A multi-device cooperative hierarchical control system and method based on parameterized step sequences

Abstract

The application discloses a multi-device cooperative hierarchical control system and method based on parameterized step sequences, which comprises an upper computer management layer, a monitoring layer and a PLC execution layer. The application separates action logic from parameters and adopts a three-level hierarchical architecture, so that production process switching only needs to modify the upper computer task queue parameters, and the changeover time is shortened from several days to 10 minutes. The application sets a multi-device space-time cooperation module, so as to realize accurate timing and space cooperation. The application constructs a standardized action logic block library and parameterized step sequence definition, so that the same step sequence can be adapted to different process parameters. The application integrates parameter verification, fault tolerance control and step sequence version management, so as to significantly enhance the reliability and recoverability of the system. The application adopts a standardized module interface and hierarchical architecture, so that a new device only needs to develop a corresponding logic block to access the system, thereby greatly improving the expansibility and integration convenience of the system.

Description

Technical Field

[0001] This invention relates to the field of industrial automation control technology, and more specifically, to a multi-device collaborative hierarchical control system and method based on parameterized step sequence. Background Technology

[0002] In the field of industrial automation control, especially in complex process control involving the coordinated operation of multiple types of equipment such as AGVs, robotic arms, pumps, and valves, achieving efficient, flexible, and reliable control has always been a core challenge in technological development. Current mainstream technical solutions mainly suffer from the following shortcomings: 1. Limitations of Fixed-Process PLC Programming: The control logic (step sequence) is directly fixed in the PLC program, and the process cannot be dynamically adjusted. When production tasks change, such as product model switching or process parameters change, such as the gripper force of the robotic arm, professional personnel need to modify the underlying PLC code. The modification cycle is long, the fault tolerance is low, and it cannot adapt to the flexible production needs of multiple varieties and small batches. Equipment downtime losses can reach more than 15% of the average daily production capacity.

[0003] 2. Defects of direct control by host computer: Although the industrial computer sends instructions directly to the equipment through scripts or high-level languages, it has a certain degree of flexibility, but the program stability is lower than that of PLC. It also lacks a standardized management mechanism, the instruction format of different devices is not uniform, the system integration is difficult, and the debugging cycle is as long as 1-2 weeks.

[0004] 3. Insufficient simple step sequence control capabilities: Existing step sequence controllers only support fixed action definitions. Parameter modifications require adjusting the hardware interface or recompiling the program one by one, failing to achieve efficient reuse of the "same step sequence with different parameters". For example, for the same "material picking" action, changing the material requires redefining the step sequence, resulting in a reuse rate of less than 30%, increasing programming and maintenance costs.

[0005] 4. Poor coordination among multiple devices: AGVs, robotic arms, and fixed equipment within the station, such as pumps and valves, are usually controlled by independent systems, and their linkage relies on customized communication protocols, resulting in the following problems: First, the timing coordination accuracy is low, with action connection delays >500ms, which can easily lead to accidents such as material falling and liquid addition deviations; second, spatial coordination is lacking, as the AGV's arrival position is not related to the robotic arm's operating range, requiring manual calibration, which is inefficient; third, the system integration is high, and new equipment requires the development of new communication interfaces, with modification costs accounting for more than 40% of the initial investment.

[0006] In summary, existing technologies cannot simultaneously meet the four core requirements of "flexibility, reliability, modularity, and collaboration." In particular, most of the disclosed technologies still focus on the control optimization of single devices, failing to address the challenges of multi-device collaboration and rapid process reconfiguration at the system level. Furthermore, existing systems lack effective intelligent processing mechanisms when dealing with complex scenarios such as multi-task parallel scheduling, breakpoint resumption after abnormal task interruptions, and automatic state recovery, relying excessively on manual intervention and impacting production continuity and traceability.

[0007] Therefore, there is an urgent need in this field for a new control architecture that enables reusable action logic, dynamically adjustable execution parameters, and precise collaboration among multiple devices, in order to overcome the shortcomings of existing technologies and meet the urgent needs of modern intelligent manufacturing for flexible production and efficient collaboration. Summary of the Invention

[0008] To address the aforementioned technical problems in related technologies, this invention proposes a multi-device collaborative hierarchical control system and method based on parameterized step sequence, which can overcome the above-mentioned shortcomings of the prior art.

