Flexible production adaptation method for industrial production line

Abstract

The invention relates to the technical field of industrial automatic production, in particular to an industrial production line flexible production adaptation method, which comprises the following steps: constructing a standardized production formula library integrating equipment key parameters and linkage logic; compatible adaptation of new and old equipment is realized through the IO-Link master station and the concentrator; one-key issuing of a production formula and collaborative configuration of equipment are realized on the basis of a Block Parameter function of IO-Link; verifying the availability of the equipment through PLC grading self-inspection after model changing; a Data Storage function is utilized to realize local storage and rapid recovery of parameters; and establishing a whole-process data tracing system. According to the invention, manual operation is replaced by digital configuration, so that the remodeling period of a production line is greatly shortened, and the remodeling efficiency is improved; a historical production formula can be reused, the labor investment and configuration error loss are reduced, and the operation and maintenance cost is reduced; rules are uniformly configured, and the production stability is enhanced; the method is compatible with an existing production line, supports progressive upgrading, gives consideration to investment protection and technical advancement, and is suitable for a multi-variety and small-batch production mode.

Description

Technical Field

[0001] This invention relates to the field of industrial automation production technology, and in particular to a method for flexible production adaptation of industrial production lines. Background Technology

[0002] As the manufacturing industry accelerates its transformation towards a production model characterized by diverse varieties, small batches, and rapid delivery, industrial production lines need to frequently switch product categories to respond to diverse order demands. Different products have varying requirements for processing technology, detection logic, and execution timing. Therefore, each product changeover necessitates adjustments to the operating parameters of on-site intelligent equipment. From sensor detection ranges and trigger thresholds to servo motor speeds and positioning accuracy, everything must be reconfigured according to the new production requirements. This process directly impacts whether new product categories can be produced smoothly according to process requirements and significantly affects the efficiency of production line changeovers.

[0003] In modern industrial production lines, field-level intelligent devices are key units that directly execute process actions and collect process data. The operating parameters of these devices directly determine the execution accuracy and cycle time of the process. All these devices are typically centrally managed by field-distributed I / O devices and uniformly scheduled by the upper-level PLC control system.

[0004] Currently, the common method for achieving flexible production line adaptation in industrial settings involves field engineers or operators executing a series of standardized configuration procedures, adjusting the parameters of each intelligent device on the production line according to pre-stored process documents. Some production lines also modify the PLC to load independent function blocks corresponding to the product, and manually review the I / O status and equipment response of key workstations. However, this method has the following significant shortcomings: 1. The equipment parameters and linkage logic for different products vary greatly. Engineers need to re-examine the configuration requirements for each type of product. When manually modifying parameters, configuration errors are prone to occur. In addition, the parameter adjustment of a single piece of equipment usually takes more than 5 minutes, resulting in a long overall production line changeover cycle and an inability to quickly respond to changes in market orders. 2. The parameter configuration information of the production line relies heavily on manual recording and storage by engineers. When personnel leave or records are lost, when switching to the production of the same type of product again, the equipment parameters need to be readjusted. This repetitive work not only reduces production efficiency, but may also lead to unstable product quality due to debugging deviations. 3. Traditional production lines lack standardized management of parameter configuration. The equipment parameter configuration rules are not uniform across different production lines and workstations. When the production line is expanded or the equipment is replaced, it is difficult to adapt the parameters of the new equipment to the original production line, which prolongs the production line transformation cycle.

[0005] Therefore, there is an urgent need for a flexible production adaptation solution that can achieve dynamic, batch, and remote unified management and control of equipment parameters, while taking into account changeover efficiency, configuration standardization, and equipment compatibility, in order to solve the above-mentioned problems existing in the current technology. Summary of the Invention

[0006] The purpose of this invention is to overcome the problems of the prior art and provide a method for flexible production adaptation of industrial production lines. This method addresses the technical problems of traditional industrial production line transformation relying on manual equipment debugging, which is time-consuming and prone to errors, lacking standardized management and traceability of parameters, and making production line modification or equipment replacement difficult.

