Workpiece counting production management system, method and application
The workpiece counting production management system, which integrates barcode scanners, marking machines, and PLC control units, solves the problem of inaccurate workpiece counting on the welding production line, realizes full-process data collection and monitoring of workpiece production, and improves the accuracy and flexibility of production management.
Patent Information
- Application Number
- CN202511437606.6
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2025-10-09
- Publication Date
- 2026-01-20
AI Technical Summary
The workpiece counting process on the existing welding production line suffers from omissions or errors, leading to increased production costs and delays in management data, which affects the accuracy and efficiency of the production management system.
The workpiece counting production management system integrates barcode scanners, marking machines, PLC control units, and host computer systems to achieve full-process data collection and monitoring. It manages the workpiece production process through QR codes and combines automatic and manual confirmation mechanisms to ensure data accuracy and real-time performance.
It enables full-process data collection and monitoring of workpiece production, automatically distinguishes between qualified and unqualified products, reduces the risk of human error, improves the accuracy and flexibility of production management, and avoids material waste.
Smart Images
Figure CN121365832A_ABST
Abstract
Description
TECHNICAL FIELD
[0001] The application belongs to the technical field of automatic production management, and particularly relates to a workpiece counting production management system, method and application. BACKGROUND
[0002] In modern manufacturing industry, a production line is a key part of an important production link such as automobile manufacturing. For an automatic welding line with highly integrated production process, accurate management of production orders and welding workpieces is crucial for production management, quality control and cost accounting. A conventional welding production line usually needs to produce multiple types of workpieces. Considering the implementation cost and design difficulty, the work of feeding and discharging workpieces on the production line is generally realized manually, which may lead to the situation of missing or miscounting workpieces in the workpiece counting link in the production process, or even the situation of producing wrong workpieces on some production lines, resulting in the increase and waste of production cost. In addition, the production data of the on-site system cannot be fully mastered, which may also lead to the delay of updating the production data of the production management system (MES) and the errors in the management and tracing links. SUMMARY
[0003] The application aims to overcome the deficiencies in the prior art and provide a workpiece counting production management system, method and application.
[0004] The technical solution adopted by the application to solve the technical problems is as follows: A workpiece counting production management system, the system comprises a process equipment and execution system, a PLC control unit, an operation touch screen, an upper computer management system, a code scanning gun, a marking machine and a production management system, the production management system, the upper computer management system, the PLC control unit, the process equipment and the execution system are sequentially connected and arranged, the code scanning gun and the marking machine are connected and arranged with the upper computer management system, and the operation touch screen is connected and arranged with the PLC control unit; the process equipment and the execution system can execute the welding production process and detect the workpiece quality according to the command of the PLC control unit, and when the NG product (defective product) appears, the NG product is offline; the PLC control unit can control and track the welding production process, exchange data with the on-site upper computer management system, obtain the product information content of the workpiece to be produced, and feed back the real-time production situation to the upper computer management system through data; the operation touch screen can communicate with the PLC control unit, and provide necessary production situation information and guiding operation for on-site production and management personnel; the upper computer management system can communicate with the production management system through electrical signals, and manage and trace the production situation of the workpiece on site through the PLC control unit; the code scanning gun can be scanned by the operator before production to scan the production order two-dimensional code issued, send the corresponding production information to the upper computer management system, and execute the subsequent logic; the marking machine can generate a two-dimensional code and print a label according to the information provided by the upper computer management system; the production management system can issue corresponding production order two-dimensional code information, and obtain the content of the production order completion through communication with the upper computer management system.
[0005] Further, the production management system is an MES production management system, which is more convenient for counting production management of workpieces.
[0006] The system as described above is applied to workpiece counting of a welding production line.