[0009] To achieve the above-mentioned technical objectives, the technical solution of the present invention is implemented as follows: A multi-device collaborative hierarchical control system based on parameterized step sequence includes: The upper computer management layer is used to define parameterized steps, which include a step identifier and at least one corresponding dynamically configurable process parameter; and to arrange a task queue consisting of at least one of the parameterized steps and their process parameter values ​​according to the production task. The monitoring layer, which is connected to the upper computer management layer, is used to receive and parse the task queue, and convert the parsed current step sequence identifier and process parameter value into standard control instructions. The PLC execution layer is communicatively connected to the monitoring layer and the physical devices. It pre-stores standardized action logic blocks that correspond one-to-one with different sequence identifiers. The PLC execution layer is used to receive the control instructions, call the corresponding standardized action logic blocks according to the step sequence identifiers, and assign the process parameter values ​​to the logic blocks to drive the multiple physical devices to perform corresponding actions in a coordinated manner, and provide real-time feedback on the execution status to the monitoring layer.

[0010] Furthermore, the host computer management layer also includes a parameter verification and fault tolerance control module, which is used to set a threshold range for the process parameters and verify whether the process parameter values ​​are within the corresponding threshold range when arranging or issuing task queues. If they exceed the threshold range, the issuance is prohibited and an alarm is generated.

[0011] Furthermore, the PLC execution layer includes a multi-device spatiotemporal coordination module, the module comprising: The timing control unit is used to issue the instruction for the next sequence within a delay of less than 100ms after receiving the completion signal of the previous sequence. The coordinate mapping unit is used to establish the mapping relationship between the station coordinates of the first device and the working range coordinates of the second device, and to automatically calibrate the action coordinates of the second device after the first device is in place; The delay compensation unit is used to preset the compensation time based on the difference in response speed of each device, so as to ensure that multiple devices operate synchronously.

[0012] Furthermore, the PLC execution layer also includes a step sequence dynamic adaptation module, the module comprising: The parameter parsing unit is used to automatically identify the type of received process parameter values; The equipment capacity matching unit is used to collect equipment status in real time and automatically adjust the parameters to the equipment's rated value and generate an alarm when the issued process parameter value exceeds the equipment's current capacity range. The adaptive calling unit is used to automatically switch to calling the corresponding standardized action logic block based on the model of the execution device.

[0013] Furthermore, the system also includes a step sequence version management module, located in the host computer management layer or monitoring layer, for recording the modification history of parameterized steps, including version number, modifier, modification time and parameter changes, and supporting the rollback of the current step sequence to any historical stable version.

[0014] Furthermore, the PLC execution layer is also used to automatically trigger a preset number of retry logics when the device malfunctions. If it still fails, the current task is paused and the fault code is uploaded to the monitoring layer. The monitoring layer provides an interface for resetting or skipping the current abnormal sequence.

[0015] A multi-device collaborative hierarchical control method based on parameterized step sequence, applied to the aforementioned system, includes the following steps: S1 defines parameterized steps in the upper computer management layer and builds a step library containing step identifiers and dynamically configurable process parameters. S2, based on the production task, arranges a task queue consisting of at least one parameterized step sequence and its specific process parameter values ​​in the upper computer management layer, and sends it down to the monitoring layer; The S3 monitoring layer parses the task queue, verifies the process parameter values ​​of the current step sequence, and converts them into standard control commands to be sent to the PLC execution layer after the verification is successful. The S4PLC execution layer calls the corresponding pre-stored standardized action logic block according to the step sequence identifier in the received control command, and assigns the process parameter value to the logic block to drive the physical equipment to perform the action. After the S5 physical device completes its action, it sends a status update to the PLC execution layer. The PLC execution layer then reports the status to the host computer management layer through the monitoring layer, triggering the execution of the next sequence in the task queue.

[0016] Furthermore, the process of driving the physical device to perform actions in step S4 further includes a multi-device spatiotemporal coordination step: Timing coordination: After the previous sequential device sends a completion signal, the PLC execution layer sends an instruction to the next sequential device within a delay of less than 100ms; Spatial coordination: Based on the preset coordinate mapping relationship between the first equipment station and the second equipment's operating range, the movement coordinates of the second equipment are automatically calibrated after the first equipment is in place.

