Jack auto-plug control management system and method

Abstract

This invention relates to the field of manufacturing management technology, specifically to an automatic plug-in / plug-out control and management system and method. The system includes a clamping action recognition module, a control sequence revision module, a signal combination verification module, an anomaly record merging module, and a scheduling table content update module. In this invention, by numbering and archiving trigger and feedback intervals, rapid identification and recording of response deviations are achieved. By adjusting the control command sequence, signal trigger conflicts and timing misalignments are eliminated. Feedback combination verification determines the correlation characteristics of abnormal actions, clarifying failure points and corresponding logic. Anomaly combination merging analysis extracts recurring fault modes of the device, improving the continuous identification capability of abnormal behavior. Synchronous revision of the scheduling command sequence ensures structural consistency between control logic and task execution, enhancing the stability, accuracy, and closed-loop execution capability of the plug-in / plug-out process under complex operating conditions.

Description

Technical Field

[0001] This invention relates to the field of manufacturing management technology, and in particular to an automatic insertion and removal control management system and method for connectors. Background Technology

[0002] Manufacturing management technology involves the systematic management and coordination of resource allocation, process arrangement, production scheduling, and equipment control in the manufacturing process, and is a core support for realizing modern intelligent manufacturing. This technology encompasses core aspects such as control and management of the manufacturing execution layer, real-time monitoring of production elements, acquisition and processing of equipment status information, collection and calculation of production data, and production instruction issuance and feedback mechanisms. It often combines information technology, automation technology, and industrial network communication technology to build a complete manufacturing operation management system to achieve orderly organization and efficient operation of the entire production process. This field is widely used in electronic manufacturing, machining, and automated assembly, and is an important component of industrial digitalization and intelligent upgrading. Among these, the traditional automatic insertion and removal control management system for connectors refers to a system device developed in the manufacturing and testing of electronic equipment to control and monitor the automatic insertion and removal of connector components. The technical issue addressed by this system is how to achieve automatic control and data management of connector connection actions during production operations. Traditional connector control and management usually solves the technical issues by manually setting fixed action procedures in conjunction with PLC controllers. Specifically, this includes manually setting the control logic by configuring the input and output port addresses of the PLC, having on-site operators manually plug and unplug connectors and observe the equipment response results, and recording the plug and unplug status information through an industrial human-machine interface and periodically compiling it into production records.

[0003] In existing technologies, the plug-in / plug-out control process relies on preset commands and manual execution, lacking the correlation numbering and time characteristic analysis of action feedback and control signals. When inconsistent plug-in / plug-out responses or overlapping actions occur, it is impossible to effectively locate command differences and response conflicts. In the face of continuous anomalies, there is a lack of combination and merging mechanisms and periodic pattern recognition methods, making it difficult to structurally identify and classify repetitive abnormal actions. At the task scheduling level, it is impossible to achieve synchronous update of instructions and closed-loop control paths, which can easily lead to lag in operation process control, misalignment of action logic, and long-term mismatch of scheduling information, affecting the response efficiency and stable operation capability of the plug-in / plug-out system in multiple batches of continuous operations. Summary of the Invention

[0004] To address the technical problems existing in the prior art, embodiments of the present invention provide an automatic plug-in / plug-out control management system and method for connectors.

[0005] On the one hand, an automatic plug-in / plug-out control and management system for connectors is provided, which includes:

[0006] The clamping action recognition module collects the execution and feedback time of the clamping component's actions during the automatic insertion and removal of the connector. By comparing the command trigger and response times, it calculates the time interval, marks deviations exceeding limits, and generates a list of differences between operation instructions and responses.

[0007] The control sequence revision module analyzes the execution sequence of clamping and advancing control commands based on the list of differences between operation commands and responses, identifies intersections and conflict points, adjusts and records the control sequence, and outputs a list of control action arrangement adjustments.

[0008] Based on the control action arrangement and adjustment list, the signal combination verification module calls the action feedback record, checks the timing logic of the three sets of actions: gripper closure, propulsion positioning, and power control, identifies synchronization failures within and between groups, and generates a record of inconsistent insertion and removal behavior combinations.

[0009] The abnormal record merging module, based on the inconsistent records of the insertion and removal behavior combinations, counts the repeated abnormal combinations of the device in a continuous cycle, arranges and classifies them by action, and forms a list of repeated abnormal combination merge items.

[0010] The scheduling table content update module updates the instruction order in the original task schedule based on the list of duplicate and abnormal combination merge items, replaces conflicting parts, completes the synchronization of scheduling control content and records the modifications, and outputs the results of automatic plug-in / plug-out control management of the socket.

[0011] As a further aspect of the present invention, the list of operational instructions and responses with differences includes clamping command timing, response feedback timing, and interval deviation number; the list of control action arrangement and adjustment includes control point identification, sequence comparison results, and replacement instruction records; the record of inconsistent insertion and removal behavior combinations includes gripper closure feedback, propulsion positioning feedback, and power on / off feedback; the list of repeated abnormal combination merging items includes device number, action arrangement method, and unit sequence number; and the automatic insertion and removal control management results of the socket include the updated work instruction sequence, scheduling table overlay information, and control module write records.

[0012] As a further aspect of the present invention, the deviation exceeding the limit refers to an abnormal situation where the interval between the actual response time of the clamping action and the command triggering time exceeds the deviation exceeding the limit threshold.

[0013] As a further aspect of the present invention, the repeated abnormal combination refers to a combination of the same type of plugging and unplugging abnormal behaviors that occur repeatedly during the execution cycle due to action synchronization failure.

[0014] As a further aspect of the present invention, the clamping action recognition module includes:

[0015] The instruction trigger acquisition submodule collects the sequence of actions and action response content performed by the clamping structure driven component during the insertion and removal of the connector, collects the clamping command trigger time point and action number, constructs a mapping relationship according to the number order, and generates a clamping command trigger time point sequence set.

[0016] The feedback timing identification submodule calls the clamping command trigger timing sequence set, collects the response number and return timing in the feedback signal, performs number matching processing, and generates a response feedback timing matching set.

