Method and system for tracing product processing data of multi-station production line

Abstract

The invention discloses a method for tracing product processing data of a multi-station production line. The method comprises the following steps: S1, distributing and binding a unique identification code for a to-be-processed product; s2, enabling the product to flow through at least two processing stations; s3, when the product passes through each processing station, executing the following steps: S31, collecting a plurality of process parameters of the station in real time; s32, on the basis of the multiple process parameters, a qualification judgment result of the machining station is generated in real time; s33, if the judgment result is unqualified, an intervention action corresponding to the current process is triggered; s34, associating and binding the unique identification code, the process parameter, the qualification judgment result and the intervention record into a data set of the processing station; and S4, performing associated storage on the data set by taking the unique identification code as a common index to form a whole-process data traceability library of the product. According to the invention, a plurality of process parameters during processing are collected in real time and online comprehensive judgment is carried out, so that the rate of defective products and the cost are reduced.

Description

Technical Field

[0001] This invention belongs to the field of industrial automation manufacturing, and in particular relates to a method and system for tracing product processing data of a multi-station production line. Background Technology

[0002] In the field of automated manufacturing, especially in the product assembly process of industries such as electronics, automobiles, and home appliances, multiple continuous or parallel automated processing stations are typically involved, such as ultrasonic welding, screw installation, snap-fit ​​assembly, and automatic vision inspection. Currently, PLCs, sensors, and host computer systems are commonly used to collect and store data from welding, screw installation, and other stations to achieve basic production monitoring.

[0003] However, in practice, such systems have significant drawbacks: First, data from each workstation is collected independently and not linked to individual product barcodes during processing, making it difficult to quickly and accurately trace product quality issues back to specific processes and original parameters. Second, existing traceability results are mostly post-processing records, such as pass or fail, and cannot be used for real-time comprehensive judgment and immediate intervention based on multi-faceted process parameters during processing, thus failing to trace the location of defects in the production process.

[0004] Therefore, there is an urgent need for a traceability method that can achieve process quality control and in-depth full-process traceability. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings of the prior art by providing a method and system for tracing product processing data in a multi-station production line. This system can monitor and adjust process parameters in real time and trace the entire process, thereby improving product quality and efficiency.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is: a method for tracing product processing data in a multi-station production line, comprising the following steps:

[0007] S1. Assign and bind a unique identifier to the product to be processed;

[0008] S2, so that the product flows through at least two processing stations in sequence;

[0009] S3. When the product passes through each of the processing stations, the following steps are performed: S31: During the processing, multiple process parameters of the station are collected in real time; S32: Based on the multiple process parameters, a pass / fail judgment result for the processing station is generated in real time; S33: If the judgment result is unqualified, an intervention action is triggered for the corresponding current processing station; S34: The unique identifier, process parameters, pass / fail judgment result, and intervention record are associated and bound to the dataset of the processing station; S4. The dataset is associated and stored with the unique identifier as a common index to form a full-process data traceability library for the product.

[0010] Furthermore, the processing station includes an ultrasonic welding station, which collects multiple process parameters including welding depth, welding pressure, welding machine power, welding energy, and frequency.

[0011] Furthermore, the processing station includes a screw assembly station, where the collected process parameters include installation angle, installation torque, and installation time.

[0012] Furthermore, the processing station includes a snap-fit ​​processing station, which collects multiple process parameters including snap-fit ​​gripping status, installation status, and quantity correspondence status.

[0013] Furthermore, the intervention actions in step S33 include alarming, stopping processing, or product diversion.

[0014] Furthermore, in step S33, the judgment logic for the qualification determination is as follows: a threshold range is set for each of the plurality of process parameters; the judgment result is qualified if and only if the real-time values ​​of all process parameters are simultaneously within their respective qualification threshold ranges, otherwise it is unqualified.

[0015] Furthermore, after step S4, the following steps are also included: S5: Based on the product full-process data traceability database, automatically generate an electronic quality report document for the product; S6: Associate the access link or QR code of the electronic quality report document with the product's logistics document.

[0016] A product processing data traceability system for a multi-station production line includes:

[0017] The allocation unit is used to assign and bind a unique identifier to the product to be processed.