[0007] Further, the steps are as follows: (1) Order information initialization and issuance When the production management system receives a new order, first, the information in the order is extracted, the necessary information in the actual production of the workpiece is obtained, and a string is formed according to the rules, then the string is encrypted through the AES encryption algorithm to generate a two-dimensional code of the to-be-produced order information, and then the two-dimensional code is issued to the operation touch screen on the production site through an industrial network; (2) Verification mechanism of the upper computer system for the production order The worker scans the two-dimensional code of the to-be-produced order information issued by the production management system through the code scanning gun, and transmits the data to the upper computer management system, and the upper computer management system reads the two-dimensional code in real time, verifies the order information content after decryption, and executes verification; If the verification is passed, step (3) is performed, if the verification is not passed, the host computer system records the error reason, and returns the two-dimensional code to the system, and the production management system checks the information issued, and generates a correct two-dimensional code of the order information to be produced or terminates the order, and the touch screen prompts the worker to confirm the scanning error information.
[0008] (3) Confirm whether the production conditions are met on site The host computer system issues the order information to be produced to the PLC control unit, and prompts the order content through the operation touch screen, the PLC control unit automatically confirms the readiness state of the on-site equipment and the safety conditions of the production line, and the production personnel confirm the completeness of the materials required by the order, and feedback through the operation touch screen; If the production conditions are met, step (4) is started, if the production conditions are not met, the order is cancelled, the host computer management system records the reason for not producing, and prompts the production management system to update the order number and reissue, this order number and the two-dimensional code of the order information to be produced are invalid and cannot be used again; (4) Execute the production process After the order information verification and production condition confirmation, the host computer system first supplements the relevant order production information, and then starts the production; If the workpiece is scrapped during the production process, the PLC control unit reports the NG of the workpiece to the host computer management system; if the workpiece does not appear NG, step (5) is executed, and the PLC control unit notifies the host computer management system that the workpiece production is completed, and the host computer management system is responsible for counting and recording the time information of the NG (defective product) and OK (qualified product) of the current order workpiece production; (5) Production order completion processing After each qualified workpiece is produced, the host computer management system determines whether the number of workpieces required by the current production order is sufficient, if the number is sufficient, the current production order is completed, the host computer system records the order completion time, generates an order product two-dimensional code label and prints it through a marking machine, the worker attaches the label to the specified position, and then scans the code through a code scanning gun, the host computer system uploads the order completion information to the production management system, and the order production process is completed, if the code is not scanned, the subsequent order production cannot be performed; (6) Production process interruption processing When the production order has not been completed and needs to be interrupted, the production personnel can apply for interrupting the production by operating the touch screen. The interrupting production request must be triggered after the current production workpiece is completed. After the interruption, the host computer management system records the order interruption time and the number of produced workpieces, and generates an unfinished order two-dimensional code label. The operator also needs to attach the unfinished order two-dimensional code label to the specified position and scan the code for confirmation. After confirmation, the host system reports the order interruption production situation to the production management system.
[0009] Further, the method further comprises the following steps: When the worker continues the interrupted order in step (6), the operation steps are as follows: For the continued production order, the production management system will generate a new production order information two-dimensional code every day or every shift according to the setting needs. The generation rule is the same as the new production order information, but the order number is different from the original production order information. After the production management system is issued, the host computer management system obtains the order information by scanning the code and determines whether the order is a continued production order. First, it determines whether there is an unfinished interrupted production order record for the workpiece by the workpiece type. If not, it is determined to be a new workpiece production order. If there is, the worker is prompted by the operation touch screen to scan the previous unfinished order two-dimensional code label before production. After scanning, the host computer management system checks whether the sum of the number of workpieces to be produced in the production order and the number of workpieces already produced in the previous unfinished order two-dimensional code is consistent with the number of workpieces required in the previous interrupted production order stored in the host system. If consistent, it starts to execute the production process, which is consistent with the new order production process. When the order production is completed, the host computer management system generates a new finished product two-dimensional code label, which can be replaced by the previous unfinished order two-dimensional code label by the worker. If not consistent, the scanning information verification error is prompted by the operation touch screen. The operator needs to rescan the correct unfinished order two-dimensional code label for production or manually check the problem.