[0017] The response interval determination submodule calls the response feedback time point matching set, calculates the time interval between triggering and feedback, compares it with the response interval threshold, filters out out-of-range numbers, and generates a list of operation instructions and response differences.

[0018] As a further aspect of the present invention, the control sequence revision module includes:

[0019] The instruction conflict extraction submodule extracts the trigger number sequence and corresponding instruction identifier from the plug-in control command based on the operation instruction and response difference list, collects the numbers, establishes an index mapping structure between the trigger number and the control sequence, and generates a conflict control instruction sequence set.

[0020] The sequence conflict identification submodule calls the conflict control instruction sequence set, calculates the order value of adjacent numbers in the list based on the sequence list composed of clamping action identifier and propulsion signal identifier, classifies and judges control points that have intersections and overlaps, and generates a sequence conflict instruction number group.

[0021] The control sequence revision submodule calls the sequence conflict instruction number group, adjusts the triggering order according to the position index of each group number in the control sequence, rebinds the number to the original instruction content, records all replaced numbers and updated content, and establishes a control action arrangement adjustment list.

[0022] As a further aspect of the present invention, the signal combination verification module includes:

[0023] The action feedback acquisition submodule collects feedback signals for three types of actions—clamp closure, propulsion positioning, and power on / off—based on the control action arrangement and adjustment list. It extracts the execution time corresponding to each record in each type of action, establishes a matching structure between the number and the feedback time, and generates a multi-action execution time sequence set.

[0024] The sequence consistency verification submodule calls the multi-action execution time sequence set to compare the time sequence of the three types of actions under the same number within the group, check whether there is a sequence error within any group, and perform cross-group detection on the sequence relationship between actions under different numbers to obtain the set of sequence abnormal numbers within and between groups;

[0025] The abnormal combination filtering submodule calls the set of abnormal numbers in the group and between groups, extracts the three types of action feedback records with the corresponding numbers, filters records where any two types of action feedback are missing or timed out at the same time, extracts the numbers and action types, and generates records of inconsistent insertion and removal behavior combinations.

[0026] As a further aspect of the present invention, the anomaly record merging module includes:

[0027] The periodic anomaly statistics submodule, based on the inconsistent insertion and removal behavior combination records, filters records with the same device number, extracts the anomaly numbers that appear repeatedly within two consecutive periods, and generates a list of repeated anomaly combination numbers.

[0028] The action mode classification submodule calls the list of repeated abnormal combination numbers, extracts the corresponding fields according to the action arrangement order of the gripper, propulsion and power supply in the abnormal record, aggregates and classifies abnormal combinations with the same arrangement structure, establishes a mapping relationship from number to arrangement structure, and generates an action arrangement classification index table.

[0029] The repeat sequence marking submodule calls the action arrangement and classification index table, extracts the device number and action number pairs associated with the repeating action, numbers them sequentially according to the group order and binds them with unique identifier values, establishes the correspondence between the number and the device, and generates a list of repeating abnormal combination merge items.

[0030] As a further aspect of the present invention, the scheduling table content update module includes:

[0031] The task instruction retrieval submodule retrieves the sequence of operation instructions in the plug-in / plug-out operation task schedule based on the list of duplicate and abnormal combination merge items, extracts the task sequence record under the corresponding device number, establishes a mapping structure between task number and execution order, and generates a task scheduling instruction index table.

[0032] The sequential synchronization comparison submodule calls the task scheduling instruction index table, performs a synchronous comparison with the original scheduling sequence record according to the replacement order in the merged item instruction, replaces and sorts the instruction items with inconsistent positions, and obtains the updated task sequence set.

[0033] The scheduling content writing submodule calls the updated task sequence set, writes the adjusted instruction content into the job control module, performs an overwrite update on the corresponding numbered item in the scheduling record, and generates the automatic plug-in / plug-out control management result.

[0034] On the other hand, the automatic plug-in / plug-out control and management method for connectors, which is executed based on the aforementioned automatic plug-in / plug-out control and management system, includes the following steps:

[0035] S1: Obtain the trigger time and feedback time of the clamping action command, calculate the time difference between the two, compare the time difference with the upper and lower limits of the clamping response range, determine whether it deviates from the threshold, filter the deviation numbers and classify them, and generate a list of differences between operation commands and responses.

[0036] S2: Call the operation instruction and response differentiation list, extract the triggering order of the corresponding clamping and pushing signals, compare the order positions to determine whether they intersect or overlap, reorder the items with misalignment and mark the replacement number, and generate a control action arrangement adjustment list;

[0037] S3: Call the control action arrangement and adjustment list, extract the feedback records of gripper closure, push positioning and power on / off, calculate the execution sequence interval of the three sets of actions, determine whether there is a combination of simultaneous response failure, and generate a record of inconsistent insertion and removal behavior combinations;

[0038] S4: Obtain the inconsistent records of the insertion and removal behavior combinations, count the device number and combination number, filter the action combinations that occur repeatedly in two consecutive cycles, classify and mark the device number for the action sequence of the repeated combinations, and generate a list of repeated abnormal combination merge items.

[0039] S5: Call the list of duplicate abnormal combination merge items, retrieve the corresponding job instruction sequence in the schedule, compare the difference between the replacement sequence and the original sequence, execute the sequence position to cover and record the update position, and generate the automatic plug-in / plug-out control management result of the socket.