[0018] A transfer unit is used to ensure that the product flows sequentially through at least two processing stations;

[0019] The workstation control unit is used to perform the following steps when the product passes through each of the processing workstations: real-time acquisition of multiple process parameters of the workstation; real-time generation of a pass / fail judgment result for the processing workstation based on the multiple process parameters; if the judgment result is unqualified, triggering an intervention action for the corresponding current processing workstation; associating and binding the unique identifier, process parameters, pass / fail judgment result, and intervention record into a dataset for the processing workstation; and the data management unit is used to associate and store the dataset with the unique identifier as a common index to form a full-process data traceability library for the product.

[0020] Due to the application of the above technical solution, the present invention has the following advantages compared with the prior art:

[0021] The method and system for tracing product processing data in a multi-station production line of the present invention can identify and trigger intervention at the moment a defect occurs by collecting multiple process parameters in real time and making online comprehensive judgments during multi-station automated processing, thereby strictly controlling product quality and effectively reducing defect rate and rework cost.

[0022] Secondly, by using the product's unique identifier as a carrier, the processing parameters scattered across various workstations are integrated into a complete traceability database. This allows for the rapid identification of abnormal workstations and parameters when product quality issues arise, greatly improving the efficiency and accuracy of problem analysis and facilitating further product optimization and yield improvement. Attached Figure Description

[0023] The technical solution of the present invention will be further described below with reference to the accompanying drawings:

[0024] Figure 1 This is a flowchart illustrating an embodiment of the present invention;

[0025] Figure 2 This is a diagram illustrating the process of using the framework of the present invention;

[0026] Figure 3 This is a schematic diagram of the product structure in one embodiment of the present invention. Detailed Implementation

[0027] To enable those skilled in the art to better understand the present application, the technical solutions in the embodiments of the present application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present application, and not all embodiments. Based on the embodiments in the present application, all other embodiments obtained by those of ordinary skill in the art without creative effort should fall within the scope of protection of the present application.

[0028] For ease of understanding, the specific processes in the embodiments of this application are described below. Please refer to [link / reference]. Figure 1 This application discloses a method for tracing product processing data in a multi-station production line, comprising the following steps: S1, assigning and binding a unique identifier to the product to be processed; S2, ensuring that the product flows through at least two processing stations sequentially; S3, when the product passes through each processing station, performing the following steps: S31: during processing, collecting multiple process parameters of the station in real time; S32: generating a pass / fail judgment result for the processing station in real time based on the multiple process parameters; S33: if the judgment result is unqualified, triggering an intervention action for the corresponding current processing station; S34: associating and binding the unique identifier, process parameters, pass / fail judgment result, and intervention record as a dataset for the processing station; S4: storing the dataset in association with the unique identifier as a common index to form a full-process data traceability library for the product.

[0029] This invention collects multiple process parameters in real time during multi-station automated processing and performs online comprehensive judgment. It can instantly identify defects and trigger intervention, reducing defect rate and rework cost. Using the product's unique identification code as a carrier, it integrates various processing parameters into a traceability database, which facilitates the traceability of product quality data, thereby improving product yield and production efficiency.

[0030] Example 1

[0031] See Figure 3 In this embodiment, we take an automated assembly line for the housing of an automotive headlight controller as an example. The production line includes three stations in sequence: an ultrasonic welding station, a screw assembly station, and a snap-fit ​​processing station. The corresponding assembly processing needs to be performed at three positions on the product: welding position S1, screw assembly position S2, and snap-fit ​​assembly position S3.

[0032] S1. Assign and bind a unique identification code to the product to be processed; in this step, the product tray is placed into the scanning area, the scanner reads the QR code, and then the host computer system creates a document indexed by this code.

[0033] S2, the product flows through three processing stations in sequence; in step S2, a servo motor-driven conveyor belt is used to transfer the product.

[0034] S3. When the product flows through the first processing station, namely the ultrasonic welding station, the following steps are performed: S31. The welding depth, welding pressure, welding machine power, welding energy and frequency in the welding station are collected in real time through the ultrasonic generator controller; S32. Based on the multiple process parameters, the qualification judgment result of the processing station is generated in real time.

