Electric appliance control cabinet production management and control method and system

Abstract

The invention discloses an electric appliance control cabinet production management and control method and system, and relates to the technical field of electric appliance cabinet production. The method comprises the following steps: typesetting at least one component according to a drawing; and automatically screwing the at least one component by a screwing device through a fastener according to the torsion operation process and the torsion value standard of each component in the at least one component after typesetting. The problems that a traditional electric appliance control cabinet is long in manufacturing period and slow in abnormity handling are solved.

Description

Technical Field

[0001] This invention relates to the field of electrical cabinet manufacturing technology, specifically to a method and system for production control of electrical control cabinets. Background Technology

[0002] In the manufacturing process of rail transit vehicles, under the background of the modular design process change of electrical control cabinets, traditional electrical control cabinets are based on control principle diagrams and have less design for the internal structure and layout of the electrical cabinets. They rely heavily on the skill level of the operators and have shortcomings such as long manufacturing cycle and slow handling of abnormalities. Summary of the Invention

[0003] This invention addresses the shortcomings of traditional electrical control cabinet manufacturing, which relies heavily on the skill level of operators, resulting in long manufacturing cycles and slow handling of anomalies. It provides a production management method and system for electrical control cabinets, solving the problems of long manufacturing cycles and slow anomaly handling in traditional electrical control cabinet manufacturing.

[0004] The present invention is achieved through the following technical solution.

[0005] In a first aspect, the present invention provides a method for production control of an electrical control cabinet, the method comprising: arranging at least one component according to a drawing; and automatically tightening the at least one component using fasteners by a tightening device according to a torque operation process and a torque value standard for each of the at least one component.

[0006] In some embodiments, the method further includes: acquiring the actual torque value of the fastener on the at least one component; comparing the actual torque value of the at least one component with the torque value standard; and storing the actual torque value of the at least one component that is within the torque value standard.

[0007] In some embodiments, the method further includes: issuing an alarm when the actual torque value of at least one component is outside the torque value standard.

[0008] In some embodiments, the method further includes: scanning the identification of the at least one component after automatic tightening to obtain pre-stored 3D model data of the same type of component and standard component scan data; performing a 3D scan on the at least one component to obtain the shape data of the at least one component; comparing the shape data of the at least one component with the pre-stored 3D model data of the same type of component and standard component scan data; and storing the shape data of the at least one component that is within the standard range of the pre-stored 3D model data of the same type of component and standard component scan data.

[0009] In some embodiments, the method further includes issuing an alarm when the shape data of at least one component is outside the standard of the pre-stored 3D drawing data of the same type of component and the standard component scan data.

[0010] In some embodiments, the method further includes: providing a detection signal to the at least one component to perform continuity and withstand voltage tests on the at least one component based on a schematic diagram and continuity withstand voltage standard data of the same type of component; comparing the detected output data with the continuity withstand voltage standard data; and storing the output data that falls within the continuity withstand voltage standard data.

[0011] In some embodiments, the method further includes: issuing an alarm when the output data is outside the conduction withstand voltage standard data.

[0012] Secondly, this invention provides an electrical control cabinet production management system, the system including: a tightening device and a torque determination module, wherein the tightening device automatically tightens at least one component arranged according to the drawings, according to the torque operation process provided by the torque determination module and the torque value standard for each component in the at least one component, using fasteners.

[0013] In some embodiments, the system further includes a scanning device and an image recognition module, wherein the scanning device is configured to: scan the identification of the at least one component after automatic tightening to obtain pre-stored 3D model data of the same type of component and standard component scan data from the image recognition module; and perform 3D scanning on the at least one component to obtain the shape data of the at least one component, wherein the image recognition module is configured to compare the shape data of the at least one component with the pre-stored 3D model data of the same type of component and standard component scan data; and store the shape data of the at least one component that falls within the standard range of the pre-stored 3D model data of the same type of component and standard component scan data.