[0007] The above objectives are achieved through the following technical solutions: A method for flexible production adaptation in industrial production lines includes the following steps: Step (1) Construct a standardized production formula library: Through HMI management of structured formulas, integrate the key parameters of equipment and process linkage logic of the corresponding production line, and synchronously input the equipment model and IO-Link communication address association information to form a standardized production formula; Step (2) Implement IO-Link adaptation for devices: Replace a small number of Ethernet smart sensors / actuators with models that support IO-Link, connect a large number of traditional DI / DO or analog devices to the IO-Link hub, and control the enable state or bypass logic of the IO-Link master station by the PLC; Step (3) One-click formula distribution and collaborative configuration: Select the production formula corresponding to the target product through the unified formula management platform. The system automatically distributes the configuration through the IO-Link communication link. Utilize the Block Parameter function of IO-Link to write or read a set of related parameters as a whole logical unit. Call the parameter block step by step for the linkage equipment group according to the preset time sequence. Step (4) PLC hierarchical self-test after model change: Verify the availability of equipment functions through equipment ID verification, parameter confirmation and equipment status feedback; Step (5) Local storage of equipment parameters: Using the Data Storage function of the IO-Link master station, an automatic backup and recovery mechanism for equipment parameters is established on the master station side to persistently save the currently effective production formula parameters and equipment identification information; Step (6) Construct a full-process data traceability system: record the history of production formula calls, parameter modification records and equipment feedback status in real time, form an unalterable configuration log, and support the retrieval and reuse of historical production formulas by product model.

[0008] Furthermore, the key parameters of the equipment mentioned in step (1) include the detection threshold of the photoelectric sensor, the alarm range of the pressure monitoring point, the action sequence of the adjustable valve island, the cylinder stroke, the pressure threshold, and the response delay.

[0009] Furthermore, in step (2), the IO-Link master station and the HMI establish a communication connection through the industrial fieldbus protocol to realize the interaction of commands and data.

[0010] Furthermore, in step (3), the preset timing is pre-configured in the main station system based on the processing technology requirements and equipment linkage logic of different products.

[0011] Furthermore, the equipment status feedback in step (4) includes equipment operating status indicators such as cylinder position signal and sensor detection signal.

[0012] Furthermore, the local non-volatile storage in step (5) ensures that the production formula parameters are not lost after a power outage or network interruption, enabling the equipment to be used as a plug and play device and to recover quickly.

[0013] Furthermore, the configuration log in step (6) is tamper-proof and can be traced throughout the entire lifecycle of the production formula's usage and modification records.

[0014] Furthermore, the standardized production formula library contains independent production formulas corresponding to different products, and each production formula encapsulates equipment parameters and linkage logic in a unified format.

[0015] Furthermore, the PLC serves as the control core, uniformly scheduling the operation of the IO-Link master station, distributed IO devices, and field intelligent devices.

[0016] Furthermore, the IO-Link hub is used to connect traditional DI / DO or analog devices, enabling compatibility and adaptation between traditional devices and the IO-Link system.

[0017] This invention provides a method for flexible production adaptation in industrial production lines. By constructing a standardized production recipe library and adapting IO-Link to achieve compatibility between new and old equipment, it leverages parameter block batch distribution and time-series collaborative configuration. Combined with PLC hierarchical self-inspection, local non-volatile storage, and full-process traceability, it enables rapid production line changeover, standardized configuration, and plug-and-play equipment, reducing labor and maintenance costs, ensuring stable production, and adapting to the needs of multi-variety, small-batch production. Compared with existing technologies, it has the following significant advantages: 1. Significantly improved production line changeover efficiency: Conventional technical solutions rely on engineers manually adjusting parameters on each device on-site, requiring several hours for production line changeovers and simultaneous modifications to the linkage logic; this solution, through a standardized production formula library combined with IO-Link technology, enables one-click distribution of production formulas and batch configuration of parameters, reducing the production line changeover cycle from several hours to tens of minutes, enabling rapid response to multi-variety, small-batch order demands and significantly improving the market responsiveness of the production line.