[0035] Taking welding depth as an example, the real-time acquisition value of welding depth is 2.58mm, while the set threshold is 2.45mm~2.55mm; S33: If the judgment result is unqualified, the intervention action of the corresponding current processing station is triggered; S34: The PLC associates and binds the unique identifier, process parameters, "unqualified judgment result and intervention record" into the dataset of the processing station and transmits it to the host computer system.

[0036] If the real-time acquisition value of the welding depth is set to 2.548mm, and the set threshold is 2.45mm~2.55mm; S33: the judgment result is qualified; S34: the PLC transmits the unique identifier, process parameters, qualified judgment result and intervention record as the dataset of the processing station to the host computer system.

[0037] In summary, the difference between a qualified and unqualified result lies in the fact that an unqualified result will lead to a shutdown or alarm, thereby strictly controlling product quality and clearly identifying which process parameter has a defect.

[0038] S3' When the product flows into the second processing station, namely the screw assembly station, the following steps are performed: S31' The installation angle, installation torque and installation time in the screw assembly station are collected in real time through the Atlas Copco tightening shaft controller; S32' Based on the multiple process parameters, the pass / fail judgment result of the processing station is generated in real time.

[0039] Taking the installation angle as an example, the real-time acquisition value of the installation angle is 185°, while the set acceptable angle range is 177°~183°; S33': If the judgment result is unqualified, the intervention action corresponding to the current processing station is triggered; S34': The PLC associates and binds the unique identifier, process parameters, "unqualified judgment result and intervention record" into the dataset of the processing station and transmits it to the host computer system.

[0040] If the real-time acquisition value of the installation angle is 182°, and the set acceptable angle range is 177°~183°; S33: the judgment result is qualified; S34': the PLC transmits the unique identifier, process parameters, qualified judgment result and intervention record as the dataset of the processing station to the host computer system.

[0041] S3'', The product flows into the third processing station, namely the buckle assembly station, where a robot is used for picking and placing. Photoelectric sensors are installed on the robot's grippers and at the installation positions. The specific steps are as follows: S31'', The photoelectric sensors collect in real time the buckle gripping status, installation status, and quantity correspondence status at the buckle assembly station; S32'', Based on the multiple process parameters, the pass / fail determination result of the processing station is generated in real time.

[0042] Here, we take installation time as an example. The real-time acquisition value of installation time is 3.3 seconds, while the set acceptable time range is 1.5s to 3.0s. S33': If the judgment result is unqualified, the intervention action of the corresponding current processing station is triggered. S34': The PLC associates and binds the unique identifier, process parameters, unqualified judgment result and intervention record into the dataset of the processing station and then transmits it to the host computer system.

[0043] If the real-time acquisition value of the installation angle is 2.3 seconds, and the set time acceptable range is 1.5s~3.0s; S33': the judgment result is qualified; S34': the PLC transmits the unique identifier, process parameters, qualified judgment result and intervention record as a dataset of the processing station to the host computer system.

[0044] S4. The host computer system associates and stores the dataset in the SQL Server database using the unique identifier as a common index, forming a full-process data traceability database for the product.

[0045] When traceability queries are required, engineers can display the product's entry and exit times and results at welding, screw, and clip stations in real time on the client interface.

[0046] Furthermore, for all processed products, the following steps are performed: S5: Based on the product's full-process data traceability database, an electronic quality report document for the product is automatically generated; S6: The access link or QR code of the electronic quality report document is associated with the product's logistics documents. This allows customers or internal quality inspectors to scan the QR code on the product and directly view a detailed digital quality report for the product in a mobile browser, improving the efficiency and transparency of quality information transmission.

[0047] It should be noted that the above embodiments are described using the example of workstations connected in series, but the present invention is not limited thereto. The system and method of the present invention are also applicable to parallel workstations, as long as the traceability data is associated with the unique product identifier at each processing workstation.