[0014] In some embodiments, the system further includes: a detection device and a continuity test module, wherein the detection device is configured to: provide a detection signal to the at least one component to perform continuity and withstand voltage tests on the at least one component based on the schematic diagram and continuity withstand voltage standard data of the same type of component; the continuity test module is configured to: compare the output data after detection with the continuity withstand voltage standard data; and store the output data that falls within the continuity withstand voltage standard data.

[0015] Compared with the prior art, the present invention has the following advantages and beneficial effects.

[0016] 1) By using intelligent algorithms and image technology, the layout and arrangement of various components inside the electrical control cabinet are solved. The manufacturing process of the electrical control cabinet is visualized and scanned, and the image results are compared with the product design drawings to determine their correctness, thereby improving the quality control of the product manufacturing process.

[0017] 2) By utilizing intelligent tightening devices and fastener torque management, the torque quality defects of key fasteners have been resolved.

[0018] 3) Based on the modular electrical cabinet design schematic, a testing device is used to solve the process quality issues of continuity and withstand voltage data for various modular circuits in the electrical control cabinet. Attached Figure Description

[0019] To more clearly illustrate the technical solutions of the exemplary embodiments of the present invention, the accompanying drawings used in the embodiments will be briefly described below. It should be understood that the following drawings only show some embodiments of the present invention and should not be considered as limiting the scope. For those skilled in the art, other related drawings can be obtained based on these drawings without creative effort.

[0020] Figure 1 This is a flowchart of a production control method for an electrical control cabinet according to an embodiment of the present invention.

[0021] Figure 2 This is a flowchart of torque value acquisition and determination according to an embodiment of the present invention.

[0022] Figure 3 This is a flowchart of the shape data acquisition and determination process according to an embodiment of the present invention.

[0023] Figure 4 This is a flowchart of continuity and withstand voltage testing according to an embodiment of the present invention.

[0024] Figure 5 This is a schematic diagram of an electrical control cabinet production management system according to an embodiment of the present invention. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments and accompanying drawings. The illustrative embodiments and descriptions of this invention are for illustrative purposes only and are not intended to limit the invention.

[0026] To address the shortcomings of traditional electrical control cabinet manufacturing, which heavily relies on the skill level of operators and suffers from long manufacturing cycles and slow handling of anomalies, this invention provides a method and system for production management and control of electrical control cabinets. The technical solution of this invention provides intelligent management and control of the electrical control cabinet manufacturing process. Based on an automated production line for electrical control cabinets, and incorporating intelligent algorithm models, the invention includes: 1) Installing scanning equipment on the production line to automatically scan and monitor the installation sequence and position of various components, as well as various marked cables. The scan results are compared with product 3D drawings and standard product scan data, and the accuracy is determined by intelligent algorithms, thereby monitoring and managing the quality of the automated production line's manufacturing process. 2) Configuring intelligent tightening tools on the automated production line, combined with a fastener torque management system, to automatically record and determine the correctness of various fastener installation torque values, eliminating incorrect or missing fasteners. 3) Providing an inspection device, based on the modular electrical cabinet design schematic, to test the continuity and withstand voltage reliability of each modular circuit in the electrical control cabinet.

[0027] Figure 1 This is a flowchart illustrating a production control method for an electrical control cabinet according to an embodiment of the present invention. (Reference) Figure 1 The production control method for this electrical control cabinet includes: S10 and S20.

[0028] In S10, at least one component is arranged according to the drawings. For example, when the modular components in the electrical control cabinet enter the assembly process, the operator arranges the various components according to the drawings, or uses a layout tool to arrange the various components according to the drawings, that is, places the various components in the specified positions on the base plate with a specified orientation.

[0029] In S20, at least one component, after being arranged in a layout, is automatically tightened by a tightening device using fasteners according to the torque operation process and the torque value standard for each component in the at least one component. An (intelligent) tightening device is a device used for automatically or semi-automatically tightening fasteners such as bolts, nuts, and bottle caps, and is widely used in vehicle manufacturing, electronic assembly, packaging machinery, and other fields.