[0018] 2. Reduced production, operation and maintenance and labor costs: Through full-process data traceability and production formula library management, historical production formulas can be directly retrieved and reused. When equipment malfunctions and needs to be replaced, it can be plugged and played with the help of local storage function, avoiding the manpower input caused by repeated debugging. At the same time, it reduces production losses such as production stoppages or product defects caused by manual configuration errors, effectively reducing production, operation and maintenance and labor costs.

[0019] 3. Enhanced standardization and stability of production configuration: This solution establishes standardized parameter configuration rules and management system. All equipment parameters and linkage logic corresponding to all products are packaged into production formulas in a unified format. When new equipment is connected or production lines are expanded or upgraded, the system can automatically match standardized parameters, avoiding production fluctuations caused by inconsistent configuration rules of different production lines and workstations, and ensuring the stability of product quality.

[0020] 4. Compatible with existing production lines and supports gradual upgrades: The solution does not require a complete replacement of old equipment. Instead, it focuses on introducing IO-Link smart interfaces at key flexible nodes. Traditional digital or analog equipment can still be used through IO-Link hubs, enabling coexistence of new and old equipment. While meeting the needs of production flexibility, it minimizes the cost of production line transformation and takes into account both the company's investment protection and technological advancement needs. Attached Figure Description

[0021] Figure 1 This is a flowchart of a method for flexible production adaptation in industrial production lines according to the present invention; Figure 2 This is a system block diagram of the various components in the method for flexible production adaptation of industrial production lines described in this invention. Detailed Implementation

[0022] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. The described embodiments are merely some, not all, of the embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0023] like Figure 1 As shown, this solution provides a method for flexible production adaptation in industrial production lines, specifically including the following steps: Step (1): Construct a standardized production formula library like Figure 2As shown, the core of the system is a structured recipe managed by an HMI, which integrates the equipment parameters of the corresponding production line in a structured manner. For key parameters such as the detection threshold of photoelectric sensors, the alarm range of pressure monitoring points, the action sequence of adjustable valve islands, cylinder stroke, pressure threshold, and response delay, standardized production recipes are formed by combining process linkage logic, and related information such as equipment model and IO-Link communication address are simultaneously entered. All equipment parameters and linkage logic corresponding to all products are packaged into production recipes in a unified format to ensure the consistency of configuration rules, laying the foundation for rapid parameter retrieval and unified management in the future.

[0024] Step (2): Achieve device IO-Link adaptation and compatibility with new and old devices. For a small number of Ethernet smart sensors / actuators, replace them with models that support IO-Link; for a large number of traditional DI / DO or analog devices, connect them to an IO-Link hub. The IO-Link master station is controlled by the PLC according to the production formula to control their enable status or bypass logic. The IO-Link master station and HMI establish a communication connection through the industrial fieldbus protocol to realize the interaction of commands and data. Under the premise of only adding or reducing a small number of devices, it gives traditional equipment flexible response capabilities, and can achieve coexistence of new and old equipment without completely replacing the old equipment, thus reducing the transformation cost.

[0025] Step (3): One-click recipe distribution and collaborative equipment configuration The system utilizes a unified formula management platform to enable one-click distribution of production formulas and collaborative equipment configuration. When a production line needs to change models, engineers only need to select the production formula corresponding to the target product in the main system, and the system will automatically distribute the configuration via the IO-Link communication link.

[0026] During this process, the Block Parameter function of IO-Link allows a group of related parameters to be written to or read from the device as a whole, eliminating the need to configure individual parameters one by one, thus significantly improving configuration efficiency and consistency. For device groups with linkage relationships, the master station calls the corresponding parameter blocks step by step according to a preset timing sequence. This preset timing sequence is pre-configured in the master station system based on the processing requirements of different products and the linkage logic of the devices, ensuring precise and conflict-free process connection and avoiding production anomalies caused by improper parameter issuance order.

[0027] Step (4): PLC self-test after model change After the PLC is changed, it performs a graded self-inspection process: First, it performs IODD verification and parameter confirmation on the equipment to ensure that the issued production formula parameters match the technical specifications of the equipment and are accurately written into the equipment; then, it indirectly verifies the functionality of the equipment through equipment status feedback, which includes indicators that reflect the operating status of the equipment, such as cylinder position signals and sensor detection signals, to ensure that the equipment parameters are configured accurately and that the production actions can be performed normally.

