the permutation matrix.

[0020] Optionally, the process of controlling the production line based on the excess area and the direction of travel includes:

[0021] A comparison is performed based on the area exceeding the limit and a preset area threshold to obtain a first comparison result;

[0022] A comparison is performed based on the stated direction of travel and a preset direction of travel to obtain a second comparison result;

[0023] The production line is controlled based on at least one of the first comparison result and the second comparison result.

[0024] Optionally, the step of controlling the production line based on at least one of the first comparison result and the second comparison result includes:

[0025] The duration of the obstruction caused by the transported object when determining the area exceeding the limit of the target LED bead on the production line is obtained.

[0026] When the duration of the occlusion 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.

[0027] Optionally, the step of controlling the production line based on at least one of the first comparison result and the second comparison result includes:

[0028] When the first comparison result indicates that the area exceeding the limit is greater than or equal to the preset area threshold, the production line is controlled to stop.

[0029] When the second comparison result indicates that the direction of travel does not conform to the preset direction of travel, the production line is controlled to stop.

[0030] When the first comparison result indicates that the area exceeding the limit is less than the preset area threshold, and the second comparison result indicates that the direction of travel conforms to the preset direction of travel, the production line is controlled to operate normally.

[0031] Optionally, controlling the production line to stop includes:

[0032] Send a stop command to the drive unit of the production line to stop the production line;

[0033] An alarm will be triggered via an audible and visual alarm device.

[0034] A control device for a production line, the device being applied to a safety light curtain, the safety light curtain comprising multiple LEDs, the production line comprising a hazardous area and a safe area, the safety light curtain being deployed at the boundary between the hazardous area and the safe area, the hazardous area being equipped with a first photoelectric sensor and a second photoelectric sensor, the device comprising:

[0035] The first acquisition module is used to acquire preset area data of the transported items on the production line;

[0036] The first determining module is used to determine multiple target LED beads among the multiple LED beads based on the preset area data;

[0037] The first judgment module is used to 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.

[0038] The second judgment module is used to determine the area of ​​the transported items on the production line that exceeds the target LED bead.

[0039] The control module is used to control the production line based on the excess area and the direction of travel.

[0040] A computer device includes a memory, a processor, and computer-readable instructions stored in the memory and executable on the processor, wherein the processor implements the aforementioned production line control method when executing the computer-readable instructions.

[0041] A readable storage medium storing computer-readable instructions thereon, which, when executed by a processor, implement the aforementioned production line control method.

[0042] The aforementioned production line control method, device, computer equipment, and storage medium acquire preset area data of the transported items on the production line; based on the preset area data, identify multiple target LEDs among the multiple LEDs; determine the travel direction of the transported items on the production line based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target LEDs; determine the over-area of ​​the transported items on the production line based on the target LEDs; and control the production line based on the over-area and the travel direction. By deploying safety light curtains at the boundary between hazardous and safe areas, and installing first and second photoelectric sensors in the hazardous area, the over-area and travel direction of the transported items can be effectively determined based on the safety light curtains, the first photoelectric sensor, and the second photoelectric sensor. This allows for accurate control of the production line based on the over-area and travel direction, effectively ensuring accurate alarm and shutdown when personnel enter, while preventing accidental shutdowns caused by goods passing through. Attached Figure Description

[0043] To more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0044] Figure 1 This is a flowchart illustrating a production line control method according to an embodiment of the present invention;

[0045] Figure 2 This is a schematic diagram of a production line structure in one embodiment of the present invention;

[0046] Figure 3 This is a schematic diagram of another production line structure in one embodiment of the present invention;

[0047] Figure 4 This is a schematic diagram of a production line control device in one embodiment of the present invention;

[0048] Figure 5 This is a schematic diagram of a computer device according to an embodiment of the present invention. Detailed Implementation

[0049] 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, not all, of the embodiments of the present invention. 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.

[0050] In one embodiment, such as Figure 1 As shown, a production line control method is provided. The method is applied to a safety light curtain, which includes multiple LEDs. The production line includes a hazardous area and a safe area. The safety light curtain is deployed at the boundary between the hazardous area and the safe area. The hazardous area is equipped with a first photoelectric sensor and a second photoelectric sensor. The method includes the following steps:

[0051] 101. Obtain the preset area data of the transported items on the production line.