[0040] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following:

[0041] By numbering and archiving the trigger and feedback intervals, rapid identification and recording of response deviations are achieved. By adjusting the sequence of control commands, signal trigger conflicts and timing misalignments are eliminated. By verifying the correlation characteristics of abnormal actions through feedback combination, the failure points and corresponding logic are identified. By analyzing and merging abnormal combinations, repeated fault modes of the device are extracted, improving the continuous identification capability of abnormal behavior. By synchronously revising the sequence of scheduling commands, the structural consistency between control logic and task execution is ensured, enhancing the stability, accuracy, and closed-loop execution capability of the plug-in / plug-out process under complex operating conditions. Attached Figure Description

[0042] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0043] Figure 1 This is a schematic diagram of the system of the present invention;

[0044] Figure 2 This is a schematic diagram of the system framework of the present invention;

[0045] Figure 3 This is a flowchart of the clamping action recognition module in this invention;

[0046] Figure 4 This is a flowchart of the control sequence revision module in this invention;

[0047] Figure 5 This is a flowchart of the signal combination verification module in this invention;

[0048] Figure 6 This is a flowchart of the anomaly record merging module in this invention;

[0049] Figure 7 This is a flowchart of the scheduling table content update module in this invention;

[0050] Figure 8 This is a flowchart of the method of the present invention. Detailed Implementation

[0051] The technical solution of the present invention will now be described with reference to the accompanying drawings.

[0052] In embodiments of the present invention, words such as "exemplarily," "for example," etc., are used to indicate that something is an example, illustration, or description. Any embodiment or design described as "exemplary" in the present invention should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of the word "exemplary" is intended to present the concept in a concrete manner. Furthermore, in embodiments of the present invention, the meaning expressed by "and / or" can be both, or either one.

[0053] In the embodiments of this invention, the terms "image" and "picture" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, they convey the same meaning. Similarly, the terms "of," "corresponding (relevant)," and "corresponding" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, they convey the same meaning.

[0054] In this embodiment of the invention, sometimes a subscript such as W1 may be written in a non-subscript form such as W1. When the difference is not emphasized, the meaning they express is the same.

[0055] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0056] This invention provides an automatic plug-in / plug-out control and management system for connectors, such as... Figure 1-2 The diagram shown illustrates an automatic plug-in / plug-out control and management system for connectors. This system includes:

[0057] The clamping action recognition module collects the sequence of actions and action response content executed by the clamping structure driving component during the insertion and removal of the connector. By recording the clamping command trigger point and the response feedback point, it calculates the time interval value between the two points, numbers and summarizes all records with interval deviations exceeding the range, and generates a list of operation instructions and response differences.

[0058] The control sequence revision module extracts the sequence of conflicting insertion and removal control commands based on the list of differences between operation instructions and responses. By comparing the sequence identifiers of clamping actions and propulsion signals, it identifies control points with overlapping sequences and triggers, executes the numbering to adjust the position, records the replacement instructions, and establishes a list of control action arrangement adjustments.

[0059] The signal combination verification module adjusts the list of control actions, calls the feedback signal records of the insertion / removal gripper closing action, the push positioning action and the power on / off action, performs a two-level sequential check on the execution time of the three sets of actions within and between groups, determines whether any two sets of actions fail to respond at the same time, organizes the action information corresponding to the abnormal combination, and generates a record of inconsistent insertion / removal behavior combinations.

[0060] The abnormal record merging module records inconsistent insertion and removal behavior combinations, counts the abnormal combinations that appear repeatedly in two consecutive cycles for the same device number, classifies them by extracting the action arrangement in the combination, marks the device and the repeated action number of each group in the classification result as the unit sequence number, and generates a list of repeated abnormal combination merging items.

[0061] The scheduling table content update module calls the duplicate and abnormal combination merging item list, retrieves the job instruction sequence set in the corresponding plug-in operation task schedule, compares the replacement order in the merged item instruction with the original task order in a synchronous manner, overwrites and updates the current schedule control content, writes it into the job control module update record, and generates the plug-in automatic plug-in control management result.

[0062] The list of differences in operation instructions and responses includes the clamping command time point, response feedback time point, and interval deviation number; the list of control action arrangement and adjustment includes control point identification, sequence comparison results, and replacement instruction records; the record of inconsistent insertion and removal behavior combinations includes gripper closure feedback, propulsion positioning feedback, and power on / off feedback; the list of repeated abnormal combination merging items includes device number, action arrangement method, and unit sequence number; and the results of automatic insertion and removal control management of the socket include the updated work instruction sequence, scheduling table overlay information, and control module write records.

[0063] Specifically, such as Figure 2 , 3 As shown, the clamping action recognition module includes:

[0064] The instruction trigger acquisition submodule collects the sequence of actions and action response content performed by the clamping structure driven component during the insertion and removal of the connector, collects the clamping command trigger time point and action number, constructs a mapping relationship according to the number order, and generates a clamping command trigger time point sequence set.

[0065] First, the system identifies the object requiring insertion / removal, such as a standardized plastic connector or battery module plug. Before data acquisition begins, the system issues a clamping command based on the production cycle schedule. This command is sent from the upper control unit to the clamping structure controller as a control signal. Upon receiving the command, the controller records the command issuance time and uses this time as the start point of the clamping instruction. Subsequently, the drive component initiates the jaw opening process. During the opening process, the position sensor continuously collects real-time data on the current opening width of the jaws until the opening width reaches the set range, for example, when the jaw opening reaches 12 mm, the system automatically determines that the opening is complete and records the completion action number and the opening completion time. This is action number 001. Next, the system determines whether the target part is aligned. After alignment, the clamping action is initiated, and the drive motor generates appropriate torque to push the jaws to close. During the closing process, the jaws are continuously monitored. Force data is collected. When the clamping force applied by the gripper is detected to be stable near the set clamping force threshold, for example, the system sets the clamping threshold to 35 Newtons based on the material and fragility of the object being clamped. If the clamping force is stable between 34 and 36 Newtons during the clamping process, it is determined to be a qualified clamping. This is recorded as action number 002, and the time point of the action completion is also recorded. Then, it is determined whether it is necessary to perform an action to maintain the clamping state. If so, the drive component is kept in a closed state for a period of time, such as 500 milliseconds, and this holding action is recorded as action number 003. Finally, the system forms a record sequence containing each action number and its trigger time in the data storage unit. For example, action number 001 corresponds to 10:23:10, action number 002 corresponds to 10:23:12, and action number 003 corresponds to 10:23:15. This constructs a set of clamping command trigger time sequence.

[0066] The feedback timing identification submodule calls the clamping command trigger timing sequence set, collects the response number and return timing in the feedback signal, performs number matching processing, and generates a response feedback timing matching set.