[0017] Furthermore, the process of driving the physical device to perform actions in step S4 also includes a step sequence dynamic adaptation step: the PLC execution layer parses and identifies the type of process parameter value; obtains the current capability status of the execution device in real time; if the issued process parameter value exceeds the device's capability range, it automatically adjusts to the device's rated value and generates an alarm; and adaptively calls the corresponding standardized action logic block according to the model of the execution device.

[0018] Furthermore, it also includes exception handling and version management steps: when the equipment performs an exception, the PLC execution layer automatically triggers a retry. If it fails, the task is paused and the fault is uploaded; the operator can reset or skip the abnormal step sequence through the monitoring layer; when it is necessary to modify the process, the process parameter values ​​in the task queue can be modified through the upper computer management layer, or the parameterized step sequence of the previous version can be rolled back through the version management module to achieve rapid changeover of production tasks.

[0019] The beneficial effects of this invention are as follows: By separating action logic from parameters and adopting a three-level hierarchical architecture, this invention enables production process switching to only require modification of the upper-level computer task queue parameters, reducing changeover time from several days to within 10 minutes, thus meeting the needs of flexible production of multiple varieties; by setting up a multi-device spatiotemporal coordination module, the action connection delay between AGV and robotic arm is less than 100ms and the spatial deviation is less than ±3mm, thereby achieving precise timing and spatial coordination and avoiding manual calibration and material loss; by constructing a standardized action logic block library and parameterized step sequence definition, the same step sequence can be adapted to different process parameters, increasing the reuse rate to over 90%, thereby significantly reducing programming and maintenance costs; by integrating parameter verification, fault tolerance control, and step sequence version management, the equipment failure rate is reduced by 40%, and production interruption losses are reduced by 70%, thereby significantly enhancing the reliability and recoverability of the system; through standardized module interfaces and hierarchical architecture, new equipment only needs to develop corresponding logic blocks to be connected to the system, reducing modification costs by 50%, thereby greatly improving the system's scalability and integration convenience. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the embodiments will be briefly introduced below. Obviously, the 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.

[0021] Figure 1 This is a schematic diagram of the three-level architecture and data flow of a multi-device collaborative hierarchical control system and method based on parameterized step sequence according to an embodiment of the present invention. Figure 2 This is a diagram of the parameterized step sequence definition and task queue arrangement interface of the multi-device collaborative hierarchical control system and method based on parameterized step sequence according to an embodiment of the present invention. Figure 3 This is a flowchart illustrating the multi-device collaborative execution logic of the multi-device collaborative hierarchical control system and method based on parameterized step sequence according to an embodiment of the present invention. Figure 4 This is a schematic diagram of PLC standardized action logic block calling in the multi-device collaborative hierarchical control system and method based on parameterized step sequence according to an embodiment of the present invention; Figure 5 This is an interface diagram of the anomaly handling and emergency control of the multi-device collaborative hierarchical control system and method based on parameterized step sequence according to an embodiment of the present invention. Detailed Implementation

[0022] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention are within the scope of protection of the present invention.

[0023] like Figure 1-5 As shown, a multi-device collaborative hierarchical control system based on parameterized step sequence according to an embodiment of the present invention includes: Level 1: Upper computer management layer, core functions: 1. Step sequence definition: Create a parameterized step sequence library containing step sequence IDs and parameter variables (such as robot arm coordinates, AGV station, pump flow); 2. Task orchestration: Generate a task queue composed of "step sequence ID + corresponding parameter value"; 3. Access control: Set step sequence editing and task distribution permissions for different roles (operator / engineer) to ensure system security.

[0024] The host computer management layer includes a parameterized step sequence definition module and a parameter verification and fault tolerance control module.

[0025] The parameterized step sequence definition module includes a step sequence ID generation unit, a parameter variable configuration unit, and a step sequence association rule unit. Its working principle and technical parameters are as follows: 1. The step sequence ID uniquely identifies the action unit (e.g., "AGV moves to station" is Seq_01, "robotic arm picks up material" is Seq_02); 2. Parameter variables support dynamic configuration, such as the Seq_01 parameter containing {target_station_id (integer), move_speed (floating-point), wait_flag (boolean)}; 3. The step sequence association rule defines the step sequence dependencies (e.g., "robotic arm picks up material" can only be executed after "AGV arrives in position"), avoiding logical conflicts.

