Intelligent manufacturing control system for prestressed anchor cable
The intelligent manufacturing control system for prestressed anchor cables has solved the problems of low process coordination efficiency, insufficient automation, and lack of process traceability in the manufacturing of prestressed anchor cables. It has achieved efficient and stable production and management, and significantly improved production efficiency and quality stability.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- 中国雅江集团有限公司
- Filing Date
- 2026-05-09
- Publication Date
- 2026-07-21
AI Technical Summary
The existing prestressed anchor cable manufacturing process suffers from problems such as low process coordination efficiency, insufficient automation, untraceable process flow, and insufficient process parallelism, resulting in low production efficiency and poor quality stability.
The prestressed anchor cable intelligent manufacturing control system is adopted, including the production management layer, process monitoring layer and equipment control layer, to achieve a high degree of integration and intelligent collaboration of the entire process. Through material traceability, real-time monitoring and equipment control, the production plan and process flow are optimized to achieve cross-parallel production and closed-loop quality control.
It significantly improves production efficiency by more than 40%, achieves a product qualification rate of over 99.5%, reduces operation and maintenance costs by 30%, and realizes safe production and scientific management.
Smart Images
Figure CN122431292A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of anchor cable manufacturing technology, and more specifically, to an intelligent manufacturing control system for prestressed anchor cables. Background Technology
[0002] As a key load-bearing component in large-scale engineering structures, the manufacturing process of prestressed anchor cables involves more than ten complex steps, including wire storage, material preparation, marking, measurement, cutting, peeling, cleaning, threading, extrusion, binding, and packaging. Currently, the manufacturing methods commonly used in the industry suffer from the following technical bottlenecks:
[0003] 1. Low process coordination efficiency: The manufacturing of prestressed anchor cables involves multiple processes such as wire storage, material cutting, coding, measurement, cutting, peeling, cleaning, threading, extrusion, binding, and packaging. In existing technologies, these processes are mostly operated independently or semi-independently, lacking system-level coordination, resulting in slow production cycle and limited capacity. 2. Insufficient automation: In traditional processes, steps such as the installation of isolation frames and pressure plates rely on manual operation, which is not only inefficient, but also has problems such as inconsistent installation accuracy, high labor intensity, and poor quality stability. 3. Untraceable process flow: Information on each component during production is not linked to the physical product in real time, making quality traceability difficult and hindering the realization of full-process digital management and quality traceability; 4. Insufficient parallelism of processes: The existing production line design has not fully optimized the parallelism of processes. There is waiting time between processes such as material feeding, cleaning, and assembly, which prevents the overall production efficiency from being maximized. Summary of the Invention
[0004] The technical problem to be solved by the present invention is to address the above-mentioned shortcomings of the prior art. The purpose of the present invention is to provide a highly integrated, intelligent, collaborative, and fully traceable intelligent manufacturing control system for prestressed anchor cables.
[0005] The technical solution of this invention is: an intelligent manufacturing control system for prestressed anchor cables, comprising: The production management layer is used to receive production orders, parse product specifications, automatically generate production plans based on product specifications, and allocate production tasks to each sub-production line of the production line according to the production plan to achieve cross-parallel production and maximize equipment utilization; it is also used to establish a material traceability database and generate a unique identifier and quality data package for each product. The process monitoring layer communicates with the production management layer; it is used to monitor the operating status of each step of the production line in real time, collect equipment data, process parameters and quality data, and transmit them to the production management layer; it dynamically displays production progress, equipment status and fault alarm information through a human-machine interface; it stores historical data, generates production reports, quality analysis reports and equipment performance reports; and it provides remote monitoring functions, allowing managers to view production status through the Web or mobile devices. The equipment control layer establishes an industrial-grade encrypted communication connection with the process monitoring layer; it is used to directly control all actuators on the production line, execute specific process control methods, respond to the instructions of the production management layer in real time, adjust production parameters, and collect on-site sensor data and upload it to the process monitoring layer.
[0006] As a further improvement, the equipment control layer includes two parallel sub-production lines and a mobile unloading platform that sequentially supplies materials to the sub-production lines. The mobile unloading platform is equipped with a parallel steel strand unloading production line and a grouting pipe unloading production line. The steel strand unloading production line includes, in sequence, a steel strand pay-off reel, a steel strand coding machine, a steel strand metering machine, a steel strand cutting machine, a stripping machine, a washing and drying machine, and a steel strand traction machine. The grouting pipe unloading production line includes, in sequence, a grouting pipe pay-off reel, a grouting pipe coding machine, a grouting pipe metering machine, and a grouting pipe traction machine. The sub-production lines are respectively equipped with a threading station, an extrusion station, a binding station, a lifting and pushing module, a conveyor chain, a coiling machine, and a packaging machine. Between the two sub-production lines are robots 1 and 2 for jointly completing the extrusion operation. One side of one sub-production line has a robot 3 for placing extrusion sleeves, and the other side of the other sub-production line has a robot 4 for placing extrusion sleeves.
