A production line material transmission state verification method and verification system

Abstract

The embodiment of the present application provides a production line material transmission state verification method and verification system. The production line comprises at least one process unit, the process unit comprises an inlet sensor and an outlet sensor, and the process interval length of the process unit is less than the length of a workpiece to be processed. The verification method comprises the following steps: acquiring the detection state of the inlet sensor and the outlet sensor in real time; judging whether the processing state of the process unit is in the inlet state, the process state and the outlet state in sequence according to the detection state of the inlet sensor and the outlet sensor; and issuing a correction error alarm when the processing state of the process unit is inconsistent with the preset processing state. The embodiment of the present application solves the problem that the existing chain type machine glass wafer flow fiber detection technology is prone to false sensing and machine downtime in a harsh environment of liquid medicine and water drops through the joint judgment of multiple sensors.

Description

Technical Field

[0001] The embodiments of the present invention relate to the field of intelligent identification and control, and in particular to a method and system for verifying the status of material transmission in a production line. Background Technology

[0002] Fiber optic inspection technology for glass sheets in chain conveyors is a sensing and detection technology used in industrial production to identify the presence or absence of glass sheets along the transmission path of chain conveyors. It relies on the optical sensing characteristics of fiber optic sensors to achieve accurate identification and signal feedback of glass sheets, and is widely used in production scenarios that require continuous transmission and inspection of glass sheets.

[0003] In existing technology, a chain conveyor drives a glass slide. When the glass slide reaches the preset detection position of the fiber optic sensor, the sensor initiates the detection process and feeds back the real-time status to the controller. In the detection system, the transmitter continuously emits laser light, and the receiver synchronously receives the laser signal. As the glass slide passes, it blocks the laser propagation, increasing the intensity of the light received by the receiver. When the intensity of the light received by the receiver reaches a preset threshold, the system determines that a glass slide has been detected and outputs a corresponding signal, completing one detection cycle.

[0004] However, existing technologies have weak resistance to harsh environments. In working areas where liquids or water droplets are present, the liquids can easily interfere with the emission and reception of the laser, causing occasional abnormal flickering of the sensor and triggering false sensing. Abnormal flickering of the sensor can easily cause equipment to shut down and stop, affecting the continuity of production. At the same time, the risk of economic loss is high. Each piece of glass produced by customers has a high value, and false sensing of the sensor can lead to misjudgment of the system logic, directly causing product scrapping and increasing production costs. Summary of the Invention

[0005] This invention provides a method and system for verifying the material transmission status of a production line. The system solves the problem of false sensing and machine downtime caused by existing fiber optic detection technology for glass sheet conveyors in harsh environments such as liquids and water droplets by using multiple sensors for joint judgment.

[0006] In a first aspect, embodiments of the present invention provide a method for verifying the material transfer status of a production line. The production line includes at least one process unit, each process unit including an infeed sensor and an outfeed sensor, and the process interval length of the process unit is less than the length of the workpiece to be processed. The method includes:

[0007] The detection status of the feed sensor and the discharge sensor is acquired in real time. Based on the detection status of the feed sensor and the discharge sensor, the processing status of the process unit is determined in sequence as feed status, process status and discharge status.

[0008] An error correction alarm is issued when the processing status of a process unit is inconsistent with the preset processing status.

[0009] Optionally, the detection status of the feed sensor and the discharge sensor is acquired in real time. Based on the detection status of the feed sensor and the discharge sensor, the processing status of the process unit is sequentially determined to be in the feeding state, the processing state, and the discharge state, including:

[0010] When the feed sensor of the current process unit is in an active state, the process unit is determined to be in a feeding state.

[0011] After the process unit is in the feeding state, the feeding sensor of the current process unit is continuously verified to be in an effective state, and the process unit is determined to be in the processing state when the discharging sensor of the current process unit is in an ineffective state.

[0012] After a process unit is in the processing state, it is determined that the process unit is in the discharge state when the discharge sensor of the current process unit is in an active state.

[0013] Optionally, the production line includes at least three consecutively arranged process units, which include an upstream process unit, a current process unit, and a downstream process unit.

[0014] The system acquires the detection status of the feed and discharge sensors in real time. Based on the detection status of the feed and discharge sensors, it sequentially determines whether the processing unit is in the feeding state, processing state, and discharge state, including:

[0015] The system acquires the detection status of the feed sensor, discharge sensor, current process unit, and downstream process unit in real time. Based on these detection statuses, it sequentially determines whether the current process unit is in the feeding state, process state, or discharge state.

[0016] When the processing status of a process unit is inconsistent with the preset processing status, an error correction alarm is issued, including:

[0017] An error correction alarm is issued when the current processing state of the process unit is inconsistent with the preset processing state.

[0018] Optionally, the detection status of the feed and discharge sensors included in the upstream process unit, the current process unit, and the downstream process unit is acquired in real time. Based on the detection status of the feed and discharge sensors included in the upstream process unit, the current process unit, and the downstream process unit, the processing status of the current process unit is sequentially determined to be in the feeding state, the processing state, and the discharge state, including:

[0019] When both the discharge sensor of the upstream process unit and the feed sensor of the current process unit are in a valid state, the current process unit is determined to be in a feeding state.