[0026] The parameter verification and fault-tolerant control module includes a parameter range verification unit, an anomaly handling unit, and an emergency reset unit. Its working principle and technical parameters are as follows: 1. Range Verification: The host computer sets parameter thresholds (e.g., peristaltic pump flow rate 0.1-100ml / min). When the range is exceeded, a pop-up warning appears in the monitoring layer, and commands are prohibited from being issued. 2. Anomaly Handling: When equipment execution is abnormal (e.g., AGV obstacle avoidance failure, robotic arm material handling timeout), the PLC automatically triggers retry logic (up to 3 times). If it still fails, the task is paused and a fault code is uploaded. 3. Emergency Reset: Supports one-click reset of the current sequence in the monitoring layer, returning the equipment to a safe state (e.g., robotic arm returning to the origin, AGV returning to the standby area), preventing equipment damage.

[0027] Level 2: Monitoring Layer. Core functions: 1. Instruction Conversion: Parses the host computer task queue into instruction formats recognizable by the PLC (such as PROFINET protocol frames); 2. Visual Monitoring: Real-time display of current step execution status, equipment operating parameters (such as AGV position, robotic arm posture), and fault alarm information; 3. Data Traceability: Stores step execution records (including parameter values, execution time, and equipment status), and supports historical data query and report export.

[0028] Level 3: PLC Execution Layer. Core functions include: 1. Logic Call: Receives instructions from the monitoring layer and calls standardized action logic blocks that match the step sequence ID (such as the FB block controlling AGV movement); 2. Parameter Loading: Assigns the issued parameter values ​​to the logic block input interface to drive physical equipment execution; 3. Status Feedback: Collects equipment execution results (such as "AGV in position" or "robotic arm successfully picked up material") and uploads them to the monitoring layer; 4. Equipment Control: Covers AGVs, robotic arms, and fixed equipment within the station (pumps, valves, conveyors), supporting multi-protocol communication such as PROFINET, Ethernet / IP, and MODBUS.

[0029] The PLC execution layer includes a multi-device spatiotemporal coordination module and a step sequence dynamic adaptation module.

[0030] The multi-device spatiotemporal coordination module includes a PLC timing control unit, an AGV-robotic arm coordinate mapping unit, and an action connection delay compensation unit. Its working principle and technical parameters are as follows: 1. Timing Coordination: The PLC uses a closed-loop control system of "completion signal - instruction issuance." After the previous step is reported as "completed," the next step instruction is issued with a delay of <100ms, ensuring precise action connection; 2. Spatial Coordination: A mapping relationship is established between the AGV station coordinates and the robotic arm's working range (e.g., station 3 corresponds to the robotic arm's material picking coordinates X=1000mm, Y=500mm). The AGV automatically calibrates its position upon arrival at the station, with a spatial deviation of <±3mm; 3. Delay Compensation: A preset compensation time is used to address differences in response speed between different devices (e.g., AGV start-up delay of 200ms, robotic arm start-up delay of 50ms), ensuring synchronized action of multiple devices.

[0031] The step sequence dynamic adaptation module includes a PLC parameter parsing unit, an equipment capability matching unit, and a logic block adaptive calling unit. Its working principle and technical parameters are as follows: 1. Parameter parsing: After receiving parameters, the PLC automatically identifies the type (e.g., speed parameters are in mm / s, force parameters are in N) to avoid parameter mismatch; 2. Capability matching: Real-time acquisition of equipment status (e.g., AGV remaining battery power, robotic arm load). If the parameters exceed the equipment's capability range (e.g., AGV maximum speed 1.5m / s, issued parameter 2m / s), it automatically adjusts to the equipment's rated value and triggers an alarm; 3. Adaptive calling: Automatically switches logic blocks according to the equipment model (e.g., for the same "material picking" step sequence, it calls the FB block of robotic arm A or robotic arm B), without requiring program modification.

[0032] The system also includes a step version management module, comprising a version recording unit, a difference comparison unit, and a rollback unit. Its working principle and technical parameters are as follows: 1. Version Recording: Stores the step modification history (modifier, modification time, parameter changes), supporting version number labeling (e.g., Seq_01_V1.0, Seq_01_V1.1); 2. Difference Comparison: Visually displays the parameter and logical differences between different version steps, facilitating problem localization; 3. Rollback Function: When a new step execution fails, it can be rolled back to a historical stable version with one click, recovery time < 1 minute, reducing production interruption losses.