[0010] Further, the various types of two-dimensional code rules involved in each production process link are shown in the two-dimensional code production rules. The host system management distinguishes different two-dimensional code types by extracting the two-dimensional code type identification code. Two-dimensional code production rules: .
[0011] Further, the system uses TCP protocol for communication. The host computer system is a TCP Server, and the remaining devices are TCP Clients. The production management system communicates with the host production management system through RESTful API, and the data is transmitted in JSON format.
[0012] The application has the advantages and positive effects that: 1、The application realizes full-process data acquisition and monitoring from order issuing, workpiece production, quality determination to finished product identification by integrating a code scanning gun, a marking machine, a PLC control unit and an upper computer system. The system can perform full-process counting and tracking on the workpiece production process, automatically distinguish OK pieces and NG pieces, and synchronize data with a production management system in real time, thereby ensuring the accuracy and real-time performance of the production data of the management system.
[0013] 2、The application focuses on designing a control mechanism for interrupting and continuing orders, which ensures flexible management of the system in the scenario of parallel production of multiple batches and multiple workpiece types, avoids workpiece omission and repeated production problems that may occur in manual management, reduces production costs and material waste, and improves the flexibility and fault tolerance of order management.
[0014] 3、The application effectively prevents unqualified products from flowing into subsequent links through encryption and decryption verification of the order two-dimensional code, automatic and manual dual confirmation of production conditions, automatic recording and separation of NG workpieces. At the same time, the operation touch screen is used to prompt operation information and error alarms in real time, thereby reducing the risk of human operation errors and improving the overall production quality and system reliability. BRIEF DESCRIPTION OF DRAWINGS
[0015] Figure 1 is a structural connection diagram of the system in the application; Figure 2 is a control flow diagram of the method in the application; Figure 3 is a control flow diagram of order continuation in the method in the application. DETAILED DESCRIPTION
[0016] The application will be further described below in conjunction with examples, which are descriptive and not limiting, and cannot limit the protection scope of the application.
[0017] The various experimental operations involved in the specific examples are conventional techniques in the art, and the parts not specifically noted in this paper can be implemented by referring to various common toolbooks, scientific and technical literature or related instructions, manuals, etc. before the application date of the application.
[0018] A workpiece counting production management system, such as Figure 1As shown, the system comprises a process equipment and execution system, a PLC control unit, an operation touch screen, an upper computer management system, a code scanning gun, a marking machine and a production management system, the production management system, the upper computer management system, the PLC control unit, the process equipment and execution system are sequentially connected and arranged, the code scanning gun and the marking machine are both connected and arranged with the upper computer management system, and the operation touch screen is connected and arranged with the PLC control unit; The process equipment and execution system can execute the welding production process and detect the workpiece quality according to the command of the PLC control unit, and when NG products (products with defects) appear, the NG products are offline; the PLC control unit can control and track the welding production process, and exchange data with the on-site upper computer management system, obtain product information content of the workpiece to be produced, and feed back the real-time production situation to the upper computer management system through data; the operation touch screen can communicate with the PLC control unit, and quickly provide necessary production situation information and guide operation for on-site production and management personnel; the upper computer management system can communicate with the production management system through electrical signals, and manage and trace the production situation of the workpiece on site through the PLC control unit; the code scanning gun can be scanned by the operator before production to scan the production order two-dimensional code issued, send the corresponding production information to the upper computer management system, and execute the subsequent logic; the marking machine can generate a two-dimensional code and print a label according to the information provided by the upper computer management system; the production management system can issue corresponding production order two-dimensional code information, and obtain the content of the production order completion through communication with the upper computer management system.
[0019] The application realizes full-process data acquisition and monitoring from order issuing, workpiece production, quality determination to finished product identification by integrating the code scanning gun, the marking machine, the PLC control unit and the upper computer system, automatically distinguishes OK pieces and NG pieces, and synchronizes data with the production management system in real time, so as to ensure the accuracy and real-time performance of the production data of the production management system.