[0007] Furthermore, the production management layer is equipped with a feeding module, which is used to confirm the locking status of the steel strand feeding reel or grouting pipe feeding reel based on the signal from the reel locking position sensor, obtain the batch number of the steel strand feeding reel or grouting pipe feeding reel, bind the batch number with the unique ID of the corresponding servo driver, store it in the database, initialize the servo driver of the steel strand feeding reel or grouting pipe feeding reel, record the material batch information, establish the starting point of the material traceability chain, update the inventory data, reduce the inventory quantity of the corresponding material, and provide a data foundation for subsequent quality traceability. The process monitoring layer displays in real time: the operating status of the loading area, batch number and binding status, communication status and enable status of each servo driver.
[0008] Furthermore, the production management layer is equipped with a branch selection module, which is used to receive the steel strand feeding production line or grouting pipe feeding production line selected by the operator, and to enable all equipment on the corresponding branch, and close the subsequent process channels of the unselected branch to prevent misoperation.
[0009] Furthermore, the production management layer is equipped with a wire feeding module, which controls the wire feeding process of the steel strand feeding production line and the grouting pipe feeding production line, enabling parallel wire feeding of steel strands and grouting pipes; during the wire feeding process, batch information is called to generate QR code data, which is sent to the laser marking machine to trigger marking, and then the vision camera is triggered to read the code. After successful verification, the material is released; the marking is obtained in real time and used to bind it to the material for life. During the feeding process, the cutting pressure and time are dynamically adjusted according to the material diameter, and the cut quality is verified by the vision system; the wear of the cutting blade is judged by the cutting current or the usage time of the cutting blade and an early warning is issued to prompt replacement in advance; Record the coding information, length data, cutting time, and stripping parameters of each steel strand to establish a quality file for each steel strand, providing data support for subsequent traceability, statistically analyze the service life of cutting blades and stripping blades, and optimize spare parts management.
[0010] Furthermore, the production management layer is equipped with a threading module for controlling the movement of the mobile unloading platform and the alignment of the hole positions. The specific process is as follows: based on the product model and the current production progress, the target hole position coordinates are calculated, the mobile unloading platform is controlled to accurately position itself to the target hole position, a secondary positioning correction is performed through the vision system to ensure the hole position alignment accuracy, a "hole position ready" signal is sent to the threading mechanism, and the traction machine is used to push the grouting pipe or steel strand to cooperate with the threading mechanism for threading. During the threading process, the threading resistance F is monitored in real time; If F ≤ F_max, continue threading; stop after detecting the "threading in place" signal, and record the threading time and resistance data; repeat the threading action according to the number of holes of the anchor cable product until the threading task of the current workpiece is completed; If F > F_max, immediately pause the traction machine, record the current resistance value and position; the traction machine should retreat 5cm, then advance at 0.5 times the speed; if the resistance returns to normal, continue threading; if it is still abnormal, trigger the "serious fault" alarm and stop the machine.
[0011] Furthermore, the production management layer is equipped with a production line scheduling module, which is used to arrange the production of two sub-production lines according to the number and sequence of holes in the product, and control the mobile unloading platform to allocate materials to the two sub-production lines. The specific process is as follows: determine the sub-production line to which the current material should be allocated according to the production plan; adopt a cross-allocation strategy: first unload the material for the lower part of the workpiece to the first sub-production line, then unload the material for the lower part of the workpiece to the second sub-production line, and then alternately unload the material for the middle part of the holes and the upper part of the holes; through cross-allocation, robots 1 and 2 can work cross-operate between the two sub-production lines to maximize equipment utilization. Real-time monitoring of the production status of the two production lines and dynamic adjustment of production task allocation, taking into account factors such as equipment maintenance and material supply to optimize production scheduling; conducting balance analysis of the entire production line, identifying bottleneck processes and proposing optimization suggestions.
