Automated production line collaborative control method and system for automobile connectors

Abstract

This invention relates to the field of integrated manufacturing technology, specifically to an automated production line collaborative control method and system for automotive connectors. The method includes the following steps: a central controller broadcasts a timer; timestamps of workstation actions are collected; the controller calculates a feature vector composed of timing phase difference and spatial position deviation; the vector is judged; if the timing deviation is large, time compensation is calculated; if the spatial deviation is large, a flexible time slot is requested; a collaborative scheduling strategy is generated to superimpose compensation for the workstation or suspend downstream execution for correction. In this invention, by broadcasting a standard timer signal and collecting workstation action timestamps and image data, real-time quantitative perception of the production line's spatiotemporal status is achieved, constructing an operational feature vector. When the phase or position deviation exceeds a threshold, simple start / stop is abandoned; precise time compensation is calculated or a flexible time slot occupancy request is generated; a dedicated timer is issued or downstream permissions are dynamically adjusted, forming a closed-loop feedback regulation to actively suppress deviation accumulation and improve the accuracy and stability of production line collaboration.

Description

Technical Field

[0001] This invention relates to the field of integrated manufacturing technology, and in particular to an automated production line collaborative control method and system for automotive connectors. Background Technology

[0002] Integrated manufacturing technology involves the centralized control and information integration of multiple machines in a factory. The core of this field lies in connecting independent automated units through computer networks and control systems to achieve the exchange of production data and the coordination of production processes. Its technological system encompasses distributed numerical control, flexible manufacturing systems, and computer-integrated manufacturing, aiming to achieve unified management and optimization of the entire production process. In the traditional automotive connector automated production line, the collaborative control method involves configuring a programmable logic controller (PLC) for independent control of each independent production station. Collaboration between stations typically relies on hard-wired input / output signals or point-to-point serial communication protocols to transmit start / stop commands and status information. The production cycle and material flow of the entire production line are mainly maintained by the fixed logic programs preset by each station's PLC.

[0003] Traditional collaborative control methods for automated automotive connector production lines involve configuring a PLC for independent control at each workstation. This collaboration relies on hard-wired input / output signals or point-to-point serial communication. This approach can only transmit simple start / stop commands and status information. The production cycle and material flow of the entire production line depend on the fixed logic programs preset at each workstation. The production line lacks the ability to perceive and dynamically adjust the operating status of each workstation in real time. When a small time or space deviation occurs at a single workstation due to equipment wear or material differences, the system cannot actively coordinate and compensate, causing the deviation to accumulate and amplify along the production chain, ultimately leading to process blockage and affecting the overall production efficiency and collaborative stability of the production line. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of existing technologies and to propose an automated production line collaborative control method and system for automotive connectors.

[0005] To achieve the above objectives, the present invention adopts the following technical solution: an automated production line collaborative control method for automotive connectors, comprising the following steps:

[0006] S1: The central controller broadcasts a standard beat signal, and the local controller executes a preset physical action to press the automotive connector terminal into the connector housing and collects the action completion timestamp. The action completion timestamp and the workstation identity identifier are combined to construct the actual execution time sequence dataset of the workstation.

[0007] S2: The central controller calculates the timing phase difference based on the actual execution timing dataset of the workstation, collects image data of the connector housing, calculates the pin coplanarity of the automotive connector terminal as the spatial position deviation, and forms the workstation operating status feature vector.

[0008] S3: Determine the feature vector of the workstation's operating status. If the timing phase difference is greater than the timing tolerance threshold, calculate the time compensation value using the Kalman filter algorithm. If the spatial position deviation is greater than the recoverable deviation threshold, generate a flexible time slot occupancy request and combine it with the time compensation value to generate a collaborative scheduling strategy set.

[0009] S4: According to the collaborative scheduling strategy set, if the time compensation value exists, a dedicated clock signal is generated by superimposing the time compensation value on the specified workstation. If the flexible time slot occupancy request exists, the downstream workstation and the workstation requesting permission are suspended. The suspension is lifted after receiving the correction completion signal.

[0010] As a further aspect of the present invention, the actual execution time sequence dataset of the workstation includes an action completion timestamp and a workstation identity identifier; the workstation running status feature vector includes a timing phase difference and a spatial position deviation; the collaborative scheduling strategy set includes a time compensation value and a flexible time slot occupancy request; and the dedicated beat signal includes a time compensation value and a workstation beat signal.

[0011] As a further aspect of the present invention, step S1 specifically comprises:

[0012] S11: The central controller broadcasts a unified standard beat signal to all local controllers in the production line via industrial Ethernet. The standard beat signal defines the theoretical start and end times of multiple workstations.

[0013] S12: After receiving the trigger command of the standard beat signal, the local controller controls the servo motor or pneumatic component to perform a preset physical action of pressing the automotive connector terminal into the connector housing, and uses a clock source to collect the current time as the action completion timestamp at the moment the preset physical action is completed.

[0014] S13: The local controller binds the action completion timestamp to its unique workstation identity and sends it to the central controller through the real-time data reporting channel. The central controller collects the reported data from all workstations and constructs a workstation actual execution time sequence dataset.

[0015] As a further aspect of the present invention, step S2 specifically comprises:

[0016] S21: The central controller extracts the action completion timestamp of the specified workstation from the actual execution timing dataset of the workstation, queries the standard beat signal to obtain the corresponding theoretical completion time, calculates the absolute value of the difference between the two, and obtains the timing phase difference;

[0017] S22: The central controller calls an industrial camera to collect high-resolution image data of the connector housing after it is pressed into the automotive connector terminal, and uses edge detection and contour extraction algorithms to locate the top coordinates of multiple pins;

[0018] S23: Based on the fitted reference plane of the top coordinates, calculate the standard deviation of the vertical distance from all the top coordinates to the reference plane, quantify the standard deviation as the pin coplanarity, and designate it as the spatial position deviation;

[0019] S24: The central controller integrates the calculated timing phase difference with the spatial position deviation to establish a two-dimensional vector and generate a workstation operating status feature vector.

[0020] As a further aspect of the present invention, step S3 specifically comprises:

[0021] S31: The central controller compares the timing phase difference in the workstation operating status feature vector with a preset timing tolerance threshold, and at the same time compares the spatial position deviation with preset recoverable deviation thresholds and unrecoverable deviation thresholds.