[0020] In the embodiment, the production management system is an MES production management system, which is more convenient for workpiece counting production management.
[0021] The system as described above is applied to workpiece counting of a welding production line.
[0022] A method for workpiece counting production management by using the system as described above, comprising the steps of Figure 2 As shown, the steps are as follows: (1) Order information initialization and issuing When the production management system receives a new order, first extract the information in the order, the actual production of the workpiece necessary information, and according to the rules into a string, the string is encrypted by AES encryption algorithm, generate the production order information two-dimensional code, then through the industrial network to the production site operation touch screen; (2) The verification mechanism of the host computer system for production orders The worker scans the production order information two-dimensional code issued by the production management system through the code scanner, and transmits the data to the host computer management system. The host computer management system reads the two-dimensional code in real time, and verifies the order information content after decryption; If the verification is passed, step (3) is performed, if the verification is not passed, the host computer system records the error reason, and returns the two-dimensional code to the system. After the production management system checks the issued information, a correct production order information two-dimensional code is generated or the order is terminated, and the operation touch screen prompts the worker to confirm the scanning error information.
[0023] (3) Confirm whether the production conditions are met The host computer system issues the production order information to the PLC control unit, and prompts the order content through the operation touch screen. The PLC control unit automatically confirms the readiness state of the on-site equipment and the safety conditions of the production line, and the production personnel confirm the completeness of the materials required by the order and feedback through the operation touch screen; If the production conditions are met, step (4) is started, if the production conditions are not met, the order is cancelled, the host computer management system records the reason for not producing, and prompts the production management system to update the order number and reissue, this order number and production information two-dimensional code are invalid and cannot be used again; (4) Execute production process After the order information verification and production condition confirmation, the host computer system first supplements the relevant production information of the order, and then starts the production; If the workpiece is scrapped during production, the PLC control unit reports the NG situation of the workpiece to the host computer management system; if the workpiece does not appear NG, execute step (5), and the PLC control unit notifies the host computer management system that the workpiece production is completed. The host computer management system is responsible for counting and recording the time information of the NG (defective product) and OK (qualified product) of the current order workpiece production; (5) Production order completion processing After each qualified workpiece is produced, the host management system judges whether the number of workpieces required for the current production order is completed, if the number is sufficient, the current production order is completed, the host system records the order completion time, generates the order product two-dimensional code label and prints it through the marking machine, the worker attaches the label to the specified position, then scans the code through the code gun, the host system uploads the order completion information to the production management system, and the order production process is completed, if the code is not scanned, the subsequent order production cannot be carried out; (6) Production interruption processing When the production order is not completed and needs to be interrupted, the production personnel can apply for interrupting the production by operating the touch screen, the interruption production request must be triggered after the current workpiece is completed; after interruption, the host management system records the order interruption time and the number of workpieces produced, and generates the uncompleted order two-dimensional code label, the operator also needs to attach the uncompleted order two-dimensional code label to the specified position and scan the code for confirmation, after confirmation, the host system reports the order interruption production information to the production management system.
[0024] The application effectively prevents unqualified products from flowing into the subsequent link through the encryption and decryption verification of the order two-dimensional code, the automatic and manual double confirmation of the production conditions, the automatic recording and separation of NG workpieces and other links. At the same time, the operation information and error alarm are prompted in real time through the operation touch screen, the risk of human operation error is reduced, and the overall production quality and system reliability are improved.