[0052] In this embodiment of the invention, the above-mentioned production line can be achieved through, for example... Figure 2 The schematic diagram of a production line further illustrates this, where AOPD is a safety light curtain, D1 is a first photoelectric sensor, D2 is a second photoelectric sensor, and x1 and x2 are the gaps between the goods and the safety light curtain. In practical applications, the safety light curtain (AOPD) can be a Type 4 through-beam infrared light curtain device, which has high resolution and fast response characteristics; the first photoelectric sensor D1 and the second photoelectric sensor D2 are preferably through-beam photoelectric switches, so as to determine the direction of movement of the target object by the sequence of obstruction.

[0053] The control method for the production line described above can be applied to a control system. This control system can be deployed within the safety light curtain. It is understood that the safety light curtain is a through-beam infrared light curtain device, which can include a transmitter and a receiver. Typically, both the transmitter and receiver are equipped with corresponding processing chips. The control system (or control method) can be deployed on the processing chip of the transmitter, or on the processing chip of the receiver. Alternatively, a separate safety controller can be set up and deployed within the safety controller. The safety controller electrically connects the safety light curtain and the photoelectric sensor to implement the control method for the production line.

[0054] The aforementioned preset area data refers to the standard size information of the transported items in the production line, which can be obtained through various methods. This data can be used to subsequently determine whether the transported items exceed area limits, have abnormal obstructions, or otherwise cause problems, and accordingly decide whether to trigger a safety response.

[0055] Specifically, the preset area data can be obtained based on historical statistical data. That is, the system samples the length, width, and height of different batches of transported goods multiple times during the initial production or operation phases, and calculates their typical size range (such as mean ± standard deviation) to generate reference area parameters for this type of transported goods. This statistical result can be categorized and managed by batch, material number, product model, etc., for quick matching and retrieval later.

[0056] Alternatively, the preset area data can be read directly from process parameters or production orders. For example, in some automated production lines, product specification data can be issued by the MES system, or the geometric boundary dimensions of the transported goods can be predefined in the formula process table. After acquisition, the dimension parameter is converted into area data and used as a comparison benchmark for subsequent rapid matching and retrieval.

[0057] The preset area data obtained through any of the above methods can be associated with the arrangement structure of the grating LED beads, thereby providing a basis for subsequent operations such as target LED bead selection and abnormal area judgment.

[0058] 102. Based on preset area data, multiple target LED beads are identified from among multiple LED beads.

[0059] In this embodiment of the invention, a target set of LEDs for area exceeding the limit can be determined from among the multiple LEDs included in the safety light curtain, based on preset area data of the transported object. The target LEDs can be understood as unobstructed LEDs, i.e., light beam channels that should not be blocked during the normal passage of the transported object.

[0060] The preset area data of the transported object typically corresponds to a standard obstruction area on the projection surface of the safety light curtain. This area is determined by the boundary dimensions of the transported object and the installation direction of the light curtain. For example, when the light curtain is installed vertically, the transported object may obstruct a section of consecutively numbered LED beads as it passes through. To identify the risk of exceeding the area limit, a certain number of LED bead numbers can be further extended upwards, downwards, or outwards in the LED bead arrangement direction of the light curtain outside the standard obstruction area, serving as a boundary determination area. This extended area constitutes the initial target LED bead candidate set.

[0061] Furthermore, to enhance adaptability and robustness, historical operational data can be used to statistically analyze the blocking frequency of each LED in previous traffic cycles and its associated system response status. If a certain LED has a low blocking frequency, but its blocking is significantly associated with non-safety response events (such as accidental shutdown, personnel intrusion, or goods stacking), then that LED can be classified as an unshieldable LED. The set of numbers formed by multiple such LEDs constitutes the target LED set (i.e., multiple target LEDs), which is used for subsequent area over-limit judgment and safety control decisions.

[0062] The above methods enable dynamic identification and precise definition of key light curtain areas, thereby effectively enhancing the ability to identify cross-boundary behavior of transported goods and the efficiency of protection and response to abnormal events without interfering with normal logistics.

[0063] 103. Based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target LED bead, determine the direction of travel of the transported items on the production line.