[0033] A multi-device collaborative hierarchical control method based on parameterized step sequence according to an embodiment of the present invention includes the following steps: 1. Step sequence definition and library construction In the host computer, parameterized steps are defined: "AGV moves to target station" is defined as step sequence Seq_01_MoveAGV, with parameters including {target_station_id (e.g., 3), move_speed (e.g., 1.0m / s), wait_after_arrive (e.g., True, indicating waiting after arrival)}; "Robot arm picks up material" is defined as step sequence Seq_02_RobotPick, with parameters including {pose_id (e.g., the coordinate ID of picking up material at point A), gripper_force (e.g., 20N), arm_speed (e.g., 50% of rated speed)}. All steps are stored in the step sequence library, supporting addition, editing, and deletion operations.

[0034] 2. Task scheduling and distribution The operator arranges production task queues on the host computer. For example, "AGV moves to station 3 → robotic arm picks up material at point A → AGV moves to station 2" would correspond to the following task queue: [(Seq_01_MoveAGV,{3,1.0,True}),(Seq_02_RobotPick,{A,20N,50%}),(Seq_01_MoveAGV,{2,1.2,False})] The host computer sends the task queue to the monitoring layer WINCC via the OPC UA protocol.

[0035] 3. Instruction Conversion and Verification WINCC parses the task queue, first extracting the first step sequence (Seq_01_MoveAGV) and its parameters, and verifying the validity of the parameters (such as whether target_station_id=3 is in the station list, whether move_speed=1.0m / s is ≤ AGV maximum speed 1.5m / s). After the verification is successful, it is converted into PROFINET protocol command {Seq_ID:01,Params:[3,1.0,1]} (1 represents True) and sent to the PLC execution layer.

[0036] 4. Step sequence execution and equipment linkage After receiving the instruction, the PLC searches for the FB_01_MoveAGV function block corresponding to Seq_01_MoveAGV in the standardized action logic block library and calls it, assigning the parameters [3,1.0,1] to the function block input interface; the function block executes its internal logic, sends navigation instructions to the AGV through the industrial wireless network, and controls the AGV to move to station 3 at a speed of 1.0m / s; after the AGV arrives at the station, it sends back a "position signal", and the PLC receives it and uploads the "Seq_01_MoveAGV execution completed" status to WINCC.

[0037] 5. Step sequence reuse and parameter adjustment When the task queue executes to the second step (Seq_02_RobotPick), the PLC calls the FB_02_RobotPick function block, passing in the parameters {20N, 50%}. If the material picking force needs to be adjusted to 25N and the speed to 80% in subsequent production, only the task queue parameters need to be modified in the host computer, without modifying the FB_02_RobotPick function block, thus achieving step reuse. The reuse rate can reach over 90%, reducing programming workload.

[0038] 6. Task Progression and Exception Handling After receiving the "Seq_01_MoveAGV Complete" signal, WINCC automatically issues the next step instruction (Seq_02_RobotPick). If the robotic arm times out (e.g., fails to pick up the material within 10 seconds), the PLC triggers the retry logic (up to 3 times). If it still fails, the fault code "Robot_Pick_Timeout" is uploaded, and WINCC will pop up an alarm. The operator can choose to "reset the step sequence" or "skip the step sequence" to ensure that the task is controllable.

[0039] To facilitate understanding of the above technical solutions of the present invention, the following detailed description of the above technical solutions of the present invention will be provided through specific usage methods.

[0040] In practical use, the multi-device collaborative hierarchical control system based on parameterized step sequence according to the present invention is a collaborative control system based on host computer, monitoring software, PLC, robotic arm and AGV. Its hardware and software adopt mature industrial-grade selections, the system architecture is clear and the deployment is reliable. Those skilled in the art can implement it completely according to the following content.

[0041] The system uses a host computer as the management and scheduling layer, WinCC V7.5 as the monitoring layer, and Siemens S7-1500 PLC as the field control layer. Stable communication is achieved through industrial Ethernet, and the system completes the linkage control, data acquisition, status monitoring and fault handling functions of the robotic arm and AGV.