[0020] After the current process unit is in the feeding state, continuously verify that the feeding sensor of the current process unit is in an effective state and the discharging sensor of the current process unit is in an ineffective state, and determine that the current process unit is in the processing state.

[0021] Once the current process unit is in the processing state, and the discharge sensor of the current process unit is in an active state, and the infeed sensor of the downstream process unit is in an active state, the process unit is determined to be in the discharge state.

[0022] Optionally, after the current process unit is in the processing state, when the discharge sensor of the current process unit is in an active state and the infeed sensor of the downstream process unit is in an active state, the determination that the process unit is in the discharge state also includes:

[0023] Pause the acquisition of the detection status of the feed sensor in the current process unit;

[0024] Continuously verify whether the discharge sensor of the current process unit is in an effective state until the discharge sensor of the current process unit changes from an effective state to an ineffective state, then resume acquiring the detection state of the feed sensor of the current process unit.

[0025] In a second aspect, embodiments of the present invention also provide a production line material transfer status verification system for performing the production line material transfer status verification method as described in any one aspect, the system comprising:

[0026] The production line includes at least one process unit, the process interval length of which is less than the length of the workpiece to be processed; the process unit includes an infeed sensor and an outfeed sensor, and the process interval length of the process unit is less than the length of the workpiece to be processed.

[0027] The data acquisition module is electrically connected to the feed sensor and is used to acquire the detection status of the feed sensor and the discharge sensor in real time.

[0028] The data processing module, which is electrically connected to the data acquisition module, is used to determine whether the processing status of the process unit is in the feeding state, the processing state, and the discharging state, based on the detection status of the feeding sensor and the discharging sensor.

[0029] The error correction module, electrically connected to the data processing module, is used to issue an error correction alarm when the processing state of the process unit is inconsistent with the preset processing state.

[0030] Optionally, the data processing module includes:

[0031] The first data processing subunit is used to determine that the process unit is in the feeding state when the feed sensor of the current process unit is in the valid state.

[0032] The second data processing subunit is used to continuously verify that the feed sensor of the current process unit is in a valid state after the process unit is in the feeding state, and to determine that the process unit is in the process processing state when the discharge sensor of the current process unit is in a invalid state.

[0033] The third data processing subunit is used to determine that the process unit is in the discharge state when the discharge sensor of the current process unit is in the process processing state.

[0034] Optionally, the production line includes at least three consecutively arranged process units;

[0035] At least three consecutively arranged process units include an upstream process unit, a current process unit, and a downstream process unit;

[0036] The data acquisition module is electrically connected to the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, the feed sensor of the downstream process unit, and the discharge sensor of the downstream process unit, respectively. It is also used to acquire the detection status of the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, the feed sensor of the downstream process unit, and the downstream process unit in real time.

[0037] The data processing module is also used to determine, in sequence, whether the processing status of the current process unit is in the feeding state, the processing state, and the discharging state based on the detection status of the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, the feed sensor of the downstream process unit, and the discharge sensor of the downstream process unit.

[0038] The error correction module is also used to issue an error correction alarm when the processing status of the current process unit is inconsistent with the preset processing status.

[0039] Optionally, the first data processing subunit is also used to determine that the current process unit is in the feeding state when both the discharge sensor of the upstream process unit and the feed sensor of the current process unit are in the valid state.

[0040] The second data processing subunit is also used to continuously verify that the feed sensor of the current process unit is in an effective state and the discharge sensor of the current process unit is in an ineffective state after the current process unit is in the feeding state, and to determine that the current process unit is in the process processing state.

[0041] The third data processing subunit is also used to determine that the process unit is in the discharge state after the current process unit is in the process processing state, when the discharge sensor of the current process unit is in the effective state and the infeed sensor of the downstream process unit is in the effective state.

[0042] Optional, also includes:

[0043] The pause module, electrically connected to the data processing module, is used to control the data processing module to pause acquiring the detection status of the feed sensor of the current process unit when the current process unit is in the process processing state.

[0044] Continuously verify whether the discharge sensor of the current process unit is in an effective state until the discharge sensor of the current process unit changes from an effective state to an ineffective state, then resume acquiring the detection state of the feed sensor of the current process unit.

[0045] This invention provides a method and system for verifying the material transfer status of a production line. The production line includes at least one process unit, which includes an infeed sensor and an outfeed sensor. The process interval length of the process unit is less than the length of the workpiece to be processed. The verification method includes: acquiring the detection status of the infeed and outfeed sensors in real time; determining, based on the detection status of the infeed and outfeed sensors, whether the processing status of the process unit is in the infeed state, process state, and outfeed state sequentially; and issuing an error correction alarm when the processing status of the process unit is inconsistent with the preset processing status. If the processing status is determined to be inconsistent with the preset processing status, or if the switching sequence of "infeed state → process state → outfeed state" is not followed, an error correction alarm is generated to avoid material transfer misalignment or missed processing. This invention, through multi-sensor joint judgment, solves the problem of easy false sensing and downtime in the harsh environment of liquid chemicals and water droplets in existing chain-type glass sheet fiber detection technology. Attached Figure Description

[0046] Figure 1 This is a schematic diagram of a production line provided in an embodiment of the present invention;

[0047] Figure 2This is a flowchart illustrating a method for verifying the material transfer status of a production line according to an embodiment of the present invention.