[0064] In this embodiment of the invention, the direction of travel 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 LED bead, and normal transport and abnormal reverse crossing behavior can be distinguished.

[0065] The first and second photoelectric sensors are both deployed on one side of the danger zone, arranged back and forth along the transport path, to detect the movement trajectory of the transported object before it approaches the safety light curtain. When the transported object sequentially blocks the first and second photoelectric sensors, further triggering the blocking event of the target LED, it can be determined that the transported object is moving from the danger zone towards the safety zone, which is a normal direction of travel.

[0066] If the blocking sequence is reversed, i.e. the second photoelectric sensor is triggered before the first photoelectric sensor, or if the target LED is blocked directly without triggering the two photoelectric sensors in sequence, the system can identify it as the transported object entering in the opposite direction or there is abnormal blocking, such as personnel crossing in reverse or dropped objects sliding backwards, which are abnormal operating behaviors.

[0067] 104. Based on the target LED beads, determine the area of ​​the transported items on the production line that exceeds the permitted area.

[0068] In this embodiment of the invention, the safety light curtain typically consists of multiple infrared transmitting and receiving pairs, arranged at equal intervals along the vertical direction (i.e., the height direction), with each pair of transmitting / receiving units defined as a "light bead". These light beads are arranged in a sequence according to their numbers, with different numbers corresponding to specific vertical height positions in physical space. The occlusion state of each light bead can be acquired in real time, forming an occlusion dataset for the current moment.

[0069] When a transported object enters the safety light curtain detection area, the set of numbers of the blocked LED beads can be periodically acquired and compared with a preset target set of LED beads. The preset target set of LED beads is a range of unblockable LED beads calculated based on the preset area data of the transported object, representing the beam area that the transported object should not touch under normal posture and standard volume. Once a target LED bead is detected to be blocked, it is preliminarily considered that the transported object may have crossed the boundary.

[0070] To quantitatively determine the area of ​​the obstruction, the area can be estimated as follows: Assuming the vertical spacing between the safety light curtain beads is d (e.g., 10mm) and the sensing width of the light curtain is w (e.g., 500mm), if the number of target light curtain beads obstructed is n, then the obstruction area S = n × d × w can be calculated. This area value represents the area of ​​the unobstructed area actually obstructed by the transported object, i.e., the "exceeding area".

[0071] 105. Control the production line based on the area exceeding the limit and the direction of travel.

[0072] In this embodiment of the invention, the area exceeding the permitted area is compared with a preset area threshold to determine whether the transported object exceeds the safety boundary. This area threshold can be set based on preset area data of the transported object; for example, it can be set as 110% of the standard area as the upper limit of tolerance, thus the preset area threshold is 10%, to improve the fault tolerance capability for abnormal states. When the judgment result shows that the actual obstructed area is greater than or equal to the set threshold, it can be determined that the current transported object exceeds the specified detection range.

[0073] Simultaneously, the actual direction of travel of the transported object can be determined based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target LED. If the determination result is that the transported object is moving from a dangerous area to a safe area, it is considered a normal transport behavior; if it is determined to be a reverse entry or an abnormal obstruction sequence, it is considered that there is an abnormal direction or an illegal intrusion event.

[0074] If either the area determination result or the travel direction determination result is abnormal (i.e., area exceeds the limit or direction is abnormal), the production line will switch from the current safe working state to an unsafe working state and execute corresponding control processing operations, such as outputting a shutdown control command, triggering an audible and visual alarm, or cutting off the equipment power supply, to ensure the safety of personnel and equipment.

[0075] The above method enables safety control logic based on a combined assessment of area and direction, effectively preventing risks to production line safety caused by transported goods crossing boundaries, reverse intrusion, or other non-compliant operations. This approach not only improves the accuracy and timeliness of safety responses but also enhances the adaptability of intelligent production lines to complex operating conditions.

[0076] In this embodiment of the invention, preset area data of the transported items on the production line is obtained; based on the preset area data, multiple target LEDs are identified among the multiple LEDs; the direction of travel of the transported items on the production line is determined based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target LEDs; the over-area of ​​the transported items on the production line is determined based on the target LEDs; and the production line is controlled based on the over-area and the direction of travel. By deploying a safety light curtain at the boundary between the hazardous area and the safe area, and setting a first photoelectric sensor and a second photoelectric sensor in the hazardous area, the over-area and direction of travel of the transported items can be effectively determined based on the safety light curtain, the first photoelectric sensor, and the second photoelectric sensor. This allows for accurate control of the production line based on the over-area and direction of travel, effectively ensuring accurate alarm and shutdown when personnel enter, while preventing accidental shutdowns caused by goods passing through.