[0030] Using an assembly line, at least one component, after being laid out, is automatically transferred to an intelligent tightening station. The intelligent tightening device then performs automatic tightening according to the production line system tasks and a pre-set torque operation flow and torque value standards for each step. For example, a laid-out circuit board is transferred along the assembly line to the intelligent tightening station. The tightening sequence (torque operation flow, i.e., the order in which torque is applied to each component) is pre-set for each component on the circuit board. Then, torque is applied to each component according to this sequence, thereby tightening each component.

[0031] Because the dimensions and materials of each component are different, different torques need to be applied based on the characteristics of each component when applying torque to each component. Therefore, this invention provides torque value standards for each component (corresponding to each process step, one component corresponds to one process step), and the tightening device applies appropriate torque to each component based on these torque value standards.

[0032] Figure 2 This is a flowchart illustrating the torque value acquisition and determination process according to an embodiment of the present invention. In some embodiments, the production control method for the electrical control cabinet further includes: torque value acquisition and determination. (See reference...) Figure 2 Torque data acquisition and determination, including: S11 to S13.

[0033] In S11, the actual torque value of the fastener on at least one component is acquired. The actual torque value of the fastener on at least one component after tightening can be acquired by a tightening device. For example, the tightening device may be equipped with a torque sensor. When tightening the component, the tightening device: on the one hand, applies the required torque to the component through the fastener based on a torque value standard; on the other hand, after applying the required torque, detects the actual torque value of the fastener on the component through the torque sensor.

[0034] In S12, the actual torque value of at least one component is compared with a torque value standard. For example, the actual torque value output by the intelligent tightening device is compared with a value within the torque value standard set by the system.

[0035] In S13, the actual torque value of at least one component that is within the torque value standard is stored. For example, after comparing the torque value output by the intelligent tightening device with the range value set by the system, the normal (within the standard) data is stored and transmitted to the QMS system (quality management system) confirmation form.

[0036] In some embodiments, the production control method for the electrical control cabinet further includes: triggering an alarm when the actual torque value of at least one component is outside the torque value standard. For example, after comparing the torque value output by the intelligent tightening device with the range value set by the system, if abnormal data is found, an alarm is triggered promptly and abnormal information is reported. Operators intervene to investigate the cause and initiate a secondary operation process. Abnormal data is recorded in the production line system, and the frequency of similar causes is analyzed to provide data support for the fault prevention model of the intelligent tightening device.

[0037] Figure 3 This is a flowchart illustrating the shape data acquisition and determination process according to an embodiment of the present invention. In some embodiments, the production control method for the electrical control cabinet further includes: shape data acquisition and determination. (See reference...) Figure 3 External shape data collection and determination, including: S21 to S24.

[0038] In step S21, the identification of at least one component after automatic tightening is scanned to obtain pre-stored 3D image data of the same type of component and standard component scan data. Exemplarily, the intelligent scanning workstation is equipped with an image scanning device (e.g., a scanner) that scans and identifies the unique identification code (e.g., a QR code) of at least one component to retrieve pre-stored 3D image data of the same type of modular component product and standard component scan data within the image recognition system. The pre-stored 3D image data of the same type of modular component product and standard component scan data are used as a comparison benchmark for inspecting at least one component.

[0039] In step S22, at least one component is subjected to a 3D scan to obtain its shape data. The image scanning device of the intelligent scanning workstation can perform 3D laser gate scanning on modular component products in an electrical control cabinet, thereby obtaining complete shape data of the modular component products. Shape data is a set of key parameters describing the physical characteristics of the product, typically including the component's location, size, outline, and connections. This shape data also includes the shape data of various marked cables.

[0040] In S23, the shape data of at least one component is compared with pre-stored 3D model data of components of the same type and standard component scan data. For example, the acquired shape data of the component is compared with 3D model data of the component and standard component scan data within an image recognition system.