[0067] During the identification process, the system sequentially calls each action number and its corresponding trigger time in the trigger sequence as a reference benchmark, and synchronously reads the feedback signal data returned by the controller or actuator. By decoding the number tag and timestamp information contained in the feedback signal, the system matches the action number in the feedback with the original trigger action number one by one. In actual operation, the actuator automatically sends an action completion feedback signal through the bus after the action is completed. For example, after the clamping action numbered 002 is completed, the system receives feedback data with the number 002 and the timestamp 10 hours 23 minutes 18 seconds. This feedback time is the feedback time of the clamping action. The system matches the number with the original trigger action number. The system associates the trigger time of number 002 in the time sequence with the feedback matching entry for number 002. For example, the action number 001 has a feedback time of 10:23:11, which corresponds to the trigger time of 10:23:10. The system matches number 001 with the above time. During the matching process, the system performs item-by-item comparison on all numbered items and builds a complete feedback matching set in the order of the numbers. The structure of each matching item is: action number, command trigger time, and feedback receiving time. The system storage module continuously updates this information in a list structure for subsequent response interval calculation operations, and finally forms a response feedback time matching set.

[0068] The response interval determination submodule calls the response feedback time point matching set, calculates the time interval between trigger and feedback, compares it with the response interval threshold, filters out out-of-range numbers, and generates a list of operation instructions and response differences.

[0069] First, the system iterates through each data item in the matching set. By comparing the command trigger time and feedback return time corresponding to the action number, the time difference is calculated to obtain the specific response interval. For example, if the command trigger time for action number 002 is 10:23:12 and the feedback time is 10:23:18, then the response interval is 6 seconds. This process is performed sequentially for each matching item. Subsequently, the system calls a preset response interval threshold to determine the response timeliness. This threshold is set based on a combination of factors, including the response performance of the gripper mechanism, the processing cycle of the control system, and environmental interference in the industrial environment. For example, in routine testing... The average response time for gripper opening and closing operations was found to be 2.5 seconds, with a fluctuation range of no more than ±1 second. To ensure normal operation under extreme interference, the system set the response interval threshold to 5 seconds. Based on this, a comparison operation was performed. For any number with a response interval greater than 5 seconds, the system identified it as a response anomaly and recorded it as a difference number. For example, the response interval of number 002 was 6 seconds, which exceeded the set threshold and was judged as an anomaly. It was added to the difference list, which was arranged by number and listed fields such as anomaly number, anomaly type, and interval time value, ultimately forming an operation instruction and response difference list.

[0070] Specifically, such as Figure 2, 4 As shown, the control sequence revision module includes:

[0071] The instruction conflict extraction submodule extracts the trigger number sequence and corresponding instruction identifier from the plug-in control command based on the list of differences between operation instructions and responses. It then collects the numbers, establishes an index mapping structure between trigger numbers and control sequences, and generates a set of conflict control instruction sequences.

[0072] First, all action numbers with abnormal feedback times are extracted from the response difference list. For example, if the system detects that the feedback times of numbers A04 and A09 exceed the set response interval threshold or the sequence deviates during the insertion / removal process, the system will categorize them into the response deviation number group. Based on this, the system further calls the complete insertion / removal control command list and analyzes the correspondence between the trigger numbers and command identifiers in each control command. For example, A01 is a clamping action, A02 is an alignment action, and A03 is a pushing action. Each command contains the command number, its function type, command trigger time, and the target execution module identifier. The system will then group number A04 and A09 into the response deviation number group. 4. Map and aggregate the corresponding propulsion command, number A09, and clamping command. Extract all numbers with response deviations and determine their position index in the control sequence. For example, number A04 is the 6th control action in the overall sequence, and number A09 is the 10th control action. Establish a structured mapping relationship between the trigger number and its index in the original control command sequence. For example, map number A04 to position index 6 and bind the command identifier "propulsion". Build a complete index mapping table in this way. All mapping results are structured and saved for subsequent conflict detection and sequential processing. Finally, output and generate a conflict control command sequence set.

[0073] The sequence conflict identification submodule calls the conflict control instruction sequence set, calculates the order value of adjacent numbers in the list based on the sequence list composed of clamping action identifier and propulsion signal identifier, classifies and judges control points with intersection and overlap, and generates sequence conflict instruction number groups.

[0074] First, the logical execution order of various action types is preset. For example, in standard insertion and removal actions, clamping should precede pushing, alignment should precede clamping, and opening should be performed after pushing. The system assigns the execution order numbers of these action types as Alignment=1, Clamping=2, Pushing=3, and Opening=4 as a reference for judging the legality of the order. Based on this, the system reads each item in the conflict control instruction sequence set one by one, identifies its action type by reading the instruction identifier, and obtains its logical order value. For example, number A04 is a pushing action with a corresponding order value of 3, and number A02 is a clamping action with a corresponding order value of 2. If number A04 appears before number A02 in the control sequence, the system marks this behavior as a reverse order type conflict. At the same time, the system also judges whether there is an execution time. In cases of overlap, for example, if the command trigger time for number A06 is 10:23:12 and the command trigger time for number A07 is 10:23:13, but the feedback time shows that A07 is completed earlier than A06, it indicates that the two actions have overlapped in physical execution and are judged as a feedback advance conflict. In addition, the system also judges that if two numbers have overlapping target modules and the interval time is less than the set safety time threshold, it is considered a trigger lag conflict. The threshold is set according to the physical response limit and minimum execution cycle of the actuator. For example, if the actuator needs at least a 2-second interval time when executing two actions consecutively, the safety interval threshold is set to 2 seconds. If the measured interval is 1.2 seconds, it is considered an over-limit conflict. Finally, the system classifies all identified conflict types by number, forming a sequential conflict command number group.

[0075] The control sequence revision submodule calls the sequence conflict instruction number group, adjusts the triggering order according to the position index of each group number in the control sequence, rebinds the number to the original instruction content, records all replaced numbers and updated content, and establishes a control action arrangement adjustment list.