[0077] It is understood that in the specific embodiments of this application, data such as area data, historical occlusion data, and occlusion duration are involved. When the embodiments in this application are applied to specific products or technologies, user permission or consent is required. Furthermore, the collection, use, and processing of related data, as well as the construction and use of production lines, safety light curtains, and photoelectric sensors, must comply with the relevant laws, regulations, and standards of the relevant countries and regions.

[0078] Optionally, in the step of determining multiple target LEDs among multiple LEDs based on preset area data, a permutation matrix of the deployment positions of multiple LEDs in the safety light curtain can also be obtained; and the target LEDs can be extracted from the permutation matrix based on the preset area data.

[0079] In this embodiment of the invention, multiple LEDs in the safety light grating can be uniformly arranged in a vertical or two-dimensional matrix to form a spatial distribution structure for detecting obstructions. To achieve more accurate detection range determination, an arrangement matrix of the LEDs in the light grating can be established first. This matrix is ​​used to describe the spatial correspondence between the number and position of each LED.

[0080] By combining the preset area data of the transported object, the number range that should be blocked in the grating area can be calculated based on parameters such as the height and width of the transported object. For example, if the height of the transported object is 300mm, the width is 400mm, and the spacing between the LEDs is 10mm, then the LED numbering blocks within a range of 30 consecutive rows and 40 columns horizontally from the bottom in the arrangement matrix can be located as the initial blocking area.

[0081] Based on the initial area, the occlusion boundary can be further extended vertically or laterally by considering the grating deployment location, risk control requirements, or historical boundary violations. Finally, the set of LED numbers corresponding to this extended area is extracted from the permutation matrix to form a target LED set for boundary violation judgment, serving as the basis for subsequent judgments of events such as abnormal occlusion of transported goods and area exceeding limits.

[0082] By introducing a mapping relationship between the LED bead arrangement matrix and the preset area, the detection area can be precisely defined, which helps to improve the sensitivity of boundary judgment and the accuracy of safety control.

[0083] Optionally, in the step of extracting target LEDs based on preset area data in the permutation matrix, historical occlusion data of the safety light curtain can also be obtained; in the historical occlusion data, occlusion records that match the preset area data are selected as target occlusion data; based on the target occlusion data, the occlusion frequency of each LED in the permutation matrix and its corresponding system response state when occluded are statistically analyzed, including unsafe responses; based on the occlusion frequency and the correlation between it and unsafe responses, target LEDs that meet the boundary judgment requirements are determined in the permutation matrix.

[0084] In this embodiment of the invention, to further improve the screening accuracy of target LED beads, in addition to directly locating the obstruction area based on preset area data, historical obstruction data of the safety light curtain can also be introduced for auxiliary judgment. Historical obstruction data typically records the state changes of each LED bead being obstructed during the passage of multiple transport items through the safety light curtain, as well as event records of whether unsafe responses were triggered.

[0085] By filtering out historical occlusion records that match the current preset area data, a set of target occlusion data can be formed, which reflects the actual occlusion of the grating by similar transport objects under normal or abnormal conditions.

[0086] Furthermore, based on this target occlusion data, the occlusion frequency of each LED in the permutation matrix can be statistically analyzed, and the corresponding system response state when occluded can be extracted, such as whether it triggers production line shutdown, alarm prompts, or other unsafe response behaviors. For LEDs that are almost never occluded in most normal occlusion records, or whose occlusion is highly correlated with unsafe response events, they can be identified as having high sensitivity to boundary crossing risks.

[0087] Based on the correlation between the above-mentioned occlusion frequency and unsafe response, target LED beads that meet the boundary judgment requirements are selected from the permutation matrix and used as key detection points for subsequent exceeding area judgment, alarm triggering and control response.

[0088] By using a target LED selection strategy based on historical data, higher discrimination accuracy and robust safety control can be achieved, making it particularly suitable for production line scenarios with diverse transport specifications, tight operating cycles, or complex environmental interference factors.