[0022] S32: If the timing phase difference is greater than the timing tolerance threshold, then activate the Kalman filter algorithm, use the historical timing phase difference sequence in the actual execution timing dataset of the workstation as the observation value, predict and output the optimal time compensation value;

[0023] S33: If the spatial position deviation is greater than the recoverable deviation threshold and less than the unrecoverable deviation threshold, it is determined to be a correctable deviation, and an elastic time slot occupancy request is immediately generated; if the spatial position deviation is greater than the unrecoverable deviation threshold, a shutdown alarm signal is generated.

[0024] S34: The central controller aggregates the time compensation value and the elastic time slot occupancy request, encapsulates them into a unified data structure, and obtains a set of collaborative scheduling strategies.

[0025] As a further aspect of the present invention, step S4 specifically comprises:

[0026] S41: The central controller parses the collaborative scheduling strategy set. If the time compensation value is detected, it locates the corresponding workstation identity, obtains the standard beat signal, and adds the time compensation value as a time offset to the trigger time point of the next cycle of the standard beat signal to generate a dedicated beat signal and sends it to the local controller of the workstation.

[0027] S42: If the request for occupancy of the flexible time slot is detected, the central controller immediately sends a suspension command to the directly downstream workstation of the requesting workstation to suspend receiving materials and performing actions, and at the same time sends a correction permission signal and spatial position deviation data to the requesting workstation.

[0028] S43: After receiving the calibration permission signal, the local controller of the requesting workstation executes a preset calibration procedure and sends a calibration completion signal back to the central controller after the calibration action is completed. After receiving the calibration completion signal, the central controller releases the suspension command to the downstream workstation.

[0029] As a further aspect of the present invention, the process of calculating the time compensation value using the Kalman filtering algorithm is specifically as follows:

[0030] S321: Initialize the state estimate and covariance matrix of the time compensation value, and define the state transition matrix and observation matrix of the time series dynamic model, and set the process noise covariance and observation noise covariance;

[0031] S322: Perform the prediction step, calculate the prior state estimate at the current time based on the state transition matrix and the state estimate at the previous time, and calculate the prior covariance matrix at the current time using the process noise covariance and the posterior covariance matrix at the previous time.

[0032] S323: Calculate the Kalman gain, which is obtained based on the prior covariance matrix, the observation matrix, and the observation noise covariance.

[0033] S324: Perform the update step, using the Kalman gain, the prior state estimate, and the current timing phase difference obtained from the workstation operating state feature vector to calculate the posterior state estimate, i.e. the optimal time compensation value.

[0034] S325: Update the posterior covariance matrix for the next round of iteration calculation, and output the optimal time compensation value to the cooperative scheduling strategy set.

[0035] As a further aspect of the present invention, the process of calculating the coplanarity of the insert as a spatial positional deviation specifically includes:

[0036] S231: The central controller preprocesses the acquired high-resolution image data, including grayscale conversion and Gaussian filtering to remove random noise, and uses the Canny operator to perform edge detection to extract the edge contours of multiple pins of the automotive connector terminal.

[0037] S232: Perform Hough transform or morphological processing on the edge contour to identify and extract the coordinates of all key points at the tip of the pin, and establish a set of coordinates for the tip of the pin.

[0038] S233: Using the least squares method, a reference plane is fitted in three-dimensional space based on the coordinate set of the pin tips. The reference plane represents the theoretically coplanar position of all pins.

[0039] S234: Traverse the coordinate set of the pin tip, calculate the Euclidean distance from the coordinates of each key point to the reference plane, and generate a set of distance deviation values;

[0040] S235: Calculate the statistical standard deviation of the distance deviation value set, use the standard deviation value as a quantitative indicator, define it as the coplanarity of the pin, and store it as the spatial position deviation in the workstation operating status feature vector.

[0041] An automated production line collaborative control system for automotive connectors, wherein the automated production line collaborative control system for automotive connectors is used to implement the aforementioned automated production line collaborative control method for automotive connectors, the system comprising:

[0042] The timing data acquisition module is used by the central controller to broadcast standard beat signals, and the local controller to execute a preset physical action of pressing the automotive connector terminal into the connector housing and collect the action completion timestamp. The action completion timestamp is combined with the workstation identity identifier to construct the actual execution timing dataset of the workstation and then transmitted to the operation status analysis module.

[0043] The operation status analysis module is used by the central controller to calculate the timing phase difference based on the actual execution timing dataset of the workstation, collect image data of the connector housing to calculate the pin coplanarity of the automotive connector terminal as a spatial position deviation, and construct a workstation operation status feature vector from the timing phase difference and the spatial position deviation, and transmit it to the collaborative strategy generation module.

[0044] The collaborative strategy generation module is used to determine the feature vector of the workstation's operating status. If the timing phase difference is greater than the timing tolerance threshold, the time compensation value is calculated using the Kalman filter algorithm. If the spatial position deviation is greater than the recoverable deviation threshold, a flexible time slot occupancy request is generated. The collaborative scheduling strategy set is generated in conjunction with the time compensation value and then transmitted to the production line cycle control module.

[0045] The production line cycle control module is used to generate a dedicated cycle signal for a specified workstation by superimposing the time compensation value on the time compensation value according to the collaborative scheduling strategy set. If the time compensation value exists, it suspends the downstream workstation and the workstation requesting permission if the flexible time slot occupancy request exists. The suspension is released after receiving the correction completion signal.

[0046] Compared with the prior art, the advantages and positive effects of the present invention are as follows:

[0047] In this invention, by broadcasting standard beat signals and collecting time stamps and image data of each workstation's actions, real-time quantitative perception of the production line's timing and spatial status is achieved. This allows for the construction of a workstation operation status feature vector. When a timing phase difference or spatial position deviation exceeds a threshold, instead of simple start-stop control, an algorithm calculates a precise time compensation value or generates a flexible time slot occupancy request. This generates a dedicated beat signal or dynamically adjusts the operating permissions of downstream workstations, forming a closed-loop feedback adjustment mechanism that actively suppresses the accumulation of operational deviations and significantly improves the accuracy of production line collaboration and operational stability. Attached Figure Description

[0048] Figure 1 This is a flowchart of the collaborative control method for automotive connector production lines according to the present invention;

[0049] Figure 2 Flowchart for constructing the actual execution time-series dataset of the workstation in this invention;

[0050] Figure 3 This is a flowchart illustrating the process of generating feature vectors for the operating status of workstations in this invention.