[0048] Figure 3 This is a flowchart illustrating another method for verifying the material transfer status of a production line provided in an embodiment of the present invention.

[0049] Figure 4 This is a flowchart illustrating another method for verifying the material transfer status of a production line provided in an embodiment of the present invention.

[0050] Figure 5 This is a flowchart illustrating another method for verifying the material transfer status of a production line provided in an embodiment of the present invention.

[0051] Figure 6 This is a schematic diagram of the structure of a production line material transfer status verification system provided in an embodiment of the present invention;

[0052] Figure 7 This is a schematic diagram of another production line material transfer status verification system provided in an embodiment of the present invention. Detailed Implementation

[0053] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0054] The terminology used in the embodiments of this invention is for the purpose of describing specific embodiments only and is not intended to limit the invention. It should be noted that directional terms such as "upper," "lower," "left," and "right" described in the embodiments of this invention are used to describe the angles shown in the accompanying drawings and should not be construed as limiting the embodiments of this invention. Furthermore, in the context, it should be understood that when referring to an element being formed "on" or "below" another element, it can be formed not only directly on or below the other element, but also indirectly on or below it through intermediate elements. The terms "first," "second," etc., are used for descriptive purposes only and do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0055] The term "comprising" and its variations as used in this invention are open-ended, meaning "including but not limited to". The term "based on" means "at least partially based on". The term "one embodiment" means "at least one embodiment".

[0056] It should be noted that the concepts of "first" and "second" mentioned in this invention are only used to distinguish the corresponding contents and are not used to limit the order or interdependence.

[0057] It should be noted that the terms "a" and "a plurality of" used in this invention are illustrative rather than restrictive. Those skilled in the art should understand that, unless otherwise expressly indicated in the context, they should be understood as "one or more".

[0058] Figure 1 This is a schematic diagram of a production line provided in an embodiment of the present invention. Figure 2 This is a flowchart illustrating a method for verifying the material transfer status of a production line according to an embodiment of the present invention. The production line includes at least one process unit 10, which includes an infeed sensor 11 and an outfeed sensor 12. The process interval length L1 of the process unit 10 is less than the length L2 of the workpiece 1 to be processed.

[0059] refer to Figure 2 The methods include:

[0060] S110. Real-time acquisition of the detection status of the feed sensor and the discharge sensor, and based on the detection status of the feed sensor and the discharge sensor, sequentially determine whether the processing status of the process unit is in the feeding state, the process state, and the discharge state.

[0061] The detection status of the feed sensor 11 and the discharge sensor 12 can be understood as whether the sensor detects the presence signal of the workpiece 1 to be processed. For example, detection is an effective state, and non-detection is an invalid state. The processing status of the process unit 10 can be understood as the stage working status of the process unit 10 during the material transfer process, which corresponds to the position of the workpiece 1 to be processed in the process interval.

[0062] Specifically, the status of the workpiece 1 to be processed is collected and detected in real time by the feed sensor 11 and the discharge sensor 12. Based on the detection status of the sensors, it is determined in turn whether the workpiece 1 to be processed is in the feed state, the process state, and the discharge state.

[0063] S120. When the processing state of the process unit is inconsistent with the preset processing state, an error correction alarm is issued.

[0064] Among them, the error correction alarm can be understood as a signal used to indicate abnormalities in the material transfer status.

[0065] Specifically, if the processing status is determined to be inconsistent with the preset processing status, or if the switching sequence of "feeding status → process status → discharge status" is not followed, an error correction alarm will be generated to avoid material transfer misalignment or missed processing.

[0066] This invention provides a method for verifying the material transfer status of a production line. The production line includes at least one process unit, each including an infeed sensor and an outfeed sensor. The process interval length of the process unit is less than the length of the workpiece to be processed. The method includes: acquiring the detection status of the infeed and outfeed sensors in real time; determining, based on the detection status of the infeed and outfeed sensors, whether the processing status of the process unit is in the infeed state, process state, and outfeed state sequentially; and issuing a correction alarm when the processing status of the process unit is inconsistent with the preset processing status. If the processing status is determined to be inconsistent with the preset processing status, or if the switching sequence of "infeed state → process state → outfeed state" is not followed, a correction alarm is generated to avoid material transfer misalignment or missed processing.

[0067] Figure 3 This is a flowchart illustrating another method for verifying the material transfer status of a production line provided in this embodiment of the invention. Regarding the above embodiment, "S110, real-time acquisition of the detection status of the infeed sensor and the discharge sensor, and based on the detection status of the infeed sensor and the discharge sensor, sequentially determining whether the processing status of the process unit is in the infeed state, the process state, and the discharge state" can be further refined as follows:

[0068] When the feed sensor of the current process unit is in an active state, the process unit is determined to be in a feeding state.

[0069] After the process unit is in the feeding state, the feeding sensor of the current process unit is continuously verified to be in an effective state, and the process unit is determined to be in the processing state when the discharging sensor of the current process unit is in an ineffective state.

[0070] After a process unit is in the processing state, it is determined that the process unit is in the discharge state when the discharge sensor of the current process unit is in an active state.

[0071] like Figure 3 As shown, the refinement process includes the following steps:

[0072] S211. When the feed sensor of the current process unit is in an active state, the process unit is determined to be in a feed state.