[0089] Optionally, in the step of controlling the production line based on the excess area and the direction of travel, a comparison can be performed based on the excess area and a preset area threshold to obtain a first comparison result; a comparison can be performed based on the direction of travel and a preset direction of travel 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.

[0090] In this embodiment of the invention, when performing production line control processing based on the area exceeding the limit and the direction of travel, a comparison mechanism can be introduced to more accurately determine the state of the transported goods. Specifically, the actual area exceeding the limit, calculated by the target LED bead blocking the transported goods, can first be compared with a preset area threshold to determine whether it exceeds the allowable range, thereby generating a first comparison result. If the area exceeding the limit is greater than or equal to the threshold, it is considered to be out of bounds; otherwise, it is considered to be fluctuating within a reasonable range.

[0091] Simultaneously, the currently detected direction of travel of the transported object can be compared with the preset compliant direction of travel to generate a second comparison result. For example, on a unidirectional production line, if the direction of travel detection results indicate that the transported object is entering in the wrong direction or has an abnormal direction, it can be determined that it does not comply with the operating specifications.

[0092] Either of the two comparison results can be used as the basis for determining whether to implement control measures on the production line. Specifically, when the first comparison result indicates that the area exceeds the limit, or the second comparison result indicates that the direction is abnormal, a safety control mechanism should be triggered, such as suspending production line operation or issuing an audible and visual alarm; while when both comparison results are normal, the normal operation of the production line should be maintained.

[0093] By introducing a dual determination mechanism based on area and direction, the ability to identify abnormal transportation behavior can be significantly enhanced, thereby improving the overall safety protection level of the system and the accuracy of production line response.

[0094] 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 duration of the obstruction of the transported object when the target LED bead is judged to exceed the area of ​​the transported object on the production line can also be obtained; when the obstruction 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.

[0095] In this embodiment of the invention, to further improve the judgment accuracy and system robustness, in addition to the control processing based on the first comparison result and the second comparison result, an analysis mechanism for the duration of occlusion can be introduced. Specifically, when determining whether the transported object occludes the target LED, the start and end times of occlusion for each target LED can be recorded in real time, and the corresponding duration of occlusion can be calculated.

[0096] If a target LED is continuously blocked for a period exceeding a preset duration threshold, the blocking is considered not an occasional accidental touch or short-term interference, but a stable and continuous blocking behavior. In this case, combining at least one of the first comparison result of area exceeding the limit and the second comparison result of abnormal direction can more reliably trigger production line control measures.

[0097] For example, if the target LED is continuously blocked for more than 500ms and the area exceeds the limit, even if the direction of travel is normal, it can be considered that there is an abnormality in the height or deviation of the transported object, and the production line should be stopped immediately. If the blocking time is short and only momentary, it can be ignored to avoid misjudgment and accidental stop.

[0098] By introducing the occlusion duration dimension as an auxiliary judgment criterion, misjudgments caused by occasional occlusion can be effectively filtered out, enhancing the system's ability to identify real abnormal states and ensuring the timeliness and rationality of control processing.

[0099] 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 production line may be stopped when the first comparison result shows that the area exceeding the limit is greater than or equal to a preset area threshold; the production line may be stopped when the second comparison result shows that the direction of travel does not conform to a preset direction of travel; and the production line may be controlled to operate normally when the first comparison result shows that the area exceeding the limit is less than a preset area threshold and the second comparison result shows that the direction of travel conforms to a preset direction of travel.

[0100] In this embodiment of the invention, to achieve more refined production line operation control, different control strategies can be executed based on the combined results of the first and second comparisons:

[0101] When the first comparison result shows that the area of ​​the transported object exceeds or equals the set area threshold, it can be determined that the current transported object is abnormal in size and may have safety hazards such as excessive height, stacking, or deviation. At this time, the production line should be stopped immediately to prevent equipment jamming, collision or personal injury during the transportation process.

[0102] If the second comparison result determines that the direction of travel of the transported object does not conform to the preset normal direction (such as detecting reverse entry or lateral interference), it should also be regarded as an abnormal situation, and the production line should be stopped to prevent dangerous events caused by misoperation or personnel intrusion.