[0051] Figure 4 This is a flowchart illustrating the process of generating the collaborative scheduling strategy set according to the present invention.

[0052] Figure 5 This is a flowchart illustrating the execution of the collaborative scheduling strategy of the present invention. Detailed Implementation

[0053] To make the objectives, technical solutions, and advantages of this invention clearer, the software-based technical solution is described in detail below with reference to system architecture diagrams and embodiments. It should be understood that the specific embodiments described herein are only for explaining the technical solutions of this invention and do not constitute a limitation on the scope of protection.

[0054] In the description of this invention, the system architecture relationships or data processing flows indicated by terms such as "layer," "module," "interface," "data flow," "client," and "server" are all defined based on the architecture diagram or flowchart corresponding to the embodiments. This way of describing is only used to clearly illustrate the logical relationships between the elements in the technical solution, and not to limit the physical deployment form. The term "multiple" includes two or more technical units, including but not limited to multiple data nodes, processing threads, service instances, or functional components and other scalable elements. The specific number is determined according to the actual business scenario and needs to be specifically specified.

[0055] Please see Figure 1 and Figure 2 This invention provides a technical solution: an automated production line collaborative control method for automotive connectors, comprising the following steps:

[0056] S1: The central controller broadcasts a standard beat signal, and the local controller executes a preset physical action to press the automotive connector terminal into the connector housing and collects the action completion timestamp. The action completion timestamp and the workstation identity identifier are combined to construct the actual execution time sequence dataset of the workstation.

[0057] The actual execution time sequence dataset of the workstation includes action completion timestamps and workstation identification identifiers;

[0058] The specific steps of S1 are as follows:

[0059] S11: The central controller broadcasts a unified standard beat signal to all local controllers in the production line via industrial Ethernet. The standard beat signal defines the theoretical start and end times of actions at multiple workstations.

[0060] S12: After receiving the trigger command of the standard beat signal, the local controller controls the servo motor or pneumatic component to perform the preset physical action of pressing the automotive connector terminal into the connector housing, and uses the clock source to collect the current time as the action completion timestamp at the moment the preset physical action is completed.

[0061] S13: The local controller binds the action completion timestamp to its unique workstation identity and sends it to the central controller through the real-time data reporting channel. The central controller collects the reported data from all workstations and constructs a workstation actual execution time sequence dataset.

[0062] The central controller, specifically a Siemens SIMATIC S7-1500 series programmable logic controller, broadcasts a unified standard cycle signal to the local controllers (Siemens SIMATIC S7-1500SP distributed I / O modules) of all workstations (WS-001, WS-002, and WS-003 as examples) on the production line at the absolute time point of 14:30:00.000. This standard cycle signal uses a synchronization signal message (SyncTelegram) to define the basic cycle time of the production line. The time interval is 5000 milliseconds (ms). For this cycle starting at 14:30:00.000, the theoretical start time of the action is... The theoretical end time of the action is 14:30:00.000. The time is 14:30:05.000. This is the basic cycle time mentioned above. This refers to the preset standard time for the production line to complete a full work cycle. The theoretical start time of the above actions... This refers to the theoretical moment when the physical action begins at the workstation, as specified by the standard cycle signal. The theoretical end time of the aforementioned action... It refers to the theoretical time when the workstation completes its physical action as specified by the standard beat signal.

[0063] After receiving the trigger command of the standard cycle signal precisely at 14:30:00.000, the local controllers of workstations WS-001, WS-002, and WS-003 respectively control the servo motors (e.g., Yaskawa Sigma-7 series servo drives, configured with 400W servo motors) at their respective workstations to perform preset physical actions, namely, pressing the automotive connector terminals (e.g., TEConnectivity 2.5mm HDSCS series terminals) into the corresponding connector housing (HDSCS 12-position housing). The local controllers continuously monitor the "positioning complete" signal fed back by the servo drives using their internal clock source (clock resolution of 1 microsecond). When the servo motor reaches the preset pressing depth (e.g., -15.50mm) and the pressure sensor feedback value reaches the preset torque (e.g., 50N), the "positioning complete" signal is set to a high level, and the local controllers acquire the current timestamp at the rising edge of this signal.

[0064] For example, the action completion timestamps collected at each workstation within 5 consecutive cycle times. The data is as follows: timestamps of the above actions. This refers to the absolute time reading collected by the local controller from its internal clock source when it detects the "positioning complete" signal.

[0065] Table 1. Actual execution time series dataset for each workstation (example cycle)

[0066] Periodic number Workstation identification Theoretical end time Action completion timestamp 1 WS-001 14:30:05.000 14:30:04.980 1 WS-002 14:30:05.000 14:30:05.150 1 WS-003 14:30:05.000 14:30:04.965 2 WS-001 14:30:10.000 14:30:09.975 2 WS-002 14:30:10.000 14:30:10.165 2 WS-003 14:30:10.000 14:30:09.950 3 WS-001 14:30:15.000 14:30:14.982 3 WS-002 14:30:15.000 14:30:15.140 3 WS-003 14:30:15.000 14:30:14.970 4 WS-001 14:30:20.000 14:30:19.978 4 WS-002 14:30:20.000 14:30:20.155 4 WS-003 14:30:20.000 14:30:19.968 5 WS-001 14:30:25.000 14:30:24.980 5 WS-002 14:30:25.000 14:30:25.148 5 WS-003 14:30:25.000 14:30:24.966

[0067] Table 1 shows the theoretical end time and actual data collection completion timestamps for the three workstations over five consecutive cycles.

[0068] The local controller (ET200SP) binds the collected action completion timestamps to their fixed, unique workstation identifiers (e.g., "WS-001") to form a data structure. For example, the data packet for WS-002 in cycle 1 is {"ID":"WS-002","Timestamp":"14:30:05.150"}. This data packet is sent to the central controller (S7-1500) through an OPCUA-based real-time data reporting channel (publish-subscribe mode). The central controller's data logging module collects the data packets reported by all workstations (WS-001, WS-002, WS-003) in all cycles, parses and stores them in a specified table in the SQL database, constructing a workstation actual execution time-series dataset.