[0012] Furthermore, the production management layer is equipped with an intelligent extrusion module, which is used to determine the extrusion position according to the process description and the number of holes in the workpiece, and send the extrusion position and process requirements to Robot 1 and Robot 2. Robot 1 and Robot 2 move to the extrusion position to jointly complete the extrusion operation of the extrusion sleeve. During the extrusion operation, the extrusion sleeve release robot of the corresponding sub-production line automatically feeds the extrusion sleeve. The extrusion pressure curve is monitored in real time and compared with the standard curve to calculate the similarity coefficient R. If R ≥ 0.95, it is judged as qualified; if R < 0.8, it is judged as unqualified and the product is marked; otherwise, it is marked for manual re-inspection. Record the pressure curve, location data, and timestamp for each extrusion to create an extrusion process archive.
[0013] Furthermore, the production management layer is equipped with a binding module, which is used to send a binding signal to the binding machine to automatically bind the isolation frame and the pressure plate after all steel strands and grouting pipes have been threaded and the extrusion process has been completed; After the binding is completed, a lifting signal is sent to the lifting and pushing module. The multiple lifting units of the lifting and pushing module lift strictly in sync. After the lifting is in place, the pushing unit pushes the anchor cable to the conveyor chain, and then the lifting and pushing module descends and resets. After the anchor cable is pushed down onto the conveyor chain, the conveyor chain is started. The speed of the conveyor chain is adjusted according to the status of the downstream coiling machine to ensure that the anchor cable can be coiled immediately after being delivered to the coiling machine. The coiled anchor cables are manually hoisted to the packaging machine for packing; Record binding data, coiling data, and packaging data, and improve product assembly records to generate a complete quality data package for the final product, including key parameters and quality inspection results for all processes; associate the complete quality data package with the product's unique QR code so that customers can obtain complete production data and quality reports by scanning.
[0014] Furthermore, the production management layer is equipped with a fault prediction and processing module, which is used to continuously collect operating current, temperature and vibration data of key equipment, establish equipment health models, analyze data change trends, and issue an "early warning" level alarm before the equipment completely fails, prompting preventive maintenance. The warning levels are as follows: Yellow warning, recommending inspection; Orange warning, recommending immediate maintenance; Red warning, recommending immediate maintenance. Establish a three-level alarm system: "emergency-stop", "critical-pause", and "warning-notification"; any safety signal or critical actuator failure will trigger the highest-level alarm and hard-wired safety loop to ensure immediate shutdown. Automatically push alarm information to the mobile devices of relevant personnel; When an alarm or malfunction occurs, the alarm code is displayed on the human-machine interface, and a "diagnostic wizard" window pops up to guide the operator to troubleshoot the fault by following the steps prompted on the interface. Store all fault records, including occurrence time, handling process, and recovery time; automatically generate fault statistical analysis; identify high-frequency fault points and root causes; and provide early reminders for preventive maintenance based on equipment operating time and usage frequency.
[0015] Beneficial effects Compared with the prior art, the advantages of this invention are as follows: 1. Significantly improved production efficiency: Through parallel production, cross-operations, and intelligent scheduling, overall production efficiency is increased by more than 40%.
[0016] 2. Significantly improved quality stability: Full-process digital traceability and closed-loop quality control result in a product qualification rate of over 99.5%.
[0017] 3. Significantly reduced operation and maintenance costs: Intelligent fault prediction and guided troubleshooting reduce unplanned downtime by 60% and maintenance costs by 30%.
[0018] 4. Comprehensive safety assurance: Multi-level safety protection and intelligent early warning to achieve zero major safety accidents.
[0019] 5. Scientific management decision-making: Based on big data analysis and optimization, it supports scientific production decisions and continuous improvement. Attached Figure Description
[0020] Figure 1 This is a diagram of the architecture of the present invention; Figure 2 This is a schematic diagram of the production process control of the present invention. Detailed Implementation
[0021] The present invention will be further described below with reference to specific embodiments shown in the accompanying drawings.
[0022] See Figures 1-2 An intelligent manufacturing control system for prestressed anchor cables includes: The production management layer, including the production management server and database server, is used to receive production orders, parse product specifications (such as different models like 7-hole, 15-hole, 19-hole, and 21-hole), and automatically generate production plans based on product specifications, including: the quantity of steel strands and grouting pipes, the spacing of isolation frames (circular components), the extrusion position and number of times, etc. Production tasks are allocated to each sub-production line (i.e., production line A, production line B) according to the production plan to achieve cross-parallel production and maximize equipment utilization. It is also used to establish a material traceability database, generating a unique identifier and quality data package for each product.
[0023] The process monitoring layer includes a monitoring computer, a human-machine interface (HMI), and a data acquisition server, which communicate with the production management layer. It is used to monitor the operating status of each step of the production line in real time, collect equipment data, process parameters, and quality data, and transmit them to the production management layer. It dynamically displays production progress, equipment status, and fault alarm information through the HMI. It stores historical data, generates production reports, quality analysis reports, and equipment effectiveness (OEE) reports. It also provides remote monitoring functions, allowing managers to view production status via the web or mobile devices.