[0103] Conversely, if the first comparison result determines that the area of ​​the transported object does not exceed the limit, and the second comparison result determines that its direction of travel is normal, that is, the transported object is in a controllable and safe state, then the production line is allowed to maintain normal operation without triggering an alarm or intervention.

[0104] By setting control logic for the above three different situations, not only can safety measures be taken in a timely manner when the size or direction of the transported goods is abnormal, but unnecessary downtime caused by minor errors or accidental events can also be effectively avoided, ensuring the safety and continuity of the production line operation.

[0105] Optionally, in the step of controlling the production line to stop, a stop command can also be sent to the production line drive device to stop the production line; and an alarm prompt can be given through an audible and visual alarm device.

[0106] In this embodiment of the invention, to ensure that the production line can respond promptly and alert operators when an unsafe condition is detected, the following specific operations can be performed during the process of controlling the production line to stop:

[0107] First, a shutdown control signal is generated based on the aforementioned judgment logic, and this signal is transmitted to the drive unit linked to the production line via wired or wireless means. Upon receiving the shutdown command, the drive unit will interrupt its control over the conveyor motor or actuator, thereby immediately stopping the production line and preventing the transported goods from continuing to move forward and causing a wider safety risk.

[0108] Secondly, after the shutdown command is issued, audible and visual alarm devices, such as buzzers and warning lights, can be triggered simultaneously to emit alarm signals at a preset alarm rhythm. This audible and visual alert will effectively remind on-site personnel to pay attention to the current abnormal state, promptly investigate the cause, and address safety hazards.

[0109] By combining electrical control with physical prompts, not only can rapid response and shutdown control be achieved, but the system's ability to warn of sudden risks can also be enhanced, thereby improving the overall safety protection level of the production line.

[0110] In one possible embodiment, the production line described above can also be as follows: Figure 3 Another schematic diagram of the production line structure is shown below, such as Figure 3 As shown, AOPD is a safety light curtain deployed at the boundary between the safe and hazardous areas. D1 is the first photoelectric sensor, D2 is the second photoelectric sensor, a and b are the gaps between the goods and the safety light curtain, and L is the length of the workpiece. It is important to note that the intersection of the first and second sensors must be located on the hazardous area side, and the intersection point must not be on the same central axis as the workpiece's movement direction. This production line layout enables production line control during bidirectional traffic detection.

[0111] On this production line, there is a correspondence between the logic value of the safety light curtain and the system safety status:

[0112] Initial state: The safety light curtain logic value is 1, and the system safety output is 1, indicating that the system will stop immediately if the light curtain is blocked;

[0113] When D1 or D2 is blocked: the safety light curtain is still 1, the safety output is 1, and the function status is "the machine stops immediately when the light curtain is blocked".

[0114] When D2 is continuously blocked for more than 2 seconds: the safety light curtain remains at 1, but the safety status is set to 1. At this time, even if the light curtain is blocked, the system will not stop immediately. The system will only be forcibly stopped if it is not restored after a preset time (such as 5 minutes).

[0115] When the safety light curtain is blocked: the safety light curtain value becomes 0, the safety output is 1, and the system function status is "the system will not stop even when the light curtain is blocked". If the preset time is exceeded, the system will stop directly.

[0116] When the safety light curtain is restored: the safety light curtain returns to 1, the safety status remains 1, and the system continues to allow goods to pass through. If the total duration exceeds 5 minutes, the system will stop.

[0117] When D1 recovers, or 1 second after D1 recovers, or when D2 recovers: the safety light curtain value gradually returns to 1, the safety status is cleared, and the system re-enters the initial safety state.

[0118] With this logic setting, when personnel accidentally enter a dangerous area and block the light curtain, the system will immediately trigger a shutdown to ensure personal safety. When goods pass through normally, the system, by judging the order of D1 and D2, the blocking time, and the restoration of the light curtain, combined with safety delay control, allows goods to pass through without triggering a shutdown, avoiding accidental shutdowns caused by material obstruction, thus balancing safety and production line continuity.