[0073] The feeding state can be understood as the state in which the workpiece 1 to be processed begins to enter the process range, triggering the feeding sensor 11 but not triggering the discharging sensor 12.

[0074] Specifically, the feed sensor 11 and the discharge sensor 12 detect the signal of the workpiece 1 to be processed in real time. When the trigger signal of the workpiece 1 to be processed is detected, and the discharge sensor 12 does not detect the trigger signal of the workpiece 1 to be processed, it is determined that the current process unit is in the feeding state. That is, at this time, part of the workpiece 1 to be processed enters the process range, does not completely cover the process range and does not trigger the discharge sensor 12.

[0075] S212. After the process unit is in the feeding state, continuously verify that the feeding sensor of the current process unit is in an effective state, and determine that the process unit is in the process processing state when the discharging sensor of the current process unit is in an ineffective state.

[0076] The process status can be understood as the state of the workpiece 1 entering the process zone, which simultaneously triggers the states of the feed sensor 11 and the discharge sensor 12.

[0077] Specifically, after the process unit is in the feeding state, the feeding sensor 11 and the discharging sensor 12 continue to acquire the status signal of the workpiece 1 to be processed; when the feeding sensor 11 detects the trigger signal of the workpiece 1 to be processed, and the discharging sensor 12 simultaneously detects the trigger signal of the workpiece 1 to be processed, it is determined that the current process unit is in the process state, and at this time the workpiece is processed within the process range.

[0078] S213. After the process unit is in the process processing state, when the discharge sensor of the current process unit is in the effective state, it is determined that the process unit is in the discharge state.

[0079] The discharge status can be understood as the state of the workpiece 1 to be processed starting to leave the process area, triggering the discharge sensor 12.

[0080] Specifically, after the process unit is in the process processing state, the feed sensor 11 and the discharge sensor 12 continue to acquire the status signal of the workpiece 1 to be processed; when the feed sensor 11 does not detect the trigger signal of the workpiece 1 to be processed, and the discharge sensor 12 detects the trigger signal of the workpiece 1 to be processed, it is determined that the process unit is in the discharge state, and at this time the workpiece 1 to be processed begins to leave the process area.

[0081] S220. When the processing state of a process unit is inconsistent with the preset processing state, an error correction alarm is issued.

[0082] Figure 4 This is a flowchart illustrating another method for verifying the material transfer status of a production line provided by an embodiment of the present invention. Regarding the above embodiment, "S110, real-time acquisition of the detection status of the infeed sensor and the discharge sensor, and based on the detection status of the infeed sensor and the discharge sensor, sequentially determining whether the processing status of the process unit is in the infeed state, the process state, and the discharge state" can be further refined as follows:

[0083] The system acquires the detection status of the feed sensor, discharge sensor, current process unit, and downstream process unit in real time. Based on these detection statuses, it sequentially determines whether the current process unit is in the feeding state, process state, or discharge state.

[0084] Furthermore, "S120, when the processing state of a process unit is inconsistent with the preset processing state, issue an error correction alarm" can be further specified as follows:

[0085] An error correction alarm is issued when the current processing state of the process unit is inconsistent with the preset processing state.

[0086] like Figure 4 As shown, the refinement process includes the following steps:

[0087] S311. Real-time acquisition of the detection status of the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, the feed sensor of the downstream process unit, and the discharge sensor of the downstream process unit. Based on the detection status of the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, the feed sensor of the downstream process unit, and the discharge sensor of the downstream process unit, sequentially determine whether the processing status of the current process unit is in the feeding state, the process state, and the discharge state.

[0088] Specifically, by acquiring the detection status of the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, the feed sensor of the downstream process unit, and the discharge sensor of the downstream process unit, the processing status of the current process unit is determined according to the following timing sequence. First, when the discharge sensor of the upstream process unit is valid, the feed sensor of the current process unit is valid, and the discharge sensor of the current process unit is invalid, the current process unit is determined to be in the feeding state, that is, the workpiece 1 to be processed has been transferred from the upstream process unit to the current process unit and partially entered the current process range. When the previous state is the feeding state, it is further determined whether it is in the processing state, and the determination condition is as follows: when the feed sensor of the current process unit is valid, the discharge sensor of the current process unit is valid, and the feed sensor of the downstream process unit is invalid, the current process unit is determined to be in the processing state, that is, the workpiece 1 to be processed has completed the feeding process, and the feed sensor and discharge sensor of the current process unit are simultaneously overridden. Finally, when the current process unit's feed sensor is invalid, the current process unit's discharge sensor is valid, and the downstream process unit's feed sensor is valid, it is determined that the current process unit is in the discharge state, that is, the workpiece 1 to be processed is transferred from the current process unit to the downstream process unit, and partially leaves the current process range.

[0089] S321. When the processing status of the current process unit is inconsistent with the preset processing status, an error correction alarm is issued.

[0090] Specifically, when comparing the current processing state of the process unit with the preset "feeding state → process state → discharge state" sequence and the corresponding sensor state combination, if the sensor state combination does not match the preset rules, it is determined that the processing state is inconsistent with the preset processing state, and an error correction alarm is issued to avoid material transfer misalignment, missed processing or repeated processing between adjacent process units.

[0091] Figure 5 This is a flowchart illustrating another method for verifying the material transfer status of a production line provided in an embodiment of the present invention.