[0069] Please see Figure 1 and Figure 3 S2: The central controller calculates the timing phase difference based on the actual execution timing dataset of the workstation, collects image data of the connector housing, calculates the pin coplanarity of the automotive connector terminal as the spatial position deviation, and forms the workstation operating status feature vector.

[0070] The workstation operation status feature vector includes timing phase difference and spatial position deviation;

[0071] The specific steps of S2 are as follows:

[0072] S21: The central controller extracts the action completion timestamp of the specified workstation from the actual execution timing dataset of the workstation, queries the standard cycle signal to obtain the corresponding theoretical completion time, calculates the absolute value of the difference between the two, and obtains the timing phase difference;

[0073] S22: The central controller calls an industrial camera to collect high-resolution image data of the connector housing after it is pressed into the automotive connector terminal, and uses edge detection and contour extraction algorithms to locate the top coordinates of multiple pins;

[0074] S23: Fit the reference plane based on the top coordinates, calculate the standard deviation of the vertical distance from all top coordinates to the reference plane, quantify the standard deviation as the pin coplanarity, and specify it as the spatial position deviation;

[0075] The process of calculating the coplanarity of the inserts as a spatial positional deviation is as follows:

[0076] S231: The central controller preprocesses the acquired high-resolution image data, including grayscale conversion and Gaussian filtering to remove random noise, and uses the Canny operator for edge detection to extract the edge contours of multiple pins of the automotive connector terminal.

[0077] S232: Perform Hough transform or morphological processing on the edge contour, identify and extract the coordinates of all key points at the tip of the pin, and establish a set of coordinates for the tip of the pin.

[0078] S233: Using the least squares method, a reference plane is fitted in three-dimensional space based on the coordinate set of the pin tip. The reference plane represents the theoretically coplanar position of all pins.

[0079] S234: Traverse the coordinate set of the pin top, calculate the Euclidean distance from the coordinates of each key point to the reference plane, and generate a set of distance deviation values;

[0080] S235: Calculate the statistical standard deviation of the set of distance deviation values, use the standard deviation value as a quantitative indicator, define it as the pin coplanarity, and store it as the spatial position deviation in the workstation operation status feature vector.

[0081] S24: The central controller integrates the calculated timing phase difference with the spatial position deviation to establish a two-dimensional vector and generate a workstation operating status feature vector.

[0082] The central controller extracts the action completion timestamp of a specified workstation (taking WS-002 in cycle 1 as an example) from the actual execution timing dataset of the workstation (see Table 1), with a value of 14:30:05.150. The central controller queries the standard cycle signal definition library to obtain the theoretical completion time corresponding to cycle 1, with a value of 14:30:05.000. The central controller performs a subtraction operation (14:30:05.150 - 14:30:05.000) to obtain +0.150 seconds (i.e., 150ms), and then performs an absolute value operation on this difference to obtain a timing phase difference of 150ms.

[0083] After the WS-002 at workstation completes its operation (after 14:30:05.150), the central controller immediately sends a trigger command to the industrial camera (e.g., Basleraceac A2440-75uc, equipped with a 5-megapixel CMOS sensor and telecentric lens) installed downstream of the WS-002. The industrial camera acquires top image data (e.g., 2448x2048 pixels, 8-bit grayscale) of the connector housing (with the terminals already pressed in) and transmits the image data to the central controller via the GigEVision interface. The central controller invokes the image processing unit to perform preprocessing operations on the 2448x2048 pixel image data: first, grayscale conversion (if not a monochrome camera), then a 5x5 Gaussian filter kernel is applied for convolution to smooth the image and remove random noise; next, the Canny operator (with a low threshold of 50 and a high threshold of 150) is used for edge detection to extract the edge contours of all automotive connector terminal pins on the connector (taking this connector with 4 pins as an example).

[0084] For the extracted edge contours, a Hough transform is performed to identify straight line segments in the contours, and morphological operations (e.g., skeleton extraction after opening) are used to find the contour corner points of each pin tip. Using the camera calibration matrix (previously obtained using the Zhang Zhengyou calibration method) and 2D image coordinates, the three-dimensional spatial coordinates (unit: mm) of the four pin tips in the workpiece coordinate system are calculated, and a pin tip coordinate set is established.

[0085] Example data: Pin tip coordinate 1 = (10.10, 5.00, 0.05) Pin tip coordinate 2 = (10.10, 10.00, -0.15) Pin tip coordinate 3 = (20.20, 5.10, 0.20) Pin tip coordinate 4 = (20.20, 10.10, 0.00).

[0086] The central controller uses the least squares method to fit a reference plane equation in three-dimensional space based on the coordinate set of the pin tips. The parameters of the fitted reference plane are obtained by performing principal component analysis (PCA) or singular value decomposition (SVD) on the coordinate set of the probe tip.

[0087] Example results: The fitted reference plane equation is .

[0088] The central controller iterates through the coordinate set of the pin tips and calculates the coordinates of each key point. The Euclidean distance to the reference plane, i.e., the distance deviation value. . Where i is the pin number (1 to 4 in this example); This represents the distance deviation from the tip of the i-th pin to the fitted reference plane; , , Represents the coordinates of the tip of the i-th pin; A, B, C, and D are the equations of the reference plane fitted in S2. The coefficients are A=0.005, B=-0.008, C=0.999, and D=-0.015, respectively.

[0089] Example: Distance deviation value 1 = mm;

[0090] Distance deviation value 2= mm;

[0091] Distance deviation value 3= mm;

[0092] Distance deviation value 4= mm;

[0093] Generate a set of distance deviation values .