[0025] In the embodiment, as shown in Figure 3 The method further includes the following steps: When the worker continues the interrupted order in step (6), the operation steps are as follows: For the continued production order, the production management system will generate a new production order information two-dimensional code every day or every shift according to the set needs, the generation rule is the same as the new production order information, but the order number is different from the original production order information; After the production management system is issued, the host computer management system obtains order information by scanning the code and determines whether the order is a continuous production order, first determines whether there is an unfinished interrupted production order record of the workpiece in the past through the workpiece type in it, if not, it is determined as a new workpiece production order, if yes, the worker is prompted by operating the touch screen to scan the previous unfinished order QR code label before production; after scanning, the host computer management system checks whether the sum of the workpiece quantity to be produced in the to-be-produced order and the sum of the workpiece quantity produced in the previous unfinished order QR code stored in the previous unfinished order QR code is consistent with the demand workpiece quantity of the previous interrupted production order stored in the upper system; if consistent, the production process is started, consistent with the new order production process, when the order production is completed, the host computer management system generates a new finished product QR code label, which is used by the worker to replace the previous unfinished order QR code label, if not consistent, the scanning information verification error is prompted by operating the touch screen, and the operator needs to scan the correct unfinished order QR code label again to execute production, or manually check the problem.
[0026] The application focuses on the design of the control mechanism of interrupted orders and continuous orders, ensures the flexible management of the system in the parallel production scene of multiple batches and multiple workpiece types, avoids the workpiece omission and repeated production problems that may occur in manual management, reduces the production cost and material waste, and improves the flexibility and fault tolerance of order management.
[0027] In the embodiment, the various types of QR codes involved in each production process link are shown in the following table 1, and the host system management distinguishes different QR code types by extracting the QR code type identification code.
[0028] Table 1 QR code production rule table
[0029] Preferably, the system communicates in the TCP protocol mode, the host computer system is a TCP Server, and the remaining devices are TCP Clients, the production management system and the host production management communicate through RESTful API, and data is transmitted in JSON format.
[0030] The method as described above is applied to workpiece counting of a welding production line.
[0031] Although the embodiments of the application are disclosed for illustrative purposes, those skilled in the art can understand that various alternatives, changes and modifications are possible without departing from the spirit and scope of the application and the appended claims, therefore, the scope of the application is not limited to the disclosed content of the embodiments.
Claims
1. A workpiece counting production management system, characterized in that: The system includes process equipment and execution system, PLC control unit, touch screen, host computer management system, barcode scanner, marking machine, and production management system. The production management system, host computer management system, PLC control unit, process equipment, and execution system are sequentially connected. The barcode scanner and marking machine are both connected to the host computer management system, and the touch screen is connected to the PLC control unit. The process equipment and execution system can execute the welding production process and inspect workpiece quality according to commands from the PLC control unit. When an NG (non-compliant) product (a defective product) is found, it is removed from the production line. The PLC control unit can control and track the welding production process, and simultaneously exchange data with the on-site host computer management system to obtain product information about the workpieces to be produced. The system feeds real-time production data back to the host computer management system; the touchscreen can communicate with the PLC control unit, providing necessary production information and operational guidance to on-site production and management personnel; the host computer management system can communicate with the production management system via electrical signals and manage and trace the production status of on-site workpieces through the PLC control unit; the barcode scanner allows operators to scan the QR code of the issued production order before production, sending the corresponding production information to the host computer management system for subsequent logic execution; the marking machine can generate QR codes and print labels based on the information provided by the host computer management system; the production management system can issue the corresponding production order QR code information and obtain the production order completion status through communication with the host computer management system.
2. The system according to claim 1, characterized in that: The production management system is a MES production management system, which makes it easier to manage the counting of workpieces during production.
3. The application of the system as described in any one of claims 1 to 2 in workpiece counting in a welding production line.