[0041] In S24, the shape data of at least one component is stored if it falls within the standard range of pre-stored 3D drawing data of the same type of component and standard component scan data. For example, after comparing the acquired component shape data with the component 3D drawing data and standard component scan data in the image recognition system, the normal data is stored and transmitted to the QMS system quality confirmation form.

[0042] In some embodiments, the production control method for electrical control cabinets further includes: triggering an alarm when the shape data of at least one component is outside the range of pre-stored 3D model data and standard component scan data of the same type. For example, after comparing the acquired component shape data with the component 3D model data and standard component scan data in the image recognition system, if abnormal data is found, an alarm is triggered promptly and abnormal information is reported. Operators intervene to investigate the cause and initiate a secondary operation process. The abnormal data is recorded in the production line system, and the cause is analyzed to provide data support for the optimization of modular component product design and manufacturing process.

[0043] Figure 4 This is a flowchart illustrating continuity and withstand voltage testing according to an embodiment of the present invention. In some embodiments, the production control method for the electrical control cabinet further includes: performing continuity and withstand voltage testing on the electrical control cabinet. (Reference) Figure 4 The continuity and withstand voltage tests include: S31 to S33.

[0044] In S31, a detection signal is provided to at least one component to perform continuity and withstand voltage tests on at least one component based on the schematic diagram and continuity and withstand voltage standard data of the same type of component. After image recognition of each modular component product is completed, the components are automatically transferred to the intelligent inspection station of the control cabinet via an assembly line. During testing, operators can manually install the test pins, scan the unique identification code (QR code) of the modular product component using a barcode scanner, retrieve the schematic diagram and continuity and withstand voltage standard data of the same type of modular component in the testing system, and after the indicator light of the intelligent testing device in the control cabinet shows "green," the operator can manually press the button to start the test. Alternatively, the control cabinet testing system can automatically collect the test data from the intelligent testing device in the control cabinet.

[0045] In step S32, the detected output data is compared with the conduction withstand voltage standard data. After providing a detection signal to at least one component, the detected output data is acquired and compared with the conduction withstand voltage standard data.

[0046] In S33, the output data that falls within the conduction withstand voltage standard data is stored. After comparing the output data with the conduction withstand voltage standard data, if the data is normal, the normal data is stored and transferred to the QMS system quality confirmation table.

[0047] In some embodiments, the production control method for the electrical control cabinet further includes: triggering an alarm when the output data is outside the conduction withstand voltage standard data. After comparing the output data with the conduction withstand voltage standard data, if abnormal data is found, an alarm is promptly triggered to report the abnormality. Operators intervene to find the cause, initiate a secondary operation process, record the abnormal data in the production line system, and analyze the reasons for the test failure, providing data support for the optimization of modular product design and manufacturing process.

[0048] In this invention, while realizing the integrated design of modular components of the electrical control cabinet, three key technologies in the manufacturing process of the electrical control cabinet are considered simultaneously: 1) Through intelligent algorithms and image technology, the layout and arrangement of various components inside the electrical control cabinet are solved, the manufacturing process of the electrical control cabinet is visualized and scanned, and the image results are compared with the product design drawings to determine their correctness, thereby improving the quality control of the product manufacturing process; 2) By using intelligent tightening devices and fastener torque management, the torque quality defects of key fasteners are solved; 3) Combining the modular electrical cabinet design principle diagram, the process quality problems of continuity and withstand voltage data of various modular circuits in the electrical control cabinet are solved through detection devices.

[0049] On the other hand, the present invention provides an electrical control cabinet production management system. Figure 5 This is a schematic diagram of an electrical control cabinet production management system according to an embodiment of the present invention. (Reference) Figure 5 The production management system for this electrical control cabinet includes a tightening device and a torque determination module. The tightening device automatically tightens at least one component according to the layout of the drawings, following the torque operation process and torque value standard provided by the torque determination module, using fasteners.