[0094] The central controller calculates the statistical standard deviation of the set of distance deviation values, which is defined as the pin coplanarity. First, the mean is calculated: Mean = (0.04545 + 0.19435 + 0.24500 + 0.00520) / 4 = 0.49000 / 4 = 0.12250 mm. Then, the variance is calculated: Variance = [(0.04545 - 0.12250)^2 + (0.19435 - 0.12250)^2 + (0.24500 - 0.12250)^2 + (0.00520 - 0.19435 ...2250)^2 + (0.19435 - 0.12250)^2 + (0.19435 - 0.12250)^2 + (0.19435 - 0.12250)^2 + (0.19435 - 0.12250)^2 + (0.19435 - 0.12250)^2 + (0.19435 - 0.12250)^2 + (0.19435 - 0.12250)^2 Variance = [(-0.07705)^2 + (0.07185)^2 + (0.12250)^2 + (-0.11730)^2] / 4 Variance = [0.0059367 + 0.0051624 + 0.01500625 + 0.0137593] / 4 = 0.03986465 / 4 Finally, calculate the standard deviation (insert coplanarity): Insert coplanarity = mm defines the coplanarity of the pin, 0.0998 mm, as the spatial position deviation and stores it in the station's operating status feature vector.

[0095] The central controller integrates the timing phase difference of 150ms calculated by WS-002 in cycle 1 with the calculated spatial position deviation of 0.0998mm to establish a two-dimensional vector {\mathrm{V}}_{002}=\left [ {150,0.0998} \right ] This vector is the feature vector of the workstation's operating status.

[0096] Please see Figure 1 and Figure 4 S3: Determine the feature vector of the workstation's operating status. If the timing phase difference is greater than the timing tolerance threshold, calculate the time compensation value using the Kalman filter algorithm. If the spatial position deviation is greater than the recoverable deviation threshold, generate a flexible time slot occupancy request and generate a collaborative scheduling strategy set in conjunction with the time compensation value.

[0097] The coordinated scheduling strategy set includes time compensation values ​​and elastic time slot occupancy requests;

[0098] The specific steps for S3 are as follows:

[0099] S31: The central controller compares the timing phase difference in the workstation operating status feature vector with the preset timing tolerance threshold, and at the same time compares the spatial position deviation with the preset recoverable deviation threshold and the unrecoverable deviation threshold.

[0100] S32: If the timing phase difference is greater than the timing tolerance threshold, the Kalman filter algorithm is activated, and the historical timing phase difference sequence in the actual execution timing dataset of the workstation is used as the observation value to predict and output the optimal time compensation value.

[0101] The process of calculating the time compensation value using the Kalman filter algorithm is as follows:

[0102] S321: Initialize the state estimate and covariance matrix of the time compensation value, and define the state transition matrix and observation matrix of the time series dynamic model, and set the process noise covariance and observation noise covariance;

[0103] S322: Perform the prediction step. Based on the state transition matrix and the state estimate of the previous time step, calculate the prior state estimate of the current time step, and use the process noise covariance and the posterior covariance matrix of the previous time step to calculate the prior covariance matrix of the current time step.

[0104] S323: Calculate the Kalman gain, which is based on the prior covariance matrix, the observation matrix, and the observation noise covariance.

[0105] S324: Perform the update step, using Kalman gain, prior state estimate and current time phase difference obtained from the station operation state feature vector to calculate the posterior state estimate, i.e. the optimal time compensation value.

[0106] S325: Update the posterior covariance matrix for the next round of iteration calculation, and output the optimal time compensation value to the cooperative scheduling strategy set;

[0107] S33: If the spatial position deviation is greater than the recoverable deviation threshold but less than the unrecoverable deviation threshold, it is determined to be a correctable deviation and an elastic time slot occupancy request is immediately generated. If the spatial position deviation is greater than the unrecoverable deviation threshold, a shutdown alarm signal is generated.

[0108] S34: The central controller aggregates the time compensation value and the elastic time slot occupancy request, encapsulates them into a unified data structure, and obtains a set of collaborative scheduling strategies.

[0109] The central controller sets timing tolerance thresholds, recoverable deviation thresholds, and unrecoverable deviation thresholds.

[0110] The timing tolerance threshold is set based on the production line buffer capacity and the minimum start-up time of downstream workstations. Experimental verification process: A standard cycle time is set. The time is 5000ms. An analog delay of 0ms to 500ms is introduced at workstation WS-002. The step size is 10ms, and 1000 loops are run under each delay setting. The material waiting time at the downstream workstation WS-003 is observed. The above standard beat Referring to the definition in S1, this is the basic cycle time of the production line. The above simulated delay... This refers to the deviation in workstation execution time introduced artificially to test the robustness of the system. The aforementioned material waiting time... This refers to the idle waiting time at the downstream workstation due to the material not arriving at the upstream workstation (WS-002). Experimental data: When the simulated delay... Material waiting time when in the range [0, 100ms] The mean is 0, and there is no interruption at the downstream workstation. When the simulation delay... When the time interval is (100ms, 200ms), the downstream workstation experiences intermittent pauses, with an average waiting time of [missing information].

[0111] for ms. When the simulation delay When the time exceeds 200ms, the production line buffer overflows, triggering an emergency stop. Based on the above data, 100ms is selected as the timing tolerance threshold.

[0112] The spatial position deviation threshold setting references the following: recoverable and non-recoverable deviation thresholds refer to the mating insertion force specifications of automotive connector terminals and corresponding sockets (e.g., EIA-364-13 standard). Experimental verification process: Prepare 100 sets of pin coplanarity... Given (measured by a coordinate measuring machine) the connector sample, the pin coplanarity... The range is from 0.01 mm to 0.50 mm, with increments of 0.01 mm. Using a mechanical testing bench (e.g., Instron 5900 series), the sample is pressed into a standard mating socket, and the maximum insertion force is recorded. The coplanarity of the aforementioned pins Referring to the definition in S2, this is the statistical standard deviation of the distance from the tip of the pin to the fitted reference plane. The aforementioned maximum insertion force... This refers to the peak force recorded by the mechanical testing platform during the indentation process. Experimental data: when the pin coplanarity... Maximum insertion force at mm The average value is 45N, which is lower than the specification limit of 50N. When the pin coplanarity... Maximum insertion force when within the range (0.05mm, 0.30mm). Coplanarity of the insert Linear growth, from 51N to 75N; within this range, perform one retraction (-1mm) and re-insertion (correction action), with maximum insertion force. It can be restored to below 50N. When the pins are coplanar... Maximum insertion force when >0.30mm If the torque exceeds 75 N, plastic deformation occurs in the terminal or socket, rendering the correction action ineffective. Based on the above data, the recoverable deviation threshold is set at 0.05 mm, and the non-recoverable deviation threshold is set at 0.30 mm.