[0119] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0120] In one embodiment, a production line control device is provided, which corresponds one-to-one with the production line control methods described in the above embodiments. For example... Figure 4 As shown, the control device for this production line 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. Detailed descriptions of each functional module are as follows:

[0121] The first acquisition module 401 is used to acquire preset area data of the transported items on the production line;

[0122] The first determining module 402 is used to determine a plurality of target LED beads among the plurality of LED beads based on the preset area data;

[0123] The first judgment module 403 is used to 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.

[0124] The second judgment module 404 is used to determine the area of ​​the transported items on the production line that exceeds the target LED bead.

[0125] The control module 405 is used to control the production line based on the excess area and the direction of travel.

[0126] Optionally, the first determining module 402 is further configured to:

[0127] Obtain the arrangement matrix of the deployment positions of the multiple LED beads in the safety light curtain;

[0128] In the arrangement matrix, the target LED bead is extracted based on the preset area data.

[0129] Optionally, the first determining module 402 is further configured to:

[0130] Obtain the historical occlusion data of the safety light curtain;

[0131] In the historical occlusion data, occlusion records that match the preset area data are selected as target occlusion data;

[0132] Based on the target occlusion data, the occlusion frequency of each LED in the permutation matrix and its corresponding system response state when occluded are statistically analyzed, and the system response state includes unsafe responses.

[0133] Based on the occlusion frequency and its correlation with unsafe responses, target LED beads that meet the boundary judgment requirements are determined in the permutation matrix.

[0134] Optionally, the control module 405 is further configured to:

[0135] A comparison is performed based on the area exceeding the limit and a preset area threshold to obtain a first comparison result;

[0136] A comparison is performed based on the stated direction of travel and a preset direction of travel to obtain a second comparison result;

[0137] The production line is controlled based on at least one of the first comparison result and the second comparison result.

[0138] Optionally, the control module 405 is further configured to:

[0139] The duration of the obstruction caused by the transported object when determining the area exceeding the limit of the target LED bead on the production line is obtained.

[0140] When the duration of the occlusion 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.

[0141] Optionally, the control module 405 is further configured to:

[0142] When the first comparison result indicates that the area exceeding the limit is greater than or equal to the preset area threshold, the production line is controlled to stop.

[0143] When the second comparison result indicates that the direction of travel does not conform to the preset direction of travel, the production line is controlled to stop.

[0144] When the first comparison result indicates that the area exceeding the limit is less than the preset area threshold, and the second comparison result indicates that the direction of travel conforms to the preset direction of travel, the production line is controlled to operate normally.

[0145] Optionally, the control module 405 is further configured to:

[0146] Send a stop command to the drive unit of the production line to stop the production line;

[0147] An alarm will be triggered via an audible and visual alarm device.

[0148] Each module in the control device of the aforementioned production line can be implemented entirely or partially through software, hardware, or a combination thereof. These modules can be embedded in the processor of a computer device in hardware form or independent of it, or stored in the memory of a computer device in software form, so that the processor can call and execute the operations corresponding to each module.

[0149] In one embodiment, a computer device is provided, which may be a terminal device, and its internal structure diagram may be as follows: Figure 5 As shown, the computer device includes a processor, memory, and network interface connected via a system bus. The processor provides computing and control capabilities. The memory includes a readable storage medium storing computer-readable instructions. The network interface communicates with external terminals via a network connection. When executed by the processor, the computer-readable instructions implement a production line control method. The readable storage medium provided in this embodiment includes both non-volatile and volatile readable storage media.

[0150] In this application embodiment, 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, it implements the steps of the production line control method described above.

[0151] In one 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, they implement the steps of the production line control method described above.

[0152] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by instructing related hardware with computer-readable instructions. These computer-readable instructions can be stored in a non-volatile readable storage medium or a volatile readable storage medium. When executed, these computer-readable instructions can include the processes of the embodiments of the methods described above. Any references to memory, storage, databases, or other media used in the embodiments provided in this application can 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 a variety of forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), dual 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.

[0153] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the above-described division of functional units and modules is used as an example. In practical applications, the above functions can be assigned to different functional units and modules as needed, that is, the internal structure of the device can be divided into different functional units or modules to complete all or part of the functions described above.

[0154] The above embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application, and should all be included within the protection scope of this application.