[0042] The host computer employs a high-performance industrial control computer, responsible for process step editing, task queue management, parameter distribution, and historical data storage. WinCC V7.5, as professional monitoring configuration software, runs on the monitoring host, enabling human-machine interaction, real-time status display, alarm prompts, data logging, and command forwarding. The PLC, as the core execution unit, parses the step sequence number and process parameters issued by the monitoring layer, and calls the corresponding function blocks to complete logical operations, position control, and interlock protection. The robotic arm and AGV complete actions such as picking up and placing materials, positioning and moving, and material transfer according to the PLC output instructions, and provide real-time feedback on position, attitude, and operating status, forming a complete closed-loop control. The communication module ensures high-speed and stable communication between the host computer, monitoring layer, PLC, and AGV, resisting electromagnetic interference in the workshop.

[0043] After system startup, the host computer establishes communication with WinCC, and WinCC establishes an industrial Ethernet connection with the PLC. Operators configure process steps, set parameters, and edit task queues on the host computer interface. After issuing control commands, the monitoring layer parses and forwards the data. The PLC matches the corresponding control logic based on the step ID, driving the robotic arm and AGV to move according to the predetermined sequence. After each step is completed, the PLC provides real-time feedback on the execution result, and the system automatically proceeds to the next step until the entire process is completed.

[0044] The system has comprehensive status monitoring, fault alarm, equipment reset, process retry and skip functions. It can display AGV position, robotic arm posture, sensor data and fault information in real time, and supports local operation and remote monitoring to ensure stable, safe and traceable system operation.

[0045] Upon receiving a stop or reset command, the PLC immediately executes the safety shutdown logic, saves the current operating state, and can quickly restore to the initial conditions according to the command to continue executing subsequent processes, meeting the requirements of continuous and reliable operation of automated production lines.

[0046] 1. System Deployment and Debugging (1) Hardware deployment The host computer and the monitoring layer industrial control computer are deployed in the workshop control room and connected to the PLC through an industrial switch; the PLC is installed in the equipment control cabinet and connected to the local IO module (controlling pumps, valves, and conveyors) through PROFINET, connected to the AGV through industrial Wi-Fi, and connected to the robotic arm through Ethernet / IP; the AGV and robotic arm are deployed on the production site. The AGV has preset station coordinates (such as station 1 and station 2), and the robotic arm has calibrated the operation coordinates (such as picking up material at point A and releasing material at point B). The coordinate mapping relationship is established and stored in the PLC.

[0047] (2) Software development and debugging: 1) Step sequence library construction: Create 10 core steps in the host computer (such as Seq_01_MoveAGV, Seq_02_RobotPick, Seq_03_PumpDispense, etc.), and define the parameters and thresholds of each step sequence (such as Seq_03_PumpDispense flow rate 0.1-100ml / min). 2) PLC logic block development: Develop corresponding FB function blocks for each step sequence, such as FB_01_MoveAGV encapsulating AGV navigation instruction sending and position signal receiving logic, and FB_02_RobotPick encapsulating robotic arm motion trajectory planning and gripper control logic. 3) Communication test: Test the instruction transmission and feedback from the host computer to the PLC to the device, and ensure that the OPCUA protocol transmission delay is <50ms and the PROFINET protocol transmission delay is <20ms; 4) Collaborative debugging: Simulate the task of "AGV moves to station 3 → robotic arm picks up material → AGV moves to station 2" to verify the action connection delay (measured at 80ms) and spatial deviation (measured at ±2mm), and adjust the parameter compensation (e.g., the robotic arm action is triggered 50ms after the AGV arrives at the station).

[0048] 2. Typical Application Scenarios and Implementation Cases (1) Scene description A flexible assembly line in an automotive parts factory needs to achieve multi-device collaboration: "AGV transports workpieces to the assembly station → robotic arm picks up workpieces → conveyor belt transports them to the testing station." Three workpiece models are switched daily, with each model corresponding to different AGV stations, robotic arm picking force, and conveyor belt speed.

[0049] (2) Implementation steps 1) Step sequence definition: Seq_01_MoveAGV: Parameters {target_station_id (1 / 2 / 3, corresponding to 3 types of workpiece assembly stations), move_speed (1.0m / s)}; Seq_02_RobotPick: Parameters {pose_id (A / B / C, corresponding to 3 types of workpiece picking coordinates), gripper_force (15N / 20N / 25N)}; Seq_03_ConveyorRun: Parameter {speed (0.5m / s / 0.8m / s / 1.0m / s)}.