[0076] The system reads each control number in the numbering group that has a sequential conflict and its position index in the original control command sequence, determines the sequence value of the corresponding action, and checks whether the current number appears after a number with a lower sequence value. If so, a numbering order adjustment operation needs to be performed. For example, number A04 is a propulsion action, and its original sequence position is before number A02. However, A02 is a clamping action with a lower sequence value. Based on this, the system moves A02 before A04, rearranging the control sequence to ensure that actions with lower sequence values ​​are executed first. During the adjustment process, the system establishes a relationship between the number and the command. The binding relationship of the content ensures that the adjustment only involves updating the position index and does not change the function of the instruction itself. If there are multiple related conflicts between the numbers, such as the numbers A05, A06, and A07 forming a feedback conflict loop, the system will rearrange the whole according to the size of the sequence value to ensure that the sequence value of the adjacent numbers before and after each number increases, avoiding crossover and lag phenomena. After the rearrangement is performed, the system will establish a complete replacement and adjustment record table, which will record the original number, the original position index, the updated index, the corresponding action identifier, and other fields, and finally establish a control action arrangement and adjustment list.

[0077] Specifically, such as Figure 2 , 5 As shown, the signal combination verification module includes:

[0078] The motion feedback acquisition submodule collects feedback signals for three types of actions—clamp closure, propulsion positioning, and power on / off—based on the control motion arrangement and adjustment list. It extracts the execution time corresponding to each record in each type of action, establishes a matching structure between the number and the feedback time, and generates a multi-action execution time sequence set.

[0079] First, the system retrieves all reordered control action numbers and their corresponding action types from the arrangement and adjustment list. The action types are limited to the three most critical actions in the insertion / removal operation: gripper closure, propulsion positioning, and power on / off. Each number uniquely corresponds to an action type; for example, number X01 corresponds to gripper closure, number X02 to propulsion positioning, and number X03 to power on / off. Based on this structure, the system configures three acquisition channels in the hardware communication interface to establish feedback data monitoring connections with the gripper drive module, propulsion cylinder module, and power control module, respectively. After the action is executed, each execution module actively sends a feedback signal back to the upper-level acquisition module. The system records the action number and time information in each feedback signal and parses the signal to confirm the action type. The system extracts precise execution time information, with feedback time precision set to milliseconds. For example, the gripper closure feedback time of X01 is recorded as 10:22:35.214, the propulsion positioning feedback time of X01 is 10:22:36.032, and the power on / off feedback time of X01 is 10:22:36.935. All time data are mapped using the number as the primary key, recording the corresponding feedback time values ​​for the three types of actions. If only some actions of a certain number are reported normally, only the received feedback is recorded, and missing feedback is left blank or marked with an anomaly flag. Finally, the system aggregates the feedback times of the three types of actions corresponding to each number, forming a multi-action execution time sequence set with the structure: Number → {Gripper Closure Feedback Time, Propulsion Positioning Feedback Time, Power On / Off Feedback Time}.

[0080] The sequence consistency verification submodule calls the multi-action execution time sequence set to compare the time sequence of three types of actions under the same number within the group, check whether there is a sequence error within any group, and perform cross-group detection on the sequence relationship between actions under different numbers to obtain the set of abnormal sequence numbers within and between groups;

[0081] The system sequentially reads the feedback times of the three types of actions corresponding to each number, and performs a logical comparison of the sequence of the three action times within the same number. The specific comparison order follows the standard procedure of the insertion / removal process: gripper closure should precede advance positioning, and advance positioning should precede power on / off. The system compares whether the sequence of the three types of feedback times satisfies this logic. If it finds that the advance feedback time in number X05 is earlier than the gripper closure feedback time (e.g., advance is 10:15:06.120, gripper is 10:15:06.830), then this sequence does not conform to the expected logic, and the system records it as an abnormal sequence within the group. Similarly, if the power on / off feedback time in number X06 is earlier than the advance positioning time, it is also considered an incorrect sequence. When determining an incorrect sequence, the system does not consider differences in action response speed, but only relies on... The system judges the absolute value of the time sequence. After completing the intra-group judgment, it further compares the abnormal numbers across numbers, especially cross-checking the execution order of similar actions between different numbers. For example, the feedback time of the push action of number X08 is 10:30:05.950, while the feedback time of the gripper closure of number X07 is 10:30:06.700. According to the control flow, clamping should be done before pushing. Therefore, the push action of X08 is earlier than the clamping action of X07 and is identified as an inter-group sequence abnormality. In order to accurately identify such problems, the system sets the time sequence tolerance to 0.1 seconds. That is, if the time difference between the two actions is less than this value, it does not constitute an abnormality. Otherwise, it is marked as an inter-group conflict. Finally, the system organizes and outputs all numbers with sequence errors within and between groups, resulting in a set of numbers with intra-group and inter-group sequence abnormalities.

[0082] The abnormal combination filtering submodule calls the set of sequential abnormal numbers within and between groups, extracts the three types of action feedback records with the corresponding numbers, filters records where any two types of action feedback are simultaneously missing and timed out, extracts the numbers and action types, and generates records of inconsistent insertion and removal behavior combinations.

[0083] The system extracts each anomaly ID and retrieves its feedback information for the three types of actions within the multi-action execution time sequence set. For each ID, the system first determines whether there is a lack of time information for two types of actions in its feedback record. For example, ID X09 only has feedback time for gripper closure, with no valid feedback time for propulsion or power on / off. The system marks this ID as "double feedback missing." Secondly, the system determines whether any two of the three types of actions have timeout feedback. To this end, a maximum feedback time delay threshold is set. Referring to the industrial automation standard control cycle and equipment response performance, the system sets this threshold to 2000 milliseconds, or 2 seconds. If the control command... If the trigger time is set to 10:12:00.000, the gripper closing feedback time to 10:12:02.350, and the push feedback time to 10:12:02.810, then both exceed the set threshold and are judged as "double feedback timeout". When the number meets either the missing or timeout condition, it can be included in the set of abnormal insertion and removal behaviors. The system uses the number as the primary key to extract the corresponding abnormal action type combination. For example, X09 is "push + power on / off feedback missing", and X11 is "clamping + push feedback timeout". All data entries that meet the conditions are sorted out in turn, and finally, a record of inconsistent insertion and removal behavior combinations is generated.