[0092] Regarding the above embodiment, "S311, real-time acquisition of the detection status of the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, the feed sensor of the downstream process unit, and the discharge sensor of the downstream process unit, and based on the detection status of the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, and the feed sensor of the downstream process unit, and sequentially determining whether the processing status of the current process unit is in the feeding state, the processing state, and the discharge state" can be further refined as follows:

[0093] When both the discharge sensor of the upstream process unit and the feed sensor of the current process unit are in a valid state, the current process unit is determined to be in a feeding state.

[0094] After the current process unit is in the feeding state, continuously verify that the feeding sensor of the current process unit is in an effective state and the discharging sensor of the current process unit is in an ineffective state, and determine that the current process unit is in the processing state.

[0095] Once the current process unit is in the processing state, and the discharge sensor of the current process unit is in an active state, and the infeed sensor of the downstream process unit is in an active state, the process unit is determined to be in the discharge state.

[0096] like Figure 5 As shown, the refinement process includes the following steps:

[0097] S411. Real-time acquisition of the detection status of the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, the feed sensor of the downstream process unit, and the discharge sensor of the downstream process unit.

[0098] Specifically, the processing status of the current process unit is determined by acquiring the detection status of the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, and the feed sensor of the downstream process unit.

[0099] S412. When both the discharge sensor of the upstream process unit and the feed sensor of the current process unit are in a valid state, it is determined that the current process unit is in a feeding state.

[0100] Specifically, when the discharge sensor of the upstream process unit is valid, the infeed sensor of the current process unit is valid, and the discharge sensor of the current process unit is invalid, it is determined that the current process unit is in the infeed state, that is, the workpiece 1 to be processed is transferred from the upstream process unit to the current process unit and partially enters the current process range.

[0101] S413. After the current process unit is in the feeding state, continuously verify that the feeding sensor of the current process unit is in an effective state and the discharging sensor of the current process unit is in an ineffective state, and determine that the current process unit is in the processing state.

[0102] Specifically, when the previous state was the feeding state, it continues to determine whether it is in the process state. When the current process unit's feeding sensor is valid, the current process unit's discharging sensor is valid, and the downstream process unit's feeding sensor is invalid, it is determined that the current process unit is in the process state, that is, the workpiece 1 to be processed has completed the feeding process, and the feeding sensor and discharging sensor of the current process unit are covered.

[0103] S414. When the current process unit is in the processing state, and the discharge sensor of the current process unit is in an effective state, and the infeed sensor of the downstream process unit is in an effective state, the process unit is determined to be in the discharge state.

[0104] Specifically, when the current process unit's feed sensor is invalid, the current process unit's discharge sensor is valid, and the downstream process unit's feed sensor is valid, the current process unit is determined to be in the discharge state, meaning that the workpiece 1 to be processed is transferred from the current process unit to the downstream process unit, partially leaving the current process range.

[0105] S420. When the processing status of the current process unit is inconsistent with the preset processing status, an error correction alarm is issued.

[0106] In an optional embodiment, in addition to "S413, when the current process unit is in the processing state, and the discharge sensor of the current process unit is in an active state, and the infeed sensor of the downstream process unit is in an active state, it is determined that the process unit is in the discharge state", the following is also included:

[0107] Pause the acquisition of the detection status of the feed sensor in the current process unit.

[0108] Continuously verify whether the discharge sensor of the current process unit is in an effective state until the discharge sensor of the current process unit changes from an effective state to an ineffective state, then resume acquiring the detection state of the feed sensor of the current process unit.

[0109] Specifically, when the current process unit is determined to be in the discharge state, the acquisition of the detection status of the current process unit's infeed sensor is simultaneously paused, i.e., the infeed is rejected, and the sensor status is no longer included in subsequent judgments. Acquisition of the current process unit's infeed sensor's detection status is resumed only when the discharge sensor changes from an active to an inactive state, i.e., the workpiece 1 is completely removed from the current process unit. This ensures that the infeed judgment can be triggered normally when the next workpiece enters, avoiding interference from the judgment of the transfer status of adjacent workpieces.

[0110] Based on the same inventive concept, this invention also provides a schematic diagram of a production line material transfer status verification system. The production line material transfer status verification system provided by this invention can execute the production line material transfer status verification method provided by any embodiment of this invention, and has the corresponding functional modules and beneficial effects of the execution method.

[0111] Figure 6 This is a schematic diagram of a production line material transfer status verification system provided in an embodiment of the present invention. The system includes:

[0112] The production line includes at least one process unit 10, wherein the process interval length of the process unit 10 is less than the length of the workpiece 1 to be processed.

[0113] The process unit 10 includes an infeed sensor 11 and an outfeed sensor 12, and the process interval length of the process unit 10 is less than the length of the workpiece 1 to be processed.

[0114] The data acquisition module 20 is electrically connected to the feed sensor 11 and is used to acquire the detection status of the feed sensor 11 and the discharge sensor 12 in real time.

[0115] The data processing module 30 is electrically connected to the data acquisition module 20 and is used to determine whether the processing state of the process unit 10 is in the feeding state, the process state, and the discharging state according to the detection state of the feeding sensor 11 and the discharging sensor 12.