[0050] In some embodiments, the tightening device is further configured to: acquire the actual torque value of the fastener on at least one component. The torque determination module is configured to: compare the actual torque value of at least one component with a torque value standard; and store the actual torque value of at least one component that is within the torque value standard.

[0051] In some embodiments, the torque determination module is further configured to: issue an alarm (abnormal feedback) when the actual torque value of at least one component is outside the torque value standard.

[0052] In some embodiments, the electrical control cabinet production management system further includes a scanning device and an image recognition module. The scanning device is used to: scan the identification mark of at least one component after automatic tightening to obtain pre-stored 3D model data of the same type of component and standard component scan data from the image recognition module; and to perform a 3D scan of at least one component to obtain the shape data of at least one component. The image recognition module is used to compare the shape data of at least one component with the pre-stored 3D model data of the same type of component and standard component scan data; and to store the shape data of at least one component that falls within the standard range of the pre-stored 3D model data of the same type of component and standard component scan data.

[0053] In some embodiments, the image recognition module is further configured to: issue an alarm (abnormal feedback) when the shape data of at least one component is outside the standard of pre-stored 3D drawing data of the same type of component and standard component scan data.

[0054] In some embodiments, the electrical control cabinet production management system further includes: a detection device and a continuity test module. The detection device is used to: provide a detection signal to at least one component to perform continuity and withstand voltage tests on at least one component based on the schematic diagram and continuity withstand voltage standard data of the same type of component. The continuity test module is used to compare the output data after detection with the continuity withstand voltage standard data; and to store the output data that falls within the continuity withstand voltage standard data.

[0055] In some embodiments, the continuity test module is also used to: issue an alarm (abnormal feedback) when the output data is outside the continuity withstand voltage standard data.

[0056] This invention utilizes image recognition technology, torque devices, and inspection devices to achieve quality management and traceability during the manufacturing process of electrical control cabinet assembly lines. It ensures that the layout and arrangement of components and the torque of fasteners during the manufacturing process are within the required standards, thereby guaranteeing the product quality of rail vehicle manufacturing. This invention achieves the following seven aspects.

[0057] (1. The layout of the electrical control cabinet assembly line has been optimized, the work content has been reasonably divided, and a standardized assembly line manufacturing organization mode has been realized.)

[0058] (2. An image-based management system was developed to record standard product scans in the system. By adding key identification points, the layout and arrangement of modular components of each function in the manufacturing process of electrical cabinets can be judged and managed in the image-based recognition system.)

[0059] (3. A fastener torque software system was deployed to manage the torque range values ​​of fasteners in the design production line, integrate the torque data of each fastener, and make intelligent responses based on the matching formula.)

[0060] (4. Modular inspection device for electrical control cabinet: Based on the design schematic of the modular electrical cabinet, it tests the continuity and withstand voltage data of each modular circuit of the electrical control cabinet. Combined with intelligent algorithms, the software system automatically determines whether it is qualified or unqualified, so as to realize the functional connection of the modular components of the electrical control cabinet.

[0061] (5. The integrated electrical control cabinet production line management system combines the three key issues of electrical control cabinet product quality management, realizes intelligent operation of the production line manufacturing process, and conducts system monitoring and management of process quality management and process data according to specific algorithms.

[0062] (6. Connect the electrical control cabinet production line management system and the enterprise internal communication system to enable the automatic push of production line manufacturing process monitoring alarm information and shutdown information to the PC and mobile APP terminals of the enterprise internal communication system in a hierarchical manner.

[0063] (7. The electrical control cabinet manufacturing production line is equipped with a comprehensive management large screen dashboard to meet the management needs of multi-level managers. From a digital perspective, it ensures quality control of the product manufacturing process in multiple aspects and dimensions.

[0064] This invention utilizes image recognition and inspection devices to coordinate the manufacturing of electrical cabinets, integrating functions such as product drawing management, standard parts scanning management, torque management, and inspection management. It automatically controls the progress of process data in the electrical control cabinet production line, giving it the following main advantages.