[0050] 2) Task scheduling and execution: When switching to workpiece A, the host computer arranges the task queue as follows: [(Seq_01_MoveAGV,{1,1.0}),(Seq_02_RobotPick,{A,15N}),(Seq_03_ConveyorRun,{0.5m / s})], and sends it to WINCC; After WINCC verifies the parameters, it sends them to the PLC. The PLC calls the corresponding FB block to control the AGV to move to station 1, the robotic arm to pick up the material with a force of 15N, and the conveyor belt to run at 0.5m / s. After the task is completed, WINCC automatically records the execution data (such as AGV movement time 20s, robotic arm material picking time 8s) to support subsequent traceability.

[0051] 3) Replacement and reuse: When switching to workpiece B, only the task queue parameters need to be modified in the host computer: [(Seq_01_MoveAGV,{2,1.0}),(Seq_02_RobotPick,{B,20N}),(Seq_03_ConveyorRun,{0.8m / s})], without modifying the PLC program; Changeover time has been reduced from 2 hours to 5 minutes, increasing production efficiency by 25%.

[0052] (3) Implementation effect Flexible production: The changeover time for all three types of workpieces is less than 10 minutes, meeting the needs of multi-variety production; Collaborative precision: The AGV and robotic arm action connection delay is 80ms, the spatial deviation is ±2mm, and no workpieces fall off; Maintenance cost: The step sequence reuse rate is 92%, the programming workload is reduced by 60%, and the equipment malfunction rate is reduced by 45%.

[0053] In summary, by utilizing the technical solutions of this invention, the separation of action logic and parameters, along with a three-tiered architecture, allows production process switching to only require modification of the host computer's task queue parameters, reducing changeover time from several days to within 10 minutes, thus meeting the flexible production needs of multiple product types. By setting up a multi-device spatiotemporal coordination module, the action connection delay between the AGV and the robotic arm is less than 100ms, and the spatial deviation is less than ±3mm, achieving precise timing and spatial coordination and avoiding manual calibration and material loss. By constructing a standardized action logic block library and parameterized step sequence definitions, the same step sequence can be adapted to different process parameters, increasing the reusability rate to over 90%, thereby significantly reducing programming and maintenance costs. By integrating parameter verification, fault tolerance control, and step sequence version management, the equipment failure rate is reduced by 40%, and production interruption losses are reduced by 70%, significantly enhancing the system's reliability and recoverability. Through standardized module interfaces and a layered architecture, new equipment can be integrated into the system simply by developing corresponding logic blocks, reducing modification costs by 50%, thus greatly improving the system's scalability and integration convenience.

[0054] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. 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 multi-device collaborative hierarchical control system based on parameterized step sequence, characterized in that, include: The upper computer management layer is used to define parameterized step sequences, which include step sequence identifiers and at least one corresponding dynamically configurable process parameter. And used to arrange a task queue consisting of at least one of the parameterized steps and its process parameter values ​​according to the production task; The monitoring layer, which is connected to the upper computer management layer, is used to receive and parse the task queue, and convert the parsed current step sequence identifier and process parameter value into standard control instructions. The PLC execution layer is communicatively connected to the monitoring layer and physical devices, and pre-stores standardized action logic blocks that correspond one-to-one with different sequence identifiers. The PLC execution layer is used to receive the control instructions, call the corresponding standardized action logic block according to the step sequence identifier, and assign the process parameter value to the logic block to drive the multiple physical devices to perform corresponding actions in a coordinated manner, and provide real-time feedback on the execution status to the monitoring layer.

2. The multi-device collaborative hierarchical control system based on parameterized step sequence according to claim 1, characterized in that, The upper computer management layer also includes a parameter verification and fault tolerance control module, which is used to set a threshold range for the process parameters and verify whether the process parameter values ​​are within the corresponding threshold range when arranging or issuing task queues. If they exceed the threshold range, the issuance is prohibited and an alarm is generated.