[0024] The equipment control layer, i.e., the field devices, includes programmable logic controllers (PLCs), servo drives, robot controllers, and dedicated controllers. It establishes an industrial-grade encrypted communication connection with the process monitoring layer. It is used to directly control all actuators on the production line: servo drives, industrial robots, cylinders, motors, etc., to execute specific process control methods, such as tension control, synchronization control, and position control. It responds to the instructions of the production management layer in real time, adjusts production parameters, and collects field sensor data and uploads it to the process monitoring layer.
[0025] The equipment control layer includes two parallel sub-production lines and a moving unloading platform that sequentially supplies materials to the sub-production lines. For example... Figure 2As shown, the mobile unloading platform is installed on the unloading platform track and is accurately positioned by a servo motor. The mobile unloading platform is equipped with parallel steel strand unloading production lines and grouting pipe unloading production lines. The steel strand unloading production line includes, in sequence, a steel strand pay-off reel, a steel strand marking machine (laser marking machine), a steel strand metering machine, a steel strand cutting machine, a stripping machine, a washing and drying machine, and a steel strand traction machine. These components are connected together by a conveyor line to achieve process coordination and automated control, thereby improving process efficiency and increasing production capacity. The grouting pipe unloading production line also includes, in sequence, a grouting pipe pay-off reel, a grouting pipe marking machine, a grouting pipe metering machine, and a grouting pipe traction machine. Similarly, these components are connected together by a conveyor line to achieve process coordination and automated control. The two sub-production lines are designated as Production Line A and Production Line B. Each sub-production line is equipped with a threading station, an extrusion station, a binding station, a lifting and pushing module, a conveyor chain, a coiling machine, and a packaging machine. Similarly, the threading station, extrusion station, and binding station are connected by a conveyor line to achieve process coordination and automated control. The lifting and pushing module and the conveyor chain are located on opposite sides of the conveyor line, and the coiling machine is located at the output end of the conveyor chain. Robots 1 and 2 are installed between the two sub-production lines to jointly complete the extrusion operation. Robot 3, used for placing extruded sleeves, is located on one side of one sub-production line (Production Line A), and robot 4, used for placing extruded sleeves, is located on one side of the other sub-production line (Production Line B).
[0026] I. The production management layer includes a material loading module. The operator uses an overhead crane to hoist the steel strand reel to the steel strand pay-off reel and the grouting pipe reel to the grouting pipe pay-off reel. The operator manually locks the reel locking mechanism, inputting / scanning the batch numbers of both reels on the HMI interface. The process monitoring layer collects the reel locking position sensor signal and transmits it to the feeding module. The feeding module confirms the locking status of the steel strand pay-off reel or grouting pipe pay-off reel based on the reel locking position sensor signal, obtains the batch number of the steel strand pay-off reel or grouting pipe pay-off reel, binds the batch number to the unique ID of the corresponding servo driver, stores it in the database, initializes the servo driver of the steel strand pay-off reel or grouting pipe pay-off reel, and is ready. It also records the material batch information, establishes the starting point of the material traceability chain, updates inventory data, and reduces the inventory quantity of the corresponding material, providing a data foundation for subsequent quality traceability.
[0027] If no locking signal is detected within 30 seconds, the HMI will display a prompt window: "Please check the disk locking mechanism." If the batch number is in an incorrect format or not entered, the HMI will prompt: "Please enter a valid batch number." If the servo drive initialization fails, the system will mark the device as "offline" and attempt to automatically switch to the backup drive.
[0028] Real-time display at the process monitoring layer: HMI Main Interface - Loading Area: Dynamic icons for the steel strand delivery reel / grouting pipe delivery reel station, displaying "No Load", "Ready", and "Running" status.
[0029] Batch number information window: Displays the entered batch number and binding status.
[0030] Device Status Bar: Displays the communication status and enable status of each servo driver.
[0031] II. The production management layer has a branch selection module. The operator clicks the start button on the HMI to select either the "Steel Strand Feeding Line" or the "Grouting Pipe Feeding Line". The branch selection module receives the operator's selection of either the steel strand feeding line or the grouting pipe feeding line and activates all equipment on the corresponding branch, including the traction machine, feed reel, and laser marking machine. It then closes subsequent process channels on unselected branches to prevent accidental operation. The steel strand feed reel / grouting pipe feed reel feeding is then started.
[0032] III. The production management layer is equipped with a wire feeding module. It is used to control the wire laying process of steel strand and grouting pipe feeding production lines, and can realize parallel wire laying of steel strand and grouting pipe.