[0065] (1. Set up production line management function, including web client, suitable for use when manufacturing starts and finishes on the production site.)

[0066] (2) Production line automation records and identifies the layout and arrangement of each component in the manufacturing process, reducing the risk of inaccuracies in the manufacturing process.

[0067] (3. Combined with the warning value set by the torque range value, automatically tighten and identify the installation quality of the fasteners of the electrical cabinet.)

[0068] (4. Flexible testing device, which can realize the continuity and withstand voltage data of the modular circuit of the electrical cabinet in advance, and improve manufacturing efficiency.)

[0069] The specific embodiments described above further illustrate the purpose, technical solution, and beneficial effects of the present invention. It should be understood that the above description is only a specific embodiment of the present invention and is not intended to limit the scope of protection of the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. An electrical control cabinet production management and control method, characterized in that, The method comprises: arranging at least one component according to a drawing; and automatically tightening the at least one component by a tightening device using fasteners according to a torque operation procedure and a torque value standard for each component in the at least one component.

2. The method of claim 1, wherein, The method further comprises: collecting an actual torque value of the fasteners on the at least one component; comparing the actual torque value of the at least one component with the torque value standard; and storing the actual torque value of the at least one component within the torque value standard.

3. The method of claim 2, wherein, The method further comprises: warning in a case that the actual torque value of the at least one component is outside the torque value standard.

4. The method according to any one of claims 1 to 3, characterized in that, The method further comprises: scanning an identity of the at least one component after automatic tightening to obtain pre-stored three-dimensional drawing data and standard component scanning data of the same type of component; performing three-dimensional scanning on the at least one component to obtain shape data of the at least one component; comparing the shape data of the at least one component with the pre-stored three-dimensional drawing data and standard component scanning data of the same type of component; and storing the shape data of the at least one component within the pre-stored three-dimensional drawing data and standard component scanning data of the same type of component.

5. The method of claim 4, wherein, The method further comprises: warning in a case that the shape data of the at least one component is outside the pre-stored three-dimensional drawing data and standard component scanning data of the same type of component.

6. The method of claim 1, wherein, The method further comprises: providing a detection signal to the at least one component to perform conduction and withstand voltage detection on the at least one component based on a schematic diagram and conduction and withstand voltage standard data of the same type of component; comparing output data after detection with the conduction and withstand voltage standard data; and storing the output data within the conduction and withstand voltage standard data.

7. The method of claim 6, wherein, The method further comprises: warning in a case that the output data is outside the conduction and withstand voltage standard data.

8. An electrical control cabinet production management and control system, characterized in that, The system comprises a tightening device and a torque determination module, wherein the tightening device automatically tightens at least one component arranged according to a drawing according to a torque operation procedure and a torque value standard for each component in the at least one component provided by the torque determination module using fasteners.

9. The system of claim 8, wherein, The system further comprises a scanning device and an image recognition module, wherein the scanning device is configured to scan an identity of the at least one component after automatic tightening to obtain pre-stored three-dimensional drawing data and standard component scanning data of the same type of component from the image recognition module, and perform three-dimensional scanning on the at least one component to obtain shape data of the at least one component, The image recognition module is configured to: compare the shape data of the at least one component with the pre-stored three-dimensional image data and standard component scanning data of the same type of component; and store the shape data of the at least one component within the standard of the pre-stored three-dimensional image data and standard component scanning data of the same type of component.

10. The system of claim 9, wherein, The system further comprises a detection device and a conduction test module, wherein, The detection device is configured to: provide a detection signal to the at least one component to perform conduction and voltage withstand detection on the at least one component based on the schematic diagram and the conduction and voltage withstand standard data of the same type of component, The conduction test module is configured to: compare the output data after detection with the conduction and voltage withstand standard data; and store the output data within the conduction and voltage withstand standard data.

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