Claims

1. A production line control method, characterized in that, The method is applied to a safety light curtain, which includes multiple LEDs. The production line includes a hazardous area and a safe area. The safety light curtain is deployed at the boundary between the hazardous area and the safe area. The hazardous area is equipped with a first photoelectric sensor and a second photoelectric sensor, which are arranged sequentially along the transport path. The method includes: Obtain the preset area data of the transported object on the production line. The preset area data corresponds to the standard occlusion area of ​​the transported object on the projection surface of the safety light curtain, which is determined by the boundary size of the transported object and the installation direction of the safety light curtain. Based on the preset area data, multiple target LED beads are identified among the multiple LED beads. The target LED beads are unobstructed LED beads, and the beam channel should not be blocked during the normal passage of the transported goods. Based on at least two of the first photoelectric sensor, the second photoelectric sensor, and the target LED bead, the direction of travel of the transported items on the production line is determined. Based on the target LED bead, determine the area of ​​the transported items on the production line that exceeds the permitted area; The production line is controlled based on the excess area and the direction of travel.

2. The production line control method as described in claim 1, characterized in that, Based on the preset area data, the determination of multiple target LED beads among the multiple LED beads includes: Obtain the arrangement matrix of the deployment positions of the multiple LED beads in the safety light curtain; In the arrangement matrix, the target LED bead is extracted based on the preset area data.

3. The production line control method as described in claim 2, characterized in that, Extracting the target LED bead from the arrangement matrix based on the preset area data includes: Obtain the historical occlusion data of the safety light curtain; In the historical occlusion data, occlusion records that match the preset area data are selected as target occlusion data; Based on the target occlusion data, the occlusion frequency of each LED in the permutation matrix and its corresponding system response state when occluded are statistically analyzed, and the system response state includes unsafe responses. Based on the occlusion frequency and its correlation with unsafe responses, target LED beads that meet the boundary judgment requirements are determined in the permutation matrix.

4. The production line control method as described in claim 1, characterized in that, The process of controlling the production line based on the excess area and the direction of travel includes: A comparison is performed based on the area exceeding the limit and a preset area threshold to obtain a first comparison result; A comparison is performed based on the stated direction of travel and a preset direction of travel to obtain a second comparison result; The production line is controlled based on at least one of the first comparison result and the second comparison result.

5. The production line control method as described in claim 4, characterized in that, The process of controlling the production line based on at least one of the first comparison result and the second comparison result includes: The duration of the obstruction caused by the transported object when determining the area exceeding the limit of the target LED bead on the production line is obtained. When the duration of the occlusion 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 as described in claim 4 or 5, characterized in that, The process of 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 indicates that the area exceeding the limit is greater than or equal to the preset area threshold, the production line is controlled to stop. When the second comparison result indicates that the direction of travel does not conform to the preset direction of travel, the production line is controlled to stop. When the first comparison result indicates that the area exceeding the limit is less than the preset area threshold, and the second comparison result indicates that the direction of travel conforms to the preset direction of travel, the production line is controlled to operate normally.

7. The production line control method as described in claim 6, characterized in that, The control of stopping the production line includes: Send a stop command to the drive unit of the production line to stop the production line; An alarm will be triggered via an audible and visual alarm device.

8. A control device for a production line, characterized in that, The device is applied to a safety light curtain, which includes multiple LEDs. The production line includes a hazardous area and a safe area. The safety light curtain is deployed at the boundary between the hazardous area and the safe area. The hazardous area is equipped with a first photoelectric sensor and a second photoelectric sensor, which are arranged sequentially along the transport path. The device includes: The first acquisition module is used to acquire the preset area data of the transported object on the production line. The preset area data corresponds to the standard occlusion area of ​​the transported object on the projection surface of the safety light curtain, which is determined by the boundary size of the transported object and the installation direction of the safety light curtain. The first determining module is used to determine multiple target LED beads among the multiple LED beads based on the preset area data. The target LED beads are unobstructed LED beads and are light beam channels that should not be blocked during the normal passage of the transported goods. The first judgment module is used to 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. The second judgment module is used to determine the area of ​​the transported items on the production line that exceeds the target LED bead. The control module is used to control the production line based on the excess area and the direction of travel.

9. A computer device comprising a memory, a processor, and computer-readable instructions stored in the memory and running on the processor, characterized in that, When the processor executes the computer-readable instructions, it implements the production line control method as described in any one of claims 1 to 7.

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

Images