[0113] The central controller acquires the feature vector of the workstation WS-002's operating status in cycle 1: {\mathrm{V}}_{002}=\left [ {150,0.0998} \right ] The comparisons are as follows: 1. Compare the timing phase difference of 150ms with the timing tolerance threshold (100ms). 2. Compare the spatial position deviation of 0.0998mm with the recoverable deviation threshold (0.05mm) and the unrecoverable deviation threshold (0.30mm).

[0114] Judgment result: 150ms>100ms, activate time compensation value calculation. Judgment result: 0.0998mm>0.05mm and 0.0998mm<0.030mm, activate elastic time slot occupancy request generation.

[0115] Execution time compensation value calculation: The central controller calls the Kalman filter algorithm. S321: Initialize parameters. Set the state transition matrix A=1 (assuming that the delays of adjacent cycles are strongly correlated); set the observation matrix H=1 (assuming that the phase difference observed by the sensor is the true state); set the process noise covariance Q=0.01, indicating that the state transition model has low uncertainty; set the observation noise covariance R=5, indicating that the sensor observation values ​​have relatively large fluctuations. Obtain the historical time-series phase difference sequence (absolute value) of WS-002 from the actual execution time-series dataset of the workstation (Table 1): (ms). Use The second-to-last value, 155ms, is used as the posterior state estimate at time k-1. Define the posterior covariance matrix at time k-1. (Initial uncertainty).

[0116] Perform the prediction step. Calculate the prior state estimate for the current time step (time k, corresponding to 148 ms of the observation). : ms calculates the prior covariance matrix at the current time step. : .

[0117] Calculate Kalman gain : .

[0118] Perform the update step. Obtain the current time-series phase difference (the observation value at time k). ),Right now The last value: =148ms. Calculate the posterior state estimate. (i.e., the optimal time compensation value) ): ms will provide the optimal time compensation value ( (Rounded down) is set to 150ms. The result... =150ms indicates that the stable physical delay of WS-002 is estimated to be 150ms, and this value will be used to adjust its subsequent clock cycles. Here, k represents the current time period; x represents the state estimate (i.e., the optimal time compensation value); A is the state transition matrix; H is the observation matrix; Q is the process noise covariance; and R is the observation noise covariance. It is a historical time-series phase difference sequence; This is an estimate of the posterior state from the previous time step; Let be the posterior covariance matrix of the previous time step; Estimate the prior state at the current moment; Let be the prior covariance matrix at the current moment; Kalman gain; The current observation value; Estimate the posterior state at the current moment; This is the calculated optimal time compensation value.

[0119] Update the posterior covariance matrix : in, This is the identity matrix. The value 3.332 will be used as... Deposit for the next cycle (cycle 6). The optimal time compensation value =150ms output to the collaborative scheduling strategy set.

[0120] Simultaneously, a deviation determination is performed: if the spatial position deviation (0.0998mm) is greater than the recoverable deviation threshold (0.05mm) but less than the unrecoverable deviation threshold (0.30mm), it is determined to be a correctable deviation. A flexible time slot occupancy request is immediately generated. (If the spatial position deviation is calculated to be 0.35mm, then 0.35 > 0.30, and the central controller will generate a shutdown alarm signal.) And stop the operation of WS-002). The above elastic time slot occupancy request. This refers to a request signal indicating that a workstation needs to temporarily occupy additional production line time to perform calibration actions. The above-mentioned stop alarm signals... This refers to an emergency stop signal triggered by the detection of an irreversible deviation.

[0121] The central controller will calculate the time compensation value =150ms and elastic time slot occupancy request The data is collected and encapsulated into a unified data structure to obtain a set of collaborative scheduling strategies for WS-002. .

[0122] Please see Figure 1 and Figure 5 S4: According to the collaborative scheduling strategy set, if there is a time compensation value, generate a dedicated clock signal by superimposing the time compensation value on the specified workstation; if there is a flexible time slot occupation request, suspend the downstream workstation and the workstation requesting permission, and release the suspension after receiving the correction completion signal.

[0123] Dedicated cycle signals include time compensation values ​​and workstation cycle signals;

[0124] The specific steps for S4 are as follows:

[0125] S41: The central controller parses the collaborative scheduling strategy set. If a time compensation value is detected, it locates the corresponding workstation identity, obtains the standard cycle signal, and adds the time compensation value as a time offset to the trigger time point of the next cycle of the standard cycle signal to generate a dedicated cycle signal and send it to the local controller of the workstation.

[0126] S42: If a flexible time slot occupancy request is detected, the central controller immediately sends a suspension command to the directly downstream workstation of the requesting workstation, causing it to suspend receiving materials and performing actions, and at the same time sends a correction permission signal and spatial position deviation data to the requesting workstation.

[0127] S43: After receiving the calibration permission signal, the local controller of the requesting station executes the preset calibration procedure and sends a calibration completion signal back to the central controller after the calibration action is completed. After receiving the calibration completion signal, the central controller releases the suspension command to the downstream station.

[0128] Central controller parses and coordinates the set of scheduling strategies .

[0129] Time compensation value detected =150ms, locate workstation identification WS-002. Obtain the standard beat signal (theoretical start) for the next cycle (cycle 6). =14:30:25.000, End of Theory The time compensation value of 150ms is used as the time offset and superimposed on the trigger time of the standard beat signal.

[0130] Generate a unique beat signal Exclusive beat signal The start time point = + =14:30:25.000 + 150ms = 14:30:25.150. Dedicated beat signal. End time + =14:30:30.000 + 150ms = 14:30:30.150. The central controller will send the dedicated beat signal. (Include and The aforementioned dedicated beat signal is sent to the local controller of the WS-002 via the PROFINET channel. It refers to a non-standard beat signal generated by the central controller for a specific workstation (WS-002), which is offset by the time compensation value.

[0131] Meanwhile, a request for elastic time slot occupancy was detected. .