[0116] The error correction module 40 is electrically connected to the data processing module 30 and is used to issue an error correction alarm when the processing state of the process unit 10 is inconsistent with the preset processing state.

[0117] Specifically, the workpiece 1 to be processed is sequentially transferred between the various process units 10 of the production line. Since the length of the process interval of the process unit 10 is less than the length of the workpiece 1 to be processed, the workpiece 1 to be processed can simultaneously cover the detection range of the feed sensor 11 and the discharge sensor 12 when transferred within a single process unit 10. The feed sensor 11 and the discharge sensor 12 are respectively set at both ends of the process interval of the process unit 10 to detect the presence signal of the workpiece 1 to be processed in real time, generate a valid (workpiece detected) or invalid (workpiece not detected) detection state, and transmit the detection state to the data acquisition module 20 in real time. The data acquisition module 20 synchronously receives and caches the detection states of all sensors, and then transmits the cached detection states to the data processing module 30 in real time. After receiving the detection states transmitted by the data acquisition module 20, the data processing module 30 sequentially judges the processing state of the process unit 10 according to preset logic, and compares it with the preset processing state (preset as the timing sequence of "feed state → process state → discharge state" and the corresponding sensor state combination); if the comparison finds that the processing state is inconsistent with the preset processing state... The error correction module 40 issues error correction alarms (such as audible and visual alarms, equipment shutdown signals) to promptly prompt operators to check for abnormal material transmission, thereby ensuring the stability of material transmission and processing on the production line.

[0118] Figure 7 This is a schematic diagram of another production line material transfer status verification system provided in an embodiment of the present invention, for reference. Figure 7 The data processing module 30 includes:

[0119] The first data processing subunit 31 is used to determine that the process unit 10 is in the feeding state when the feed sensor 11 of the current process unit 10 is in the effective state.

[0120] The second data processing subunit 32 is used to continuously verify that the feed sensor 11 of the current process unit 10 is in a valid state after the process unit 10 is in the feeding state, and to determine that the process unit 10 is in the process processing state when the discharge sensor 12 of the current process unit 10 is in a non-valid state.

[0121] The third data processing subunit 33 is used to determine that the process unit 10 is in the discharge state when the discharge sensor 12 of the current process unit 10 is in the discharge state after the process unit 10 is in the process processing state.

[0122] Specifically, the first data processing subunit 31 receives the detection status of the feed sensor 11 of the current process unit 10 transmitted by the data acquisition module 20 in real time. When the feed sensor 11 is detected to be in an effective state and the discharge sensor 12 is detected to be in an ineffective state, the current process unit 10 is determined to be in the feed state. After receiving the feed status result output by the first data processing subunit 31, the second data processing subunit 32 continuously acquires the detection status of the feed sensor 11 and the discharge sensor 12 of the current process unit 10. Under the premise that the feed sensor 11 remains in an effective state, when the discharge sensor 12 is detected to switch from an ineffective state to an effective state, the current process unit 10 is determined to switch from the feed state to the processing state. After receiving the processing status result output by the second data processing subunit 32, the third data processing subunit 33 continuously monitors the detection status of the discharge sensor 12 of the current process unit 10. When the feed sensor 11 is detected to switch from an effective state to an ineffective state and the discharge sensor 12 remains in an effective state, the current process unit 10 is determined to switch from the processing state to the discharge state.

[0123] Optionally, the production line includes at least three consecutively arranged process units 10; the at least three consecutively arranged process units 10 include an upstream process unit, a current process unit, and a downstream process unit;

[0124] The data acquisition module 20 is electrically connected to the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, the feed sensor of the downstream process unit, and the discharge sensor of the downstream process unit, respectively.

[0125] The data processing module 30 is also used to acquire in real time the detection status of the feed sensor of the upstream process unit, the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, the feed sensor of the downstream process unit, and the discharge sensor of the downstream process unit. Based on the detection status of the above sensors, it sequentially determines whether the processing status of the current process unit is in the feed state, the process state, and the discharge state.

[0126] The error correction module 40 is also used to issue an error correction alarm when the processing state of the current process unit is inconsistent with the preset processing state.

[0127] Specifically, the data processing module 30, based on the correlation of the states of multiple unit sensors, sequentially determines the processing state of the current process unit according to a preset timing logic: by acquiring the detection states of the discharge sensor of the upstream process unit, the feed sensor of the current process unit, the discharge sensor of the current process unit, and the feed sensor of the downstream process unit, the processing state of the current process unit is determined. When the discharge sensor of the upstream process unit is valid, the feed sensor of the current process unit is valid, and the discharge sensor of the current process unit is invalid, it is determined that the current process unit is in the feeding state, that is, the workpiece 1 to be processed has been transferred from the upstream process unit to the current process unit and partially entered the current process interval. When the previous state was the feeding state, it continues to determine whether it is in the process state. When the feed sensor of the current process unit is valid, the discharge sensor of the current process unit is valid, and the feed sensor of the downstream process unit is invalid, it is determined that the current process unit is in the process state, that is, the workpiece 1 to be processed has completed the feeding process, and the feed and discharge sensors of the current process unit are simultaneously overridden. When the feed sensor of the current process unit is invalid, the discharge sensor of the current process unit is valid, and the feed sensor of the downstream process unit is valid, the current process unit is determined to be in the discharge state, that is, the workpiece 1 to be processed is transferred from the current process unit to the downstream process unit and partially leaves the current process range.