[0084] Specifically, such as Figure 2 , 6 As shown, the exception record merging module includes:

[0085] The periodic anomaly statistics submodule is based on records of inconsistent insertion and removal behavior combinations. It filters records with the same device number, extracts the anomaly numbers that appear repeatedly in two consecutive periods, and generates a list of repeated anomaly combination numbers.

[0086] First, all inconsistent records within the current cycle are retrieved. Each record contains fields such as device number, action number, exception type, and feedback timestamp. The system performs an initial screening based on device number, identifying sets of exception records with identical device numbers through field value comparison. For example, if device number D01 has two records in the current cycle, one for clamping timeout and the other for propulsion failure, the system marks them as a group. Then, the system further extracts exception records from two adjacent work cycles, determining whether the same device number has appeared in two consecutive cycles. If an anomaly is detected in both cycle T1 and T2 for device number D01, the system determines that the number is a duplicate anomaly. Then, it performs aggregate analysis on the associated action numbers to ensure that there are consecutive duplicate anomaly records for the same action number in at least two cycles. If the action number A01 under D01 is missing clamping feedback or clamping timeout in both cycle T1 and T2, it is determined to be a duplicate anomaly. The system constructs device numbers and action numbers that meet the above conditions into a combination item, such as {D01, A01}, and then performs number classification and organization to finally generate a list of duplicate anomaly combination numbers.

[0087] The action mode classification submodule calls the list of duplicate abnormal combination numbers, extracts the corresponding fields according to the action order of the gripper, propulsion, and power supply in the abnormal records, aggregates and classifies abnormal combinations with the same arrangement structure, establishes a mapping relationship between the number and the arrangement structure, and generates an action arrangement classification index table.

[0088] For each group of abnormal records associated with a specific number, the system extracts the action type, specifically the sequence of actions involving the gripper, propulsion, and power supply. The system reads the action type sequence information from each abnormal combination record one by one, for example, if one combination record is gripper → power supply → propulsion, and another is propulsion → gripper → power supply, the system compares the position and order of the three actions in each combination to confirm consistency. If the action sequence is consistent across all combinations, it is determined to be the same arrangement structure. The system groups these structurally consistent records together for classification and categorization. In specific processing, the system generates a unique structure for each arrangement structure. The system encodes data such as gripper → propulsion → power supply as structure code S1, propulsion → gripper → power supply as S2, and then assigns all numbers to their respective structure codes, constructing a mapping table between numbers and structure codes. For example, D01, D03, and D06 all belong to structure S1, while D04 and D09 belong to structure S2. The arrangement structure here is only related to the order of action feedback time and is not affected by the numerical value of the action number. Through structure coding, numbers with the same execution order are uniformly categorized. Finally, the system organizes all mapping data and stores it in an index table with the structure {device number → action arrangement structure code}, forming an action arrangement classification index table.

[0089] The repeat sequence marking submodule calls the action arrangement and classification index table, extracts the device number and action number pairs associated with the repeating action, numbers them sequentially according to the group order and binds them with unique identifier values, establishes the correspondence between the number and the device, and generates a list of repeating abnormal combination merge items.

[0090] The system sequentially extracts all device numbers under each structure code from the index table and combines them with the previously generated abnormal action numbers. For example, structure code S1 contains device numbers D01, D03, and D06, with corresponding action numbers A01, A04, and A09. The system arranges these combinations in ascending order of device numbers and assigns a sequential number to each item in the same group, such as D01→1, D03→2, and D06→3. Finally, a unique identifier value, such as UID-S1-001, is generated for the entire combination group to mark the abnormal action combination corresponding to that group. The system pairs each device number with its associated action number and binds them with a unique identifier, such as {D01, A01, UID-S1-001}, {D03, A04, UID-S1-001}, and {D06, A09, UID-S1-001}. The system establishes a complete mapping relationship between the device number, action number, and identifier value and records it in a structured list. The list fields include: unique identifier, device number, action number, group sequence number, action arrangement structure, etc. The final output is a list of duplicate and abnormal combination merged items.

[0091] Specifically, such as Figure 2 , 7 As shown, the scheduling table content update module includes:

[0092] The task instruction retrieval submodule retrieves the sequence of operation instructions in the plug-in / plug-out operation task schedule based on the list of duplicate and abnormal combination merge items, extracts the task sequence record under the corresponding device number, establishes a mapping structure between task number and execution order, and generates a task scheduling instruction index table.

[0093] First, all device numbers with abnormal records and their associated action numbers are extracted from the merged item list. Then, each is searched and matched against the plug-in / plug-out operation task scheduling data table. Each job instruction in the task scheduling data table contains fields such as task number, device number, execution action, planned sequence, target location, and timestamp. The system uses the device number as the primary index field. By comparing the device number in the merged item with the field values ​​in the scheduling table, a matching relationship is confirmed, and the complete task sequence record corresponding to that device number is extracted. For example, if device number D07 has 5 job tasks in the schedule, with action numbers B01 to B05, the system determines their execution order based on the time field, selecting the earliest... The task is set to a sequence value of 1, which is incremented sequentially to form a mapping structure {task number → execution order}. During this process, if the same device number corresponds to multiple work records, the system will sort them in ascending order according to the time field, and then perform a secondary check in combination with the action type to confirm whether the actions are physically continuous. If there is a time interval between two tasks that is greater than a preset threshold (e.g., 5 minutes), the system will treat them as two different batches and not include them in the same task chain. The threshold setting is based on the process cycle time setting and the operator's changeover time. Finally, the system will structure and organize all device numbers that meet the conditions and their task execution order information to form a mapping relationship from task number to execution order, and summarize and generate a task scheduling instruction index table.