[0132] The central controller immediately sends a suspend command to WS-003, the direct downstream station of WS-002. (For example, a Modbus / TCP write operation sets address 40001 of the WS-003 to 1). The local controller of the WS-003 receives a suspend command. Then, the servo motor's operation is paused, and the conveyor belt receiving materials from WS-002 stops. Simultaneously, the central controller sends a calibration permission signal to WS-002. The spatial position deviation data of 0.0998mm calculated by S2 is also sent out. The above suspension command... This refers to the control command sent by the central controller to the downstream workstation (WS-003) to suspend its operation. The aforementioned calibration permission signal... This refers to the control command sent by the central controller to the deviation station (WS-002), authorizing it to execute the correction procedure.

[0133] The local controller of WS-002 receives a calibration permission signal. After obtaining the spatial position deviation data, a preset correction procedure is executed (e.g., based on the spatial position deviation being in the range of (0.05, 0.30], a "slight secondary pressurization" correction is performed). This correction procedure controls the servo motor to perform a retraction action (e.g., the Z-axis moves up by 1.0 mm), and then performs a controlled downward action (e.g., the Z-axis is pressed down to -15.45 mm, slightly shallower than the original -15.50 mm, and the torque is limited to 30 N).

[0134] After the calibration is completed, the local controller of the WS-002 sends a "calibration completed" signal back to the central controller. .

[0135] The central controller receives the "correction action completed" signal. Then, immediately release the suspend command on the downstream workstation WS-003 (for example, set the address 40001 of WS-003 to 0). After receiving the release command, the local controller of WS-003 resumes normal operation and prepares for... (14:30:25.150) After that, receive the material from WS-002.

[0136] An automated production line collaborative control system for automotive connectors, the automated production line collaborative control system for automotive connectors being used to execute the aforementioned automated production line collaborative control method for automotive connectors, the system comprising:

[0137] The timing data acquisition module is used by the central controller to broadcast standard beat signals, and the local controller to execute the preset physical action of pressing the automotive connector terminals into the connector housing and collect the action completion timestamp. The action completion timestamp and the workstation identity identifier are combined to construct the actual execution timing dataset of the workstation and transmitted to the operation status analysis module.

[0138] The operation status analysis module is used by the central controller to calculate the timing phase difference based on the actual execution timing dataset of the workstation, collect image data of the connector housing to calculate the pin coplanarity of the automotive connector terminal as the spatial position deviation, and form the workstation operation status feature vector by the timing phase difference and the spatial position deviation, and then transmit it to the collaborative strategy generation module.

[0139] The collaborative strategy generation module is used to determine the feature vector of the workstation's operating status. If the timing phase difference is greater than the timing tolerance threshold, the time compensation value is calculated using the Kalman filter algorithm. If the spatial position deviation is greater than the recoverable deviation threshold, a flexible time slot occupancy request is generated. The collaborative scheduling strategy set is generated in conjunction with the time compensation value and then transmitted to the production line cycle control module.

[0140] The production line cycle control module is used to generate a dedicated cycle signal for a specified workstation by superimposing a time compensation value on the time compensation value if a time compensation value exists, and to suspend the downstream workstation and the workstation requesting permission if a flexible time slot occupancy request exists, and to release the suspension after receiving the correction completion signal.

[0141] The above embodiments illustrate preferred embodiments of the present invention. Any equivalent adjustments to the technical solution based on software engineering methods are within the scope of protection, including but not limited to: implementing algorithm logic using different programming languages, refactoring functional modules into services, adjusting data interaction protocols, and optimizing resource scheduling strategies. Any implementation scheme derived from reasonable modifications to the data processing flow, service call chain, or system architecture layer without departing from the core technology of the present invention should be considered within the scope of protection defined by the claims of the present invention.

Claims

1. A method for coordinated control of an automated production line for automotive connectors, characterized in that, Includes the following steps: S1: The central controller broadcasts a standard beat signal, and the local controller executes a preset physical action to press the automotive connector terminal into the connector housing and collects the action completion timestamp. The action completion timestamp and the workstation identity identifier are combined to construct the actual execution time sequence dataset of the workstation. S2: The central controller calculates the timing phase difference based on the actual execution timing dataset of the workstation, collects image data of the connector housing, calculates the pin coplanarity of the automotive connector terminal as the spatial position deviation, and forms the workstation operating status feature vector. S3: Determine the feature vector of the workstation's operating status. If the timing phase difference is greater than the timing tolerance threshold, calculate the time compensation value using the Kalman filter algorithm. If the spatial position deviation is greater than the recoverable deviation threshold, generate a flexible time slot occupancy request and combine it with the time compensation value to generate a collaborative scheduling strategy set. S4: According to the collaborative scheduling strategy set, if the time compensation value exists, a dedicated beat signal is generated by superimposing the time compensation value on the specified workstation; if the elastic time slot occupancy request exists, the downstream workstation and the workstation requesting permission are suspended, and the suspension is lifted after receiving the correction completion signal. The specific steps in S3 are as follows: S31: The central controller compares the timing phase difference in the workstation operating status feature vector with a preset timing tolerance threshold, and at the same time compares the spatial position deviation with preset recoverable deviation thresholds and unrecoverable deviation thresholds. S32: If the timing phase difference is greater than the timing tolerance threshold, then activate the Kalman filter algorithm, use the historical timing phase difference sequence in the actual execution timing dataset of the workstation as the observation value, predict and output the optimal time compensation value; S33: If the spatial position deviation is greater than the recoverable deviation threshold and less than the unrecoverable deviation threshold, it is determined to be a correctable deviation, and an elastic time slot occupancy request is immediately generated; if the spatial position deviation is greater than the unrecoverable deviation threshold, a shutdown alarm signal is generated. S34: The central controller aggregates the time compensation value and the elastic time slot occupancy request, encapsulates them into a unified data structure, and obtains a set of collaborative scheduling strategies.

2. The automated production line collaborative control method for automotive connectors according to claim 1, characterized in that, The actual execution time sequence dataset of the workstation includes action completion timestamps and workstation identity identifiers; the workstation running status feature vector includes timing phase difference and spatial position deviation; the collaborative scheduling strategy set includes time compensation value and elastic time slot occupancy request; and the dedicated beat signal includes time compensation value and workstation beat signal.