[0033] The process flow of the steel strand cutting production line is as follows: 1. Steel strand reel unloading → 2. Laser marking for traceability → 3. High-precision measurement → 4. Precision cutting → 5. Peeling → 6. Cleaning and drying → 7. Traction to waiting position.
[0034] The process flow of the grouting pipe feeding production line is as follows: 1. Grouting pipe coil unloading → 2. Laser marking for traceability → 3. High-precision measurement → 4. Precision cutting → 5. Traction to the waiting position.
[0035] During the delivery process, after the laser marking machine receives the "material in place" photoelectric signal, the delivery module retrieves the batch information, generates QR code data, and sends it to the laser marking machine to trigger marking. After the laser marking machine completes marking, it triggers the vision camera to read the code. Once verification is successful, the material is released. The delivery module acquires the marked code in real time for permanent binding with the material. If three consecutive verifications fail, the material is paused and marked as "marking abnormal," while the HMI displays the last NG image for analysis.
[0036] During the wire feeding process, the wire feeding module dynamically adjusts the cutting pressure and time based on the material diameter and sends this information to the cutting machine (steel strand cutting machine or grouting pipe cutting machine). The cutting machine starts cutting after detecting that the material has arrived. After the cutting is complete, the cut quality is verified by the vision system and uploaded. The wire feeding module judges the wear of the cutting blade by the cutting current or the usage time of the cutting blade and issues a warning to prompt replacement in advance.
[0037] The feed module dynamically adjusts the cutting pressure, depth, and length based on the material batch number and sends this information to the peeling machine. The peeling machine initiates peeling upon detecting the material's arrival. After peeling is complete, the material continues to be fed into the washing and drying machine. After washing and drying, the traction machine pulls it to the waiting position. Grouting pipes, however, do not require peeling, washing, or drying after cutting; they are directly pulled to the waiting position.
[0038] The wire laying module records the coding information, length data, cutting time, and stripping parameters of each steel strand / grouting pipe, establishes a quality file for each steel strand / grouting pipe, provides data support for subsequent traceability, statistically analyzes the service life of cutting blades and stripping blades, and optimizes spare parts management.
[0039] Real-time display at the process monitoring layer: Branch line monitoring screen: Displays the real-time speed, current, and synchronization error value of the traction machine and cable reel.
[0040] The system dynamically displays the length of material already cut and the set target length, with a progress bar providing an intuitive overview.
[0041] Tension monitoring curve of the pay-off reel: real-time display of tension value, color-changing alarm when the limit is exceeded.
[0042] The code scanning monitoring sub-screen displays the real-time image from the code scanning camera, and the "Code Scanning Result" list shows the OK / NG status and the code scanned content.
[0043] Measurement display: Large-character display of real-time cumulative length, preset cutting length, and encoder status indicator.
[0044] Equipment operation monitoring: The animation illustrates each step of the cutting process and displays the cutting motor current and cylinder operation status.
[0045] Peeling parameter settings: peeling length, depth, and speed setting boxes, real-time display of the current position and speed of the servo electric cylinder.
[0046] IV. The production management layer is equipped with a threading module. The process for controlling the movement of the mobile unloading platform and the alignment of the holes is as follows: Based on the product model (7 holes, 15 holes, 19 holes, 21 holes, etc.) and the current production progress, the coordinates of the target hole position are calculated. The mobile unloading platform (servo motor) is controlled to accurately position itself to the target hole position with a positioning accuracy of ±0.1mm. A secondary positioning correction is performed through the vision system to ensure the hole alignment accuracy. A "hole position ready" signal is sent to the threading mechanism, and the traction machine is used to push the grouting pipe or steel strand to cooperate with the threading mechanism for threading.
[0047] During the threading process, the threading resistance F (resistance of the traction machine or the resistance of the threading mechanism) is monitored in real time. If F ≤ F_max, continue threading; stop after detecting the "threading in place" signal, and record the threading time and resistance data; repeat the threading action according to the number of holes of the anchor cable product until the threading task of the current workpiece is completed; If F > F_max, immediately stop the traction machine, record the current resistance value and position, and the HMI will pop up a "Resistance Abnormal" warning, showing possible causes: incorrect hole position, material bending, guide mechanism failure; the traction machine will retreat 5cm and then advance at 0.5 times the speed; if the resistance returns to normal, continue threading; if it is still abnormal, trigger a "Critical Fault" alarm and stop the machine.
[0048] Real-time display at the process monitoring layer: Beam threading monitoring interface: Real-time display of beam threading force-displacement curve, preset resistance safety line, and beam threading progress bar.