[0094] The sequential synchronization comparison submodule calls the task scheduling instruction index table, compares it with the original scheduling sequence record according to the replacement order in the merged item instruction, replaces and sorts the instruction items with inconsistent positions, and obtains the updated task sequence set.

[0095] First, the new sorting value of each instruction number is extracted based on the order replacement information in the merged item list. Then, the original scheduling order value of the same device number under the same number is extracted from the index table. The original scheduling order is compared with the merged item order one by one. If the order position is found to be inconsistent, for example, action number B03 is sorted as 2 in the merged item but as 4 in the original schedule, it is marked as an item that needs adjustment. The system records the old order and new order of the number and performs the order replacement operation. Before performing the replacement, the system will check whether the adjacent numbers above and below the number will cause a sequence conflict due to the change. If it is found that two actions overlap in time after the change (such as overlapping start times or an interval of less than 30 seconds), the system will postpone the start time of one of the actions until there is no conflict. The adjustment interval is set to 30 seconds based on the actuator response time and control instruction buffer cycle. To prevent multi-point linkage from going out of control, the system will also check the continuity and time integrity of the entire action chain. If necessary, the execution order and time of all subsequent action numbers will be adjusted in batches. Finally, all task numbers whose order has been changed, the corresponding old and new orders and adjustment time data are recorded in a unified manner, and the updated task order set is output.

[0096] The scheduling content is written to the submodule, which calls the updated task sequence set. The adjusted instruction content is written to the job control module, and the corresponding numbered item in the scheduling record is overwritten and updated to generate the automatic plug-in / plug-out control management result.

[0097] The system retrieves the updated task sequence data and locates the task record table in the job control system. It then compares the task number field to find the corresponding record row and overwrites its "sequence number" and "execution time" fields, ensuring that the original scheduling sequence information in the database is replaced by the new values. During the writing process, the system verifies the format and field validity of each written value. For example, the sequence value must be a positive integer and the time field format must be "HH:MM:SS". If an abnormal format or conflicting time is detected, the system will automatically stop writing and record an error log, ensuring that no data corruption occurs during batch writing. All updated task sequence content is synchronized to the job control module via an interface, ensuring that the real-time control logic remains consistent with the database. After writing is complete, the system records all updated task numbers, new sequences, writing times, and execution flags, ultimately forming a data list with the structure {task number, device number, new sequence, writing status}, which is then archived and saved, generating the automatic plug-in / plug-out control management results.

[0098] Please see Figure 8 The automatic plug-in / plug-out control and management method for sockets is implemented based on the aforementioned automatic plug-in / plug-out control and management system, and includes the following steps:

[0099] S1: Obtain the trigger time and feedback time of the clamping action command, calculate the time difference between the two, compare the time difference with the upper and lower limits of the clamping response range, determine whether it deviates from the threshold, filter the deviation numbers and classify them, and generate a list of differences between operation commands and responses.

[0100] S2: Call the list of operation instructions and response differences, extract the triggering order of the corresponding clamping and pushing signals, compare the order positions to determine whether they intersect or overlap, reorder the items with misalignment and mark the replacement number, and generate a control action arrangement adjustment list;

[0101] S3: Call the control action arrangement and adjustment list, extract the feedback records of gripper closure, propulsion positioning and power on / off, calculate the execution sequence interval of the three sets of actions, determine whether there is a combination of simultaneous response failure, and generate a record of inconsistent insertion and removal behavior combinations;

[0102] S4: Obtain records of inconsistent insertion and removal behavior combinations, count device numbers and combination numbers, filter action combinations that occur repeatedly in two consecutive cycles, classify and label the action sequence of repeated combinations with device numbers, and generate a list of repeated abnormal combination merge items.

[0103] S5: Call the list of duplicate exception combinations, retrieve the corresponding job instruction sequence in the schedule, compare the difference between the replacement sequence and the original sequence, execute the sequence position overwrite and record the update position, and generate the automatic plug-in / plug-out control management results.

[0104] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. An automatic plug-in / plug-out control and management system, characterized in that, The system includes: The clamping action recognition module collects the execution and feedback time of the clamping component's actions during the automatic insertion and removal of the connector. By comparing the command trigger and response times, it calculates the time interval, marks deviations exceeding limits, and generates a list of differences between operation instructions and responses. The control sequence revision module analyzes the execution sequence of clamping and advancing control commands based on the list of differences between operation commands and responses, identifies intersections and conflict points, adjusts and records the control sequence, and outputs a list of control action arrangement adjustments. Based on the control action arrangement and adjustment list, the signal combination verification module calls the action feedback record, checks the timing logic of the three sets of actions: gripper closure, propulsion positioning, and power control, identifies synchronization failures within and between groups, and generates a record of inconsistent insertion and removal behavior combinations. The abnormal record merging module, based on the inconsistent records of the insertion and removal behavior combinations, counts the repeated abnormal combinations of the device in a continuous cycle, arranges and classifies them by action, and forms a list of repeated abnormal combination merge items. The scheduling table content update module updates the instruction order in the original task schedule based on the list of duplicate and abnormal combination merge items, replaces conflicting parts, completes the synchronization of scheduling control content and records the modification, and outputs the automatic plug-in / plug-out control management results of the socket. The control order revision module includes: The instruction conflict extraction submodule extracts the trigger number sequence and corresponding instruction identifier from the plug-in control command based on the operation instruction and response difference list, collects the numbers, establishes an index mapping structure between the trigger number and the control sequence, and generates a conflict control instruction sequence set. The sequence conflict identification submodule calls the conflict control instruction sequence set, calculates the order value of adjacent numbers in the list based on the sequence list composed of clamping action identifier and propulsion signal identifier, classifies and judges control points that have intersections and overlaps, and generates a sequence conflict instruction number group. The control sequence revision submodule calls the sequence conflict instruction number group, adjusts the triggering order according to the position index of each group number in the control sequence, rebinds the number to the original instruction content, records all replaced numbers and updated content, and establishes a control action arrangement adjustment list.