3. The automated production line collaborative control method for automotive connectors according to claim 1, characterized in that, The specific steps of S1 are as follows: S11: The central controller broadcasts a unified standard beat signal to all local controllers in the production line via industrial Ethernet. The standard beat signal defines the theoretical start and end times of multiple workstations. S12: After receiving the trigger command of the standard beat signal, the local controller controls the servo motor or pneumatic component to perform a preset physical action of pressing the automotive connector terminal into the connector housing, and uses a clock source to collect the current time as the action completion timestamp at the moment the preset physical action is completed. S13: The local controller binds the action completion timestamp to its unique workstation identity and sends it to the central controller through the real-time data reporting channel. The central controller collects the reported data from all workstations and constructs a workstation actual execution time sequence dataset.

4. The automated production line collaborative control method for automotive connectors according to claim 1, characterized in that, The specific steps of S2 are as follows: S21: The central controller extracts the action completion timestamp of the specified workstation from the actual execution timing dataset of the workstation, queries the standard beat signal to obtain the corresponding theoretical completion time, calculates the absolute value of the difference between the two, and obtains the timing phase difference; S22: The central controller calls an industrial camera to collect high-resolution image data of the connector housing after it is pressed into the automotive connector terminal, and uses edge detection and contour extraction algorithms to locate the top coordinates of multiple pins; S23: Based on the fitted reference plane of the top coordinates, calculate the standard deviation of the vertical distance from all the top coordinates to the reference plane, quantify the standard deviation as the pin coplanarity, and designate it as the spatial position deviation; S24: The central controller integrates the calculated timing phase difference with the spatial position deviation to establish a two-dimensional vector and generate a workstation operating status feature vector.

5. The automated production line collaborative control method for automotive connectors according to claim 1, characterized in that, The specific steps of S4 are as follows: S41: The central controller parses the collaborative scheduling strategy set. If the time compensation value is detected, it locates the corresponding workstation identity, obtains the standard beat signal, and adds the time compensation value as a time offset to the trigger time point of the next cycle of the standard beat signal to generate a dedicated beat signal and sends it to the local controller of the workstation. S42: If the request for occupancy of the flexible time slot is detected, the central controller immediately sends a suspension command to the directly downstream workstation of the requesting workstation to suspend receiving materials and performing actions, and at the same time sends a correction permission signal and spatial position deviation data to the requesting workstation. S43: After receiving the calibration permission signal, the local controller of the requesting workstation executes a preset calibration procedure and sends a calibration completion signal back to the central controller after the calibration action is completed. After receiving the calibration completion signal, the central controller releases the suspension command to the downstream workstation.

6. The automated production line collaborative control method for automotive connectors according to claim 1, characterized in that, The process of calculating the time compensation value using the Kalman filtering algorithm is as follows: S321: Initialize the state estimate and covariance matrix of the time compensation value, and define the state transition matrix and observation matrix of the time series dynamic model, and set the process noise covariance and observation noise covariance; S322: Perform the prediction step, calculate the prior state estimate at the current time based on the state transition matrix and the state estimate at the previous time, and calculate the prior covariance matrix at the current time using the process noise covariance and the posterior covariance matrix at the previous time. S323: Calculate the Kalman gain, which is obtained based on the prior covariance matrix, the observation matrix, and the observation noise covariance. S324: Perform the update step, using the Kalman gain, the prior state estimate, and the current timing phase difference obtained from the workstation operating state feature vector to calculate the posterior state estimate, i.e. the optimal time compensation value. S325: Update the posterior covariance matrix for the next round of iteration calculation, and output the optimal time compensation value to the cooperative scheduling strategy set.

7. The automated production line collaborative control method for automotive connectors according to claim 4, characterized in that, The process of calculating the coplanarity of the insert as a spatial positional deviation is as follows: S231: The central controller preprocesses the acquired high-resolution image data, including grayscale conversion and Gaussian filtering to remove random noise, and uses the Canny operator to perform edge detection to extract the edge contours of multiple pins of the automotive connector terminal. S232: Perform Hough transform or morphological processing on the edge contour to identify and extract the coordinates of all key points at the tip of the pin, and establish a set of coordinates for the tip of the pin. S233: Using the least squares method, a reference plane is fitted in three-dimensional space based on the coordinate set of the pin tips. The reference plane represents the theoretically coplanar position of all pins. S234: Traverse the coordinate set of the pin tip, calculate the Euclidean distance from the coordinates of each key point to the reference plane, and generate a distance deviation value; S235: Calculate the statistical standard deviation of the distance deviation value set, use the standard deviation value as a quantitative indicator, define it as the coplanarity of the pin, and store it as the spatial position deviation in the workstation operating status feature vector.

8. An automated production line collaborative control system for automotive connectors, characterized in that, The system is used to implement the automated production line collaborative control method for automotive connectors according to any one of claims 1-7, the system comprising: The timing data acquisition module is used by the central controller to broadcast standard beat signals, and the local controller to execute a preset physical action of pressing the automotive connector terminal into the connector housing and collect the action completion timestamp. The action completion timestamp is combined with the workstation identity identifier to construct the actual execution timing dataset of the workstation and then transmitted to the operation status analysis module. The operation status analysis module is used by the central controller to calculate the timing phase difference based on the actual execution timing dataset of the workstation, collect image data of the connector housing to calculate the pin coplanarity of the automotive connector terminal as a spatial position deviation, and construct a workstation operation status feature vector from the timing phase difference and the spatial position deviation, and transmit it to the collaborative strategy generation module. The collaborative strategy generation module is used to determine the feature vector of the workstation's operating status. If the timing phase difference is greater than the timing tolerance threshold, the time compensation value is calculated using the Kalman filter algorithm. If the spatial position deviation is greater than the recoverable deviation threshold, a flexible time slot occupancy request is generated. The collaborative scheduling strategy set is generated in conjunction with the time compensation value and then transmitted to the production line cycle control module. The production line cycle control module is used to generate a dedicated cycle signal for a specified workstation by superimposing the time compensation value on the time compensation value according to the collaborative scheduling strategy set. If the time compensation value exists, it suspends the downstream workstation and the workstation requesting permission if the flexible time slot occupancy request exists. The suspension is released after receiving the correction completion signal.

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