[0028] Step (5): Local storage and quick recovery of device parameters The IO-Link master station's Data Storage function enables each device to have local non-volatile storage capabilities, persistently saving currently effective production recipe parameters and device identification information. This design not only ensures that parameters are not lost in the event of sudden events such as power outages or network interruptions, but also enables plug-and-play and rapid recovery of devices. When a device malfunctions and needs to be replaced, the new device can directly read the locally stored parameter information after being connected to the system, and can be quickly put into production without re-adjusting the parameters.

[0029] Step (6): Establish a full-process data traceability system A full-process data traceability system is established to record the history of production formula calls, parameter modification records, and equipment feedback status in real time, forming an immutable configuration log. This configuration log completely preserves the entire lifecycle information of the production formula from call and modification to execution. In the event of personnel turnover or loss of production formulas, historical production formulas can be quickly retrieved by product model and reused directly, avoiding repeated debugging work and ensuring the continuity and stability of production.

[0030] As a specific embodiment of this solution, a manufacturing enterprise has multiple production lines that need to cope with the demand for multi-variety, small-batch orders. The production lines need to frequently switch product categories. Traditional changeover methods rely on manual parameter configuration, which has many problems. After adopting the flexible production adaptation method for industrial production lines of this invention, the specific implementation process is as follows: 1. Construct a standardized production formula library: For various products manufactured by the enterprise, the key parameters of the equipment corresponding to each product are integrated through HMI. The key parameters of the equipment include the detection threshold of photoelectric sensors, the alarm range of pressure monitoring points, the action sequence of adjustable valve islands, cylinder stroke, pressure threshold, response delay, etc. Combined with the process linkage logic of each product, standardized production formulas are formed in a unified format, and the corresponding equipment model, IO-Link communication address and other related information are entered. All production formulas are centrally stored in a unified formula management platform to form a complete production formula library.

[0031] 2. Equipment IO-Link Adaptation and Retrofit: Equipment on the production line is categorized, and a small number of Ethernet smart sensors / actuators are replaced with IO-Link-compatible models. For the large number of traditional DI / DO or analog devices, they are connected to IO-Link hubs one by one. The IO-Link master station and HMI communicate via the industrial fieldbus protocol. The PLC acts as the control core, uniformly scheduling the operation of the IO-Link master station, distributed IO devices, and field intelligent devices, controlling the enable state or bypass logic of the IO-Link master station to ensure that both traditional and intelligent devices can integrate into the system and operate normally.

[0032] 3. Production Line Changeover Operation: When a production line needs to switch products, the engineer finds and selects the production formula corresponding to the target product in the HMI's formula management platform. After clicking the "issue command," the system automatically sends the parameters of the production formula to the relevant equipment via the IO-Link communication link. During the issuance process, the IO-Link's Block Parameter function is used to write a set of related parameters for the product's production as a logical unit into the corresponding equipment. For equipment groups with interlocking relationships, the master station calls the corresponding parameter blocks step by step according to the pre-configured timing sequence, ensuring that each piece of equipment starts up in an orderly manner according to process requirements and that there are no conflicts in the process transitions.

[0033] 4. Graded Self-Inspection and Status Confirmation: After the production formula parameters are issued, the PLC automatically starts the graded self-inspection process. First, it performs IODD verification on each device to confirm that the parameters match the device's technical specifications. Then, it confirms the parameters to verify that they have been accurately written into the device. Subsequently, by receiving status signals from the device, such as cylinder position signals and sensor detection signals, it determines whether the device can perform production functions normally. After the self-inspection is passed, the production line can start producing the target product.

[0034] 5. Data Traceability and Recipe Reuse: During production, the end-to-end data traceability system records in real time the time the production recipe is called, parameter modifications, and feedback status during equipment operation, forming an immutable configuration log. If the product needs to be produced again later, and the engineer originally responsible for debugging has left the company or the production recipe has been lost, staff can quickly retrieve the corresponding historical production recipe from the recipe management platform using the product model. This recipe can then be directly used for production line configuration without needing to re-analyze parameters or re-adjust equipment.