[0049] Hole guidance screen: Real-time display of hole position images and guide lines captured by the vision system, and hole alignment result (success / failure) indication.
[0050] Equipment status monitoring: Displays the real-time status and alarm information of the traction machine and threading mechanism.
[0051] V. The production management layer includes a production line scheduling module. This system is used to control a moving material feeding platform to distribute materials to two sub-production lines (production line A and production line B) based on the number and sequence of holes in the product. The specific process is as follows: The sub-production line to which the current material should be allocated is determined according to the production plan; a cross-allocation strategy is adopted: first, material for the lower holes of the workpiece is fed to the first sub-production line (production line A), then material for the lower holes of the workpiece is fed to the second sub-production line (production line B), and then material for the middle and upper holes is alternately distributed to production lines A and B. Through cross-allocation, robots 1 and 2 can work cross-operate between the two sub-production lines, maximizing equipment utilization. That is, robot 3 feeds extrusion sleeves to production line A, robot 4 feeds extrusion sleeves to production line B, and robots 1 and 2 cross-operate between production lines A and B to jointly complete the extrusion operation. By rationally arranging the production cycle, the waiting time of robots 1 and 2 is minimized, and their utilization rate is high.
[0052] The production line scheduling module monitors the production status of the two production lines in real time and dynamically adjusts the allocation of production tasks, taking into account factors such as equipment maintenance and material supply to optimize production scheduling; it also performs a balance analysis on the entire production line, identifies bottleneck processes, and proposes optimization suggestions.
[0053] Real-time display at the process monitoring layer: Platform transplantation monitoring: Top-down view, dynamically displays the real-time position of the platform and the target position, real-time display of X / Z axis coordinates, and production line 1 / 2 status indication.
[0054] Production line load monitoring: Displays the current production status, work-in-process quantity, equipment utilization rate, etc. of production lines A and B.
[0055] Production progress dashboard: Visually displays a comparison of the production progress of two production lines.
[0056] VI. The production management layer is equipped with an intelligent extrusion module. This is used to determine the extrusion position according to the process specifications and the number of holes in the workpiece. For example, based on the total length L and number of holes of the product (pressure-dispersing anchor cable), the extrusion positions are calculated three times: First extrusion position: P1 = 0.4 × L (two-fifths of the way); Second extrusion position: P2 = 0.6 × L (three-fifths of the way); Third extrusion position: P3 = 0.8 × L (four-fifths of the way). As extrusion proceeds, the number of steel strands gradually decreases, eventually reducing to two-fifths. The extrusion position and process requirements are sent to Robot 1 and Robot 2. Robot 1 and Robot 2 move to the extrusion position and jointly complete the extrusion sleeve extrusion operation. During the extrusion operation, the corresponding sub-production line's extrusion sleeve feeding robot automatically feeds the extrusion sleeve.
[0057] Cross-operation logic: When the mobile unloading platform unloads materials to production line A, robots 1 and 2 perform extrusion operations on production line B; when the mobile unloading platform unloads materials to production line B, robots 1 and 2 perform extrusion operations on production line A. The waiting time for robots 1 and 2 is minimized by safely scheduling the extrusion operation time and the unloading operation.
[0058] The intelligent extrusion module monitors the extrusion pressure curve in real time and compares it with the standard curve to calculate the similarity coefficient R. If R ≥ 0.95, it is judged as qualified; if R < 0.8, it is judged as unqualified and the product is marked; otherwise, it is marked for manual re-inspection.
[0059] The intelligent extrusion module records the pressure curve, location data, and timestamp of each extrusion, forming an extrusion process archive.
[0060] Real-time display at the process monitoring layer: Robot extrusion workstation screen: A simplified 3D model shows the real-time posture of two robots, compares the real-time extrusion pressure curve with the standard curve, and displays the status of each extrusion position.
[0061] VII. The production management layer is equipped with a binding module. Used to send a binding signal to the binding machine after all steel strands and grouting pipes have been threaded and the extrusion process is completed, so as to automatically bind the isolation frame and pressure plate.
[0062] After the binding is completed, a lifting signal is sent to the lifting and pushing module. The multiple lifting units (electric cylinders) of the lifting and pushing module strictly synchronize the lifting in a bus synchronous periodic position mode. After the lifting is in place, the pushing unit (pneumatic cylinder or electric push rod) pushes the anchor cable to the conveyor chain, and then the lifting and pushing module descends and resets.