3. The multi-device collaborative hierarchical control system based on parameterized step sequence according to claim 1, characterized in that, The PLC execution layer includes a multi-device spatiotemporal coordination module, which includes: The timing control unit is used to issue the instruction for the next sequence within a delay of less than 100ms after receiving the completion signal of the previous sequence. The coordinate mapping unit is used to establish the mapping relationship between the station coordinates of the first device and the working range coordinates of the second device, and to automatically calibrate the action coordinates of the second device after the first device is in place. The delay compensation unit is used to preset the compensation time based on the difference in response speed of each device, so as to ensure that multiple devices operate synchronously.

4. The multi-device collaborative hierarchical control system based on parameterized step sequence according to claim 1, characterized in that, The PLC execution layer also includes a step sequence dynamic adaptation module, which includes: The parameter parsing unit is used to automatically identify the type of received process parameter values; The equipment capacity matching unit is used to collect equipment status in real time and automatically adjust the parameters to the equipment's rated value and generate an alarm when the issued process parameter value exceeds the equipment's current capacity range. The adaptive calling unit is used to automatically switch to calling the corresponding standardized action logic block based on the model of the execution device.

5. The multi-device collaborative hierarchical control system based on parameterized step sequence according to claim 1, characterized in that, The system also includes a step sequence version management module, located in the host computer management layer or monitoring layer, which is used to record the modification history of parameterized steps, including version number, modifier, modification time and parameter changes, and supports rolling back the current step sequence to any historical stable version.

6. The multi-device collaborative hierarchical control system based on parameterized step sequence according to claim 1, characterized in that, The PLC execution layer is also used to automatically trigger a preset number of retry logics when the equipment malfunctions. If it still fails, the current task is paused and the fault code is uploaded to the monitoring layer. The monitoring layer provides an interface for resetting or skipping the current abnormal sequence.

7. A multi-device collaborative hierarchical control method based on parameterized step sequence, applied to the system described in any one of claims 1 to 6, characterized in that, Includes the following steps: S1 defines parameterized steps in the upper computer management layer and builds a step library containing step identifiers and dynamically configurable process parameters. S2, based on the production task, arranges a task queue consisting of at least one parameterized step sequence and its specific process parameter values ​​in the upper computer management layer, and sends it down to the monitoring layer; The S3 monitoring layer parses the task queue, verifies the process parameter values ​​of the current step sequence, and converts them into standard control commands to be sent to the PLC execution layer after the verification is successful. The S4 PLC execution layer calls the corresponding pre-stored standardized action logic block according to the step sequence identifier in the received control command, and assigns the process parameter value to the logic block to drive the physical equipment to perform the action; After the S5 physical device completes its action, it sends a status update to the PLC execution layer. The PLC execution layer then reports the status to the host computer management layer through the monitoring layer, triggering the execution of the next sequence in the task queue.

8. The multi-device collaborative hierarchical control method based on parameterized step sequence according to claim 7, characterized in that, The process of driving the physical device to perform actions in step S4 further includes a multi-device spatiotemporal coordination step: Timing coordination: After the previous sequential device sends a completion signal, the PLC execution layer sends an instruction to the next sequential device within a delay of less than 100ms; Spatial coordination: Based on the preset coordinate mapping relationship between the first equipment station and the second equipment's operating range, the movement coordinates of the second equipment are automatically calibrated after the first equipment is in place.

9. The multi-device collaborative hierarchical control method based on parameterized step sequence according to claim 7, characterized in that, The process of driving the physical device to perform actions in step S4 also includes a step sequence dynamic adaptation step: the PLC execution layer parses and identifies the type of process parameter value; obtains the current capability status of the execution device in real time; if the issued process parameter value exceeds the device's capability range, it automatically adjusts to the device's rated value and generates an alarm; and adaptively calls the corresponding standardized action logic block according to the model of the execution device.

10. The multi-device collaborative hierarchical control method based on parameterized step sequence according to claim 7, characterized in that, It also includes exception handling and version management steps: when the equipment performs an exception, the PLC execution layer automatically triggers a retry. If it fails, the task is paused and the fault is uploaded; the operator can reset or skip the abnormal step sequence through the monitoring layer; when the process needs to be modified, the process parameter values ​​in the task queue can be modified through the upper computer management layer, or the parameterized step sequence of the previous version can be rolled back through the version management module to achieve rapid changeover of production tasks.

Images