[0035] Through the above implementation process, the company's production line can be changed without manual adjustment of parameters for each device, achieving rapid and accurate changeover. At the same time, with the help of production formula library management and data traceability functions, the stability and continuity of production are ensured, giving full play to the technical advantages of this invention in flexible production adaptation.

[0036] The above description is merely illustrative of the embodiments of the present invention and is not intended to limit the present invention. For those skilled in the art, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A method for flexible production adaptation in industrial production lines, characterized in that, Includes the following steps: Step (1) Construct a standardized production formula library: Through HMI management of structured formulas, integrate the key parameters of equipment and process linkage logic of the corresponding production line, and synchronously input the equipment model and IO-Link communication address association information to form a standardized production formula; Step (2) Implement IO-Link adaptation for devices: Replace a small number of Ethernet smart sensors / actuators with models that support IO-Link, connect a large number of traditional DI / DO or analog devices to the IO-Link hub, and control the enable state or bypass logic of the IO-Link master station by the PLC; Step (3) One-click formula distribution and collaborative configuration: Select the production formula corresponding to the target product through the unified formula management platform. The system automatically distributes the configuration through the IO-Link communication link. Utilize the Block Parameter function of IO-Link to write or read a set of related parameters as a whole logical unit. Call the parameter block step by step for the linkage equipment group according to the preset time sequence. Step (4) PLC hierarchical self-test after model change: Verify the availability of equipment functions through equipment ID verification, parameter confirmation and equipment status feedback; Step (5) Local storage of equipment parameters: Using the Data Storage function of the IO-Link master station, an automatic backup and recovery mechanism for equipment parameters is established on the master station side to persistently save the currently effective production formula parameters and equipment identification information; Step (6) Construct a full-process data traceability system: record the history of production formula calls, parameter modification records and equipment feedback status in real time, form an unalterable configuration log, and support the retrieval and reuse of historical production formulas by product model.

2. The method for flexible production adaptation of an industrial production line according to claim 1, characterized in that, The key parameters of the equipment mentioned in step (1) include the detection threshold of the photoelectric sensor, the alarm range of the pressure monitoring point, the action sequence of the adjustable valve island, the cylinder stroke, the pressure threshold and the response delay.

3. The method for flexible production adaptation of an industrial production line according to claim 1, characterized in that, In step (2), the IO-Link master station and the HMI establish a communication connection through the industrial fieldbus protocol to realize the interaction of commands and data.

4. The method for flexible production adaptation of an industrial production line according to claim 1, characterized in that, In step (3), the preset timing is pre-configured in the main station system based on the processing technology requirements and equipment linkage logic of different products.

5. The method for flexible production adaptation of an industrial production line according to claim 1, characterized in that, In step (4), the equipment status feedback includes equipment operating status indicators such as cylinder position signal and sensor detection signal.

6. The method for flexible production adaptation of an industrial production line according to claim 1, characterized in that, In step (5), the local non-volatile storage ensures that the production formula parameters are not lost after a power outage or network interruption, enabling the equipment to be used as a plug and play device and to recover quickly.

7. The method for flexible production adaptation of an industrial production line according to claim 1, characterized in that, The configuration log in step (6) is immutable and can be traced throughout the entire lifecycle of the production formula, including usage and modification records.

8. The method for flexible production adaptation of an industrial production line according to claim 1, characterized in that, The standardized production formula library contains independent production formulas for different products, and each production formula encapsulates equipment parameters and linkage logic in a unified format.

9. The method for flexible production adaptation of an industrial production line according to claim 1, characterized in that, The PLC serves as the control core, uniformly scheduling the operation of the IO-Link master station, distributed IO devices, and field intelligent devices.

10. The method for flexible production adaptation of an industrial production line according to claim 1, characterized in that, The IO-Link hub is used to connect traditional DI / DO or analog devices, enabling compatibility and adaptation between traditional devices and the IO-Link system.

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