[0128] Optionally, the first data processing subunit 31 is further configured to determine that the current process unit is in the feeding state when both the discharge sensor of the upstream process unit and the feed sensor of the current process unit 10 are in a valid state; the second data processing subunit 32 is further configured to determine that the current process unit is in the processing state after the current process unit is in the feeding state, continuously verifying that the feed sensor of the current process unit is in a valid state and the discharge sensor of the current process unit is in a invalid state; the third data processing subunit 33 is further configured to determine that the process unit 10 is in the discharging state after the current process unit is in the processing state, when the discharge sensor of the current process unit is in a valid state and the feed sensor of the downstream process unit is in a valid state.

[0129] Specifically, the first data processing subunit 31 receives the detection status of the discharge sensor of the upstream process unit and the feed sensor of the current process unit 10 from the data acquisition module 20 in real time. When it detects that the discharge sensor of the upstream process unit is in an effective state and the feed sensor of the current process unit 10 is in an effective state, it determines that the current process unit is in the feeding state. At this time, the workpiece 1 to be processed is transferred from the upstream process unit to the current process unit, and part of the workpiece 1 to be processed enters the current process range, still overlapping with the detection area of ​​the upstream process unit. After receiving the feeding status result output by the first data processing subunit 31, the second data processing subunit 32 continues to acquire the detection status of the feed sensor and discharge sensor of the current process unit 10. Under the premise that the feed sensor remains in an effective state and the discharge sensor of the current process unit 10 is in an ineffective state, it determines that the current process unit switches from the feeding state to the processing state. At this time, the workpiece 1 to be processed has completely entered the current process range and has not yet triggered the detection range of the discharge sensor. After receiving the process processing status result output by the second data processing subunit 32, the third data processing subunit 33 continuously monitors the detection status of the discharge sensor of the current process unit 10 and the feed sensor of the downstream process unit. When it is detected that the discharge sensor of the current process unit 10 is in an effective state and the feed sensor of the downstream process unit is in an effective state, it determines that the current process unit has switched from the process processing state to the discharge state. At this time, part of the workpiece 1 to be processed leaves the current process area and begins to enter the detection area of ​​the downstream process unit.

[0130] Optionally, the production line material transfer status verification system further includes: a pause module 50, electrically connected to the data processing module 30, used to control the data processing module 30 to pause acquiring the detection status of the feed sensor of the current process unit when the current process unit is in the process processing state; continuously verifying whether the discharge sensor of the current process unit is in a valid state until the discharge sensor of the current process unit 10 changes from a valid state to a non-valid state, and then resuming the acquisition of the detection status of the feed sensor of the current process unit.

[0131] Specifically, when the data processing module 30 determines that the current process unit is in the processing state, the pause module 50 controls the data processing module 30 to pause acquiring the detection status of the feed sensor of the current process unit. At this time, the status of the feed sensor is no longer included in the basis for subsequent processing status judgment. During the pause, the data processing module 30 continuously verifies the detection status of the discharge sensor of the current process unit; when it detects that the discharge sensor of the current process unit changes from an effective state to an ineffective state (i.e., the workpiece to be processed has completely left the current process unit), the pause module 50 controls the data processing module 30 to resume acquiring the detection status of the feed sensor of the current process unit, ensuring that the feed status judgment process can be triggered normally when the next workpiece to be processed enters.

[0132] Note that the above description is merely a preferred embodiment of the present invention and the technical principles employed. Those skilled in the art will understand that the present invention is not limited to the specific embodiments described herein, and various obvious changes, readjustments, combinations, and substitutions can be made without departing from the scope of protection of the present invention. Therefore, although the present invention has been described in detail through the above embodiments, the present invention is not limited to the above embodiments, and may include many other equivalent embodiments without departing from the concept of the present invention, the scope of which is determined by the scope of the appended claims.