[0063] During the lifting process, the actual position of each electric cylinder is collected in real time, and the synchronization error is calculated. ΔP = max(P_actual) - min(P_actual), where max(P_actual) is the highest position and min(P_actual) is the lowest position; If ΔP ≤ 0.5mm, the synchronization is considered good; if 0.5mm < ΔP ≤ 1.0mm, the speed of the lagging electric cylinder is automatically adjusted; if ΔP > 1.0mm, the synchronization is considered to have failed, and the system will immediately stop and sound an alarm.
[0064] Safety interlock: When the safety light curtain in the lifting area is triggered, the lifting will stop immediately.
[0065] After the anchor cable is pushed onto the conveyor chain, the conveyor chain is started. The speed of the conveyor chain is adjusted according to the status of the downstream coiling machine to ensure that the anchor cable can be coiled immediately after being delivered to the coiling machine. The initial speed of the conveyor chain is V_conveyor. The status of the downstream process (coiling machine) is monitored in real time. If the coiling machine is busy, the conveyor speed is automatically reduced; if the downstream is idle, the conveyor speed is automatically increased. The conveyor belt speed V = V_base × (1 + k × ΔT), where ΔT is the downstream waiting time and k is the adjustment coefficient.
[0066] The coiled anchor cables are manually hoisted to the packaging machine for packing.
[0067] The binding module records binding data, coiling data, and packaging data, and completes the product assembly record to generate a complete quality data package for the final product, including key parameters and quality inspection results for all processes. The complete quality data package is associated with the product's unique QR code, allowing customers to obtain complete production data and quality reports by scanning the code.
[0068] Real-time display at the process monitoring layer: Overview of the binding station: Each binding machine icon displays the status of "Waiting / Working / Completed / Fault", and a warning of remaining binding tape.
[0069] Lifting and Pushing Monitoring: Displays the synchronization status of all lifting units (e.g., green / red), the module number and error value of the maximum synchronization error, and the action status of the side pushing mechanism.
[0070] The packaging area at the end of the line displays the operating status of the conveyor line, reeling machine, and baling machine, as well as the number of reel layers, current diameter, and warning of remaining film roll on the baling machine.
[0071] 8. The production management layer is equipped with a fault prediction and handling module. It is used to continuously collect operating current, temperature, and vibration data of key equipment, establish equipment health models, analyze data change trends, and issue "early warning" level alarms before the equipment completely fails, prompting preventive maintenance.
[0072] The warning levels are as follows: Yellow warning, recommending inspection; Orange warning, recommending immediate maintenance; Red warning, recommending immediate maintenance.
[0073] Establish a three-level alarm system: "emergency-stop", "serious-pause", and "warning-notification". Any safety signal (light curtain trigger, door switch opening) or critical actuator failure will trigger the highest level alarm and hard-wired safety circuit to ensure immediate shutdown.
[0074] Alarm information will be automatically pushed to the mobile devices of relevant personnel.
[0075] When an alarm or malfunction occurs, the alarm code is displayed on the human-machine interface, and a "diagnostic wizard" window pops up to guide the operator to troubleshoot the fault by following the on-screen prompts step by step.
[0076] For example, the guided steps are: "Step 1: Check if the indicator light of the photoelectric sensor at station X is on" → "Step 2: If it is not on, check the sensor power supply wiring" → "Step 3: If the power supply is normal, replace the sensor". This greatly reduces the technical threshold and time required for troubleshooting, shortening the average fault diagnosis time by more than 60%.
[0077] The fault prediction and handling module stores all fault records, including occurrence time, handling process, and recovery time. It automatically generates fault statistical analysis, identifies high-frequency fault points and root causes, and provides early reminders for preventive maintenance based on equipment operating time and usage frequency.
[0078] Real-time display at the process monitoring layer: Fault dashboard: Displays current alarm information in real time, sorted by urgency.
[0079] Maintenance reminders: Based on equipment operating time and usage frequency, provide advance reminders for preventative maintenance.
[0080] The process monitoring layer can also display: Fault History: Stores all fault records, including the time of occurrence, the handling process, and the recovery time.
[0081] Fault Analysis Report: Fault statistical analysis, high-frequency fault points and root causes.
[0082] 9. The production management layer includes an optimization and analysis module. The optimization and analysis module is used to implement the following functions: 1. Production efficiency analysis: Real-time calculation of overall equipment efficiency (OEE), analysis of time utilization, performance efficiency, and quality pass rate.
[0083] 2. Capacity Forecasting: Based on historical data and current production pace, forecast future output to assist in production planning.
[0084] 3. Quality trend analysis: Statistically analyze the quality data of each process to identify quality fluctuation trends and potential problems.
[0085] 4. Energy Management: Monitor energy consumption across the entire production line, identify high-energy-consuming processes, and propose energy-saving optimization suggestions.