[0048] The product processing data traceability method of the multi-station production line of the present invention has been widely used in multiple automated production lines in the fields of automotive electronics and home appliance manufacturing. After adopting this traceability method, the first pass rate of the production line has increased by an average of about 2.5%, and the average analysis and traceability time for product quality problems has been shortened from more than 4 hours to less than 30 minutes. At the same time, product quality has been improved and production costs have been reduced.

[0049] This invention also discloses a product processing data traceability system for a multi-station production line, comprising: an allocation unit for allocating and binding a unique identifier to a product to be processed; a circulation unit for ensuring that the product flows through at least two processing stations sequentially; a station control unit for performing the following steps when the product passes through each processing station: real-time acquisition of multiple process parameters of the station; real-time generation of a pass / fail judgment result for the processing station based on the multiple process parameters; triggering an intervention action for the corresponding current processing station if the judgment result is unqualified; associating and binding the unique identifier, process parameters, pass / fail judgment result, and intervention record as a dataset for the processing station; and a data management unit for associating and storing the dataset with the unique identifier as a common index to form a full-process data traceability library for the product.

[0050] This system, through the aforementioned usage methods, can effectively improve product quality, reduce costs, and meet actual production and processing needs.

[0051] The above-described embodiments are only used to illustrate the technical solutions of this application, and are not intended to limit them. Although this application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some of the technical features. Such modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the spirit and scope of the technical solutions of the embodiments of this application.

Claims

1. A method for tracing product processing data in a multi-station production line, characterized in that, Includes the following steps: S1. Assign and bind a unique identifier to the product to be processed; S2, so that the product flows through at least two processing stations in sequence; S3. When the product passes through each of the aforementioned processing stations, the following steps are performed: S31: During the processing, multiple process parameters of this station are collected in real time; S32: Based on the multiple process parameters, generate the qualification judgment result of the processing station in real time; S33: If the judgment result is unqualified, the intervention action of the corresponding current processing station will be triggered; S34: Associate and bind the unique identifier, process parameters, qualification judgment result and intervention record as the dataset of this processing station; S4. The dataset is associated and stored using the unique identifier as a common index to form a full-process data traceability library for the product.

2. The method for tracing product processing data in a multi-station production line as described in claim 1, characterized in that: The processing station includes an ultrasonic welding station, which collects multiple process parameters including welding depth, welding pressure, welding machine power, welding energy, and frequency.

3. The method for tracing product processing data in a multi-station production line as described in claim 1, characterized in that: The processing station includes a screw assembly station, where the collected process parameters include installation angle, installation torque, and installation time.

4. The method for tracing product processing data in a multi-station production line as described in claim 1, characterized in that: The processing station includes a buckle processing station, which collects multiple process parameters including buckle gripping status, installation status, and quantity correspondence status.

5. The method for tracing product processing data in a multi-station production line as described in claim 1, characterized in that: The intervention actions in step S33 include alarming, stopping processing, or product diversion.

6. The method for tracing product processing data in a multi-station production line as described in claim 1, characterized in that: In step S33, the judgment logic for the qualification determination is as follows: a threshold range is set for each of the plurality of process parameters; the judgment result is qualified if and only if the real-time values ​​of all process parameters are simultaneously within their respective qualification threshold ranges, otherwise it is unqualified.

7. The method for tracing product processing data in a multi-station production line as described in claim 1, characterized in that: After step S4, the following steps are also included: S5: Based on the product full-process data traceability database, automatically generate an electronic quality report document for the product; S6: Associate the access link or QR code of the electronic quality report document with the product's logistics document.

8. A product processing data traceability system for a multi-station production line, characterized in that, include: The allocation unit is used to assign and bind a unique identifier to the product to be processed. A transfer unit is used to ensure that the product flows sequentially through at least two processing stations; The workstation control unit is used to perform the following steps when the product passes through each of the processing workstations: real-time acquisition of multiple process parameters of the workstation; real-time generation of a pass / fail judgment result for the processing workstation based on the multiple process parameters; if the judgment result is unqualified, triggering an intervention action for the corresponding current processing workstation; and associating and binding the unique identifier, process parameters, pass / fail judgment result, and intervention record into a dataset for the processing workstation. The data management unit is used to associate and store the dataset with the unique identifier as a common index, forming a full-process data traceability library for the product.

Images