Claims

1. A method for verifying the material transfer status of a production line, the production line comprising at least one process unit, the process unit including an infeed sensor and an outfeed sensor, and the process interval length of the process unit being less than the length of the workpiece to be processed, characterized in that, The method includes: The detection status of the feed sensor and the discharge sensor is acquired in real time. Based on the detection status of the feed sensor and the discharge sensor, the processing status of the process unit is sequentially determined to be in the feeding state, the processing state, and the discharge state. When the processing state of the process unit is inconsistent with the preset processing state, an error correction alarm is issued; The detection status of the feed sensor and the discharge sensor is acquired in real time. Based on the detection status of the feed sensor and the discharge sensor, the processing status of the process unit is sequentially determined to be in the feeding state, the processing state, and the discharge state, including: When the feed sensor of the current process unit is in an active state, the process unit is determined to be in a feeding state. After the process unit is in the feeding state, the feeding sensor of the current process unit is continuously verified to be in an effective state, and when the discharging sensor of the current process unit is in an ineffective state, the process unit is determined to be in the processing state. After the process unit is in the processing state, when the discharge sensor of the current process unit is in the effective state, it is determined that the process unit is in the discharge state. The production line includes at least three consecutively arranged process units, which include an upstream process unit, a current process unit, and a downstream process unit. The detection status of the feed sensor and the discharge sensor is acquired in real time. Based on the detection status of the feed sensor and the discharge sensor, the processing status of the process unit is sequentially determined to be in the feeding state, the processing state, and the discharge state, including: The detection status of the feed sensor, discharge sensor, feed sensor, discharge sensor, feed sensor, and discharge sensor of the current process unit, as well as the feed sensor and discharge sensor of the downstream process unit, is acquired in real time. Based on the detection status of these sensors, the processing status of the current process unit is sequentially determined to be in the feeding state, processing state, and discharge state. When the processing state of the process unit is inconsistent with the preset processing state, an error correction alarm is issued, including: When the processing state of the current process unit is inconsistent with the preset processing state, an error correction alarm is issued; The detection status of the feed sensor and the discharge sensor included in the upstream process unit, the current process unit, and the downstream process unit is acquired in real time. Based on the detection status of the feed sensor and the discharge sensor included in the upstream process unit, the current process unit, and the downstream process unit, the processing status of the current process unit is sequentially determined to be in the feeding state, the processing state, and the discharge state, including: When both the discharge sensor of the upstream process unit and the feed sensor of the current process unit are in a valid state, it is determined that the current process unit is in a feeding state. After the current process unit is in the feeding state, the feeding sensor of the current process unit is continuously verified to be in an effective state and the discharging sensor of the current process unit is in an ineffective state, and the current process unit is determined to be in the processing state. After the current process unit is in the processing state, when the discharge sensor of the current process unit is in an active state and the infeed sensor of the downstream process unit is in an active state, it is determined that the process unit is in the discharge state.

2. The material transfer status verification method according to claim 1, characterized in that, After the current process unit is in the processing state, when the discharge sensor of the current process unit is in an active state and the infeed sensor of the downstream process unit is in an active state, determining that the process unit is in the discharge state also includes: Pause the acquisition of the detection status of the feed sensor of the current process unit; The system continuously verifies whether the discharge sensor of the current process unit is in an effective state until the discharge sensor of the current process unit changes from an effective state to an ineffective state, at which point it resumes acquiring the detection state of the feed sensor of the current process unit.

3. A production line material transfer status verification system, used to execute the production line material transfer status verification method as described in any one of claims 1 to 2, characterized in that, include: The production line includes at least one process unit, wherein the process interval length of the process unit is less than the length of the workpiece to be processed. The process unit includes an infeed sensor and an outfeed sensor; The data acquisition module is electrically connected to the feed sensor and is used to acquire the detection status of the feed sensor and the discharge sensor in real time. The data processing module, electrically connected to the data acquisition module, is used to determine, in sequence, whether the processing state of the process unit is in the feeding state, the processing state, and the discharging state based on the detection states of the feeding sensor and the discharging sensor. The error correction module, electrically connected to the data processing module, is used to issue an error correction alarm when the processing state of the process unit is inconsistent with the preset processing state.

4. The production line material transfer status verification system according to claim 3, characterized in that, The data processing module includes: The first data processing subunit is used to determine that the process unit is in the feeding state when the feed sensor of the current process unit is in the effective state. The second data processing subunit is used to continuously verify that the feed sensor of the current process unit is in a valid state after the process unit is in the feeding state, and to determine that the process unit is in the process processing state when the discharge sensor of the current process unit is in a invalid state. The third data processing subunit is used to determine that the process unit is in the discharge state after the process unit is in the process processing state and when the discharge sensor of the current process unit is in the effective state.

5. The production line material transfer status verification system according to claim 4, characterized in that, The production line includes at least three consecutively arranged process units; The at least three consecutively arranged process units include an upstream process unit, a current process unit, and a downstream process unit; The data acquisition module is electrically connected to the feed sensor, discharge sensor, feed sensor, discharge sensor of the current process unit, feed sensor of the current process unit, feed sensor of the downstream process unit, and discharge sensor of the downstream process unit, respectively. It is also used to acquire the detection status of these sensors in real time. The data processing module is further used to sequentially determine whether the current process unit is in the feeding state, processing state, or discharge state based on the detection status of these sensors. The error correction module is also used to issue an error correction alarm when the processing state of the current process unit is inconsistent with the preset processing state.

6. The production line material transfer status verification system according to claim 5, characterized in that, The first data processing subunit is further configured to determine that the current process unit is in the feeding state when both the discharge sensor of the upstream process unit and the feed sensor of the current process unit are in the effective state. The second data processing subunit is further configured to continuously verify that the feed sensor of the current process unit is in a valid state and the discharge sensor of the current process unit is in a invalid state after the current process unit is in the feeding state, and determine that the current process unit is in the process processing state. The third data processing subunit is further configured to determine that the process unit is in the discharge state after the current process unit is in the process processing state, when the discharge sensor of the current process unit is in the effective state and the infeed sensor of the downstream process unit is in the effective state.

7. The production line material transfer status verification system according to claim 6, characterized in that, Also includes: A pause module, electrically connected to the data processing module, is used to control the data processing module to pause acquiring the detection status of the feed sensor of the current process unit when the current process unit is in the process processing state. The system continuously verifies whether the discharge sensor of the current process unit is in an effective state until the discharge sensor of the current process unit changes from an effective state to an ineffective state, at which point it resumes acquiring the detection state of the feed sensor of the current process unit.

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