2. The automatic plug-in / plug-out control and management system for connectors according to claim 1, characterized in that: The list of operational instructions and responses with differences includes the clamping command time point, response feedback time point, and interval deviation number. The list of control action arrangement and adjustment includes control point identification, sequence comparison results, and replacement instruction records. The record of inconsistent insertion and removal behavior combinations includes gripper closure feedback, propulsion positioning feedback, and power on / off feedback. The list of repeated abnormal combination merge items includes device number, action arrangement method, and unit sequence number. The automatic insertion and removal control management results of the socket include the updated work instruction sequence, scheduling table overlay information, and control module write records.

3. The automatic plug-in / plug-out control and management system for connectors according to claim 1, characterized in that: The deviation exceeding the limit refers to an abnormal situation where the interval between the actual response time of the clamping action and the command trigger time exceeds the deviation exceeding the threshold.

4. The automatic plug-in / plug-out control and management system for connectors according to claim 1, characterized in that: The repeated abnormal combination refers to the same type of plug-in abnormal behavior combination that occurs repeatedly during the execution cycle due to action synchronization failure.

5. The automatic plug-in / plug-out control and management system for connectors according to claim 1, characterized in that: The clamping action recognition module includes: The instruction trigger acquisition submodule collects the sequence of actions and action response content performed by the clamping structure driven component during the insertion and removal of the connector, collects the clamping command trigger time point and action number, constructs a mapping relationship according to the number order, and generates a clamping command trigger time point sequence set. The feedback timing identification submodule calls the clamping command trigger timing sequence set, collects the response number and return timing in the feedback signal, performs number matching processing, and generates a response feedback timing matching set. The response interval determination submodule calls the response feedback time point matching set, calculates the time interval between triggering and feedback, compares it with the response interval threshold, filters out out-of-range numbers, and generates a list of operation instructions and response differences.

6. The automatic plug-in / plug-out control and management system for connectors according to claim 1, characterized in that: The signal combination verification module includes: The action feedback acquisition submodule collects feedback signals for three types of actions—clamp closure, propulsion positioning, and power on / off—based on the control action arrangement and adjustment list. It extracts the execution time corresponding to each record in each type of action, establishes a matching structure between the number and the feedback time, and generates a multi-action execution time sequence set. The sequence consistency verification submodule calls the multi-action execution time sequence set to compare the time sequence of the three types of actions under the same number within the group, check whether there is a sequence error within any group, and perform cross-group detection on the sequence relationship between actions under different numbers to obtain the set of sequence abnormal numbers within and between groups; The abnormal combination filtering submodule calls the set of abnormal numbers in the group and between groups, extracts the three types of action feedback records with the corresponding numbers, filters records where any two types of action feedback are missing or timed out at the same time, extracts the numbers and action types, and generates records of inconsistent insertion and removal behavior combinations.

7. The automatic plug-in / plug-out control and management system for connectors according to claim 1, characterized in that: The anomaly record merging module includes: The periodic anomaly statistics submodule, based on the inconsistent insertion and removal behavior combination records, filters records with the same device number, extracts the anomaly numbers that appear repeatedly within two consecutive periods, and generates a list of repeated anomaly combination numbers. The action mode classification submodule calls the list of repeated abnormal combination numbers, extracts the corresponding fields according to the action arrangement order of the gripper, propulsion and power supply in the abnormal record, aggregates and classifies abnormal combinations with the same arrangement structure, establishes a mapping relationship from number to arrangement structure, and generates an action arrangement classification index table. The repeat sequence marking submodule calls the action arrangement and classification index table, extracts the device number and action number pairs associated with the repeating action, numbers them sequentially according to the group order and binds them with unique identifier values, establishes the correspondence between the number and the device, and generates a list of repeating abnormal combination merge items.

8. The automatic plug-in / plug-out control and management system for connectors according to claim 1, characterized in that: The scheduling table content update module includes: The task instruction retrieval submodule retrieves the sequence of operation instructions in the plug-in / plug-out operation task schedule based on the list of duplicate and abnormal combination merge items, extracts the task sequence record under the corresponding device number, establishes a mapping structure between task number and execution order, and generates a task scheduling instruction index table. The sequential synchronization comparison submodule calls the task scheduling instruction index table, performs a synchronous comparison with the original scheduling sequence record according to the replacement order in the merged item instruction, replaces and sorts the instruction items with inconsistent positions, and obtains the updated task sequence set. The scheduling content writing submodule calls the updated task sequence set, writes the adjusted instruction content into the job control module, performs an overwrite update on the corresponding numbered item in the scheduling record, and generates the automatic plug-in / plug-out control management result.

9. An automatic plug-in / plug-out control and management method for connectors, characterized in that, The automatic plug-in / plug-out control and management system according to any one of claims 1-8 includes the following steps: S1: Obtain the trigger time and feedback time of the clamping action command, calculate the time difference between the two, compare the time difference with the upper and lower limits of the clamping response range, determine whether it deviates from the threshold, filter the deviation numbers and classify them, and generate a list of differences between operation commands and responses. S2: Call the operation instruction and response differentiation list, extract the triggering order of the corresponding clamping and pushing signals, compare the order positions to determine whether they intersect or overlap, reorder the items with misalignment and mark the replacement number, and generate a control action arrangement adjustment list; S3: Call the control action arrangement and adjustment list, extract the feedback records of gripper closure, push positioning and power on / off, calculate the execution sequence interval of the three sets of actions, determine whether there is a combination of simultaneous response failure, and generate a record of inconsistent insertion and removal behavior combinations; S4: Obtain the inconsistent records of the insertion and removal behavior combinations, count the device number and combination number, filter the action combinations that occur repeatedly in two consecutive cycles, classify and mark the device number for the action sequence of the repeated combinations, and generate a list of repeated abnormal combination merge items. S5: Call the list of duplicate abnormal combination merge items, retrieve the corresponding job instruction sequence in the schedule, compare the difference between the replacement sequence and the original sequence, execute the sequence position to cover and record the update position, and generate the automatic plug-in / plug-out control management result of the socket.

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