4. A method for workpiece counting production management using the system as described in any one of claims 1 to 2, characterized in that: The steps are as follows: (1) Initialization and distribution of order information When the production management system receives a new order, it first extracts the information from the order, takes the necessary information for the actual production of the workpiece, and assembles it into a string according to the rules. After encrypting the string with the AES encryption algorithm, it generates a QR code for the order information to be produced. Then, it sends the QR code to the operation touch screen on the production site through the industrial network. (2) Verification mechanism of production orders by the host computer system Workers scan the QR codes of production orders issued by the production management system using barcode scanners and transmit the data to the host computer management system. The host computer management system reads the QR codes in real time, decrypts them, and then verifies the order information. If the verification passes, proceed to step (3). If the verification fails, the host computer system records the reason for the error and returns the QR code to the modified system. The production management system verifies the information and then regenerates the correct QR code for the order to be produced or terminates the order. At the same time, the touch screen displays the QR code error message for the worker to confirm. (3) Confirm whether the site meets the production conditions. The host computer system sends the production order information to the PLC control unit and displays the order details through the touch screen. The PLC control unit automatically confirms the readiness status of the field equipment and the safety conditions of the production line. At the same time, the production personnel confirm the availability of the materials required for the order and provide feedback through the touch screen. If the production conditions are confirmed, proceed to step (4). If the production conditions are not met, the order is cancelled. The host computer management system records the reason for non-production and prompts the production management system to update the order number and reissue it. This order number and the QR code for the production information are invalid and cannot be used again. (4) Execute the production process After the order information verification and production conditions confirmation are passed, the host computer system first supplements the relevant order production information, and then begins to execute production; If a workpiece is rejected during production, the PLC control unit will report the rejection status of the workpiece to the host computer management system. If no rejection status occurs, step (5) will be executed. At the same time, the PLC control unit will notify the host computer management system that the workpiece production is completed. The host computer management system is responsible for counting and recording the time information of the rejection (defective products) and OK (qualified products) status of the workpiece production of the current order. (5) Production order completion processing After each qualified workpiece is produced, the host computer management system determines whether the required number of workpieces for the current production order has been completed. If the quantity is sufficient, the current production order is completed. The host computer system records the order completion time, generates a QR code label for the finished product, and prints it using a marking machine. The worker attaches the label to the designated location and scans it with a barcode scanner to confirm. The host computer system then uploads the order completion status to the production management system, and the entire production process for this order is complete. If the barcode is not scanned, subsequent orders cannot be produced. (6) Handling interruptions in the production process When a production order is not yet completed and production needs to be interrupted, production personnel can apply to interrupt production by operating the touch screen. The interruption request can only be triggered after the current workpiece being produced is completed. After the interruption, the host computer management system records the order interruption time and the number of workpieces already produced, and generates an incomplete order QR code label. The operator also needs to attach the incomplete order QR code label to the designated location and scan the code to confirm. After confirmation, the host system reports the order interruption status to the production management system.
5. The method according to claim 4, characterized in that: The method further includes the following steps: When a worker resumes an interrupted order in step (6), the operation steps are as follows: For subsequent production orders, the production management system will regenerate new QR codes for the orders to be produced every day or every shift according to the set requirements. The generation rules are the same as for the new orders to be produced, but the order number is different from the original orders to be produced. After the production management system is issued, the host computer management system obtains order information by scanning codes and determines whether the order is a continuation production order. First, it checks the workpiece type to see if there is a previous incomplete interrupted production order record for that workpiece. If not, it is determined to be a new workpiece production order. If there is, the touchscreen prompts the worker to scan the QR code label of the previous incomplete order before production. After scanning, the host computer management system checks whether the sum of the number of workpieces to be produced in the production order and the number of completed workpieces stored in the QR code of the previous incomplete order matches the number of workpieces required for the previous interrupted production order stored in the host computer system. If they match, the production process begins, consistent with the production process for new orders. When the order is completed, the host computer management system generates a new finished product QR code label, which the worker uses to replace the previous incomplete order QR code label. If they do not match, the touchscreen prompts a scanning information verification error, and the operator needs to rescan the correct incomplete order QR code label to start production, or manually troubleshoot the problem.
6. The method according to any one of claims 4 to 5, characterized in that: The various QR code rules involved in each production process are shown in the following QR code production rules. The upper-level system distinguishes different QR code types by extracting the QR code type identifier code. QR code generation rules: 。 7. The system according to any one of claims 1 to 2, characterized in that: All systems use the TCP protocol for communication. The host computer system is a TCP server, and the other devices are TCP clients. The production management system communicates with the host production management system through a RESTful API, and data is transmitted in JSON format.