[0086] 5. Personnel Performance: Record operator operation data and production results to assist in personnel performance management.
[0087] 6. Based on big data analytics and stored production data, automatically optimize process parameters for each stage. For example: Example 1: Automatically adjust the traction speed according to the characteristics of the wire to maximize production efficiency while ensuring quality.
[0088] Example 2: Automatically adjust cleaning and drying parameters based on ambient temperature to ensure a balance between cleaning effectiveness and energy consumption.
[0089] Example 3: Automatically adjust motion parameters based on the degree of equipment wear to compensate for mechanical errors.
[0090] The optimized parameters are automatically saved to the process formula library for use in subsequent production.
[0091] This invention connects the equipment or workstations involved in the prestressed anchor cable manufacturing process, including cable storage, feeding, coding, metering, cutting, peeling, cleaning, threading, extrusion, and binding, through a conveyor line. This integrates the previously independently operated equipment into a whole. The production management layer centrally controls the start-up of all equipment on the production line (i.e., the equipment control layer) to achieve automated production. The process monitoring layer monitors the status of each piece of equipment or workstation in real time and adjusts the control parameters of each piece of equipment or workstation according to the status, ensuring the production cycle of the entire production line and reducing equipment waiting time.
[0092] This invention innovatively integrates the steel strand cutting production line and the grouting pipe cutting production line onto a single mobile cutting platform. It also sets up two production lines (Line A and Line B) for the strand threading, extrusion, and binding processes. Because the strand threading, extrusion, and binding processes are time-consuming, the mobile cutting platform cross-supplys materials to both Line A and Line B, improving the efficiency of both production lines. Furthermore, Line A and Line B share a set of robots 1 and 2 for the extrusion operation, saving one set of robots compared to the original independently operated extrusion stations. The production management layer monitors the entire production line's operating status in real time through the process monitoring layer, rationally scheduling the working rhythm of each piece of equipment, saving waiting time, and improving the overall efficiency of the production line.
[0093] The above are merely preferred embodiments of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the structure of the present invention, and these will not affect the effectiveness of the implementation of the present invention or the practicality of the patent.
Claims
1. An intelligent manufacturing control system for prestressed anchor cables, characterized in that, include: The production management layer is used to receive production orders, parse product specifications, automatically generate production plans based on product specifications, and allocate production tasks to each sub-production line of the production line according to the production plan to achieve cross-parallel production and maximize equipment utilization; it is also used to establish a material traceability database and generate a unique identifier and quality data package for each product. The process monitoring layer is connected to the production management layer in real time; it is used to monitor the operating status of each step of the production line in real time, collect equipment data, process parameters and quality data, and transmit them to the production management layer; it dynamically displays production progress, equipment status and fault alarm information through human-machine interface (HMI); it stores historical data and generates production reports, quality analysis reports and equipment effectiveness (OEE) reports. It also provides remote monitoring capabilities, allowing managers to view production status via the web or mobile devices; The equipment control layer establishes an industrial-grade encrypted communication connection with the process monitoring layer; it is used to directly control all actuators on the production line, execute specific process control methods, respond to the instructions of the production management layer in real time, adjust production parameters, and collect on-site sensor data and upload it to the process monitoring layer.
2. The intelligent manufacturing control system for prestressed anchor cables according to claim 1, characterized in that, The equipment control layer includes two parallel sub-production lines and a mobile unloading platform that sequentially supplies materials to the sub-production lines. The mobile unloading platform is equipped with a parallel steel strand unloading production line and a grouting pipe unloading production line. The steel strand unloading production line includes, in sequence, a steel strand pay-off reel, a steel strand coding machine, a steel strand metering machine, a steel strand cutting machine, a stripping machine, a washing and drying machine, and a steel strand traction machine. The grouting pipe unloading production line includes, in sequence, a grouting pipe pay-off reel, a grouting pipe coding machine, a grouting pipe metering machine, and a grouting pipe traction machine. The sub-production lines are equipped with a threading station, an extrusion station, a binding station, a lifting and pushing module, a conveyor chain, a coiling machine, and a packaging machine. Between the two sub-production lines are robots 1 and 2 for jointly completing the extrusion operation. One side of one sub-production line has a robot 3 for placing extrusion sleeves, and the other side of the other sub-production line has a robot 4 for placing extrusion sleeves.
3. The intelligent manufacturing control system for prestressed anchor cables according to claim 2, characterized in that, The production management layer is equipped with a material feeding module, which is used to confirm the locking status of the steel strand pay-off reel or grouting pipe pay-off reel based on the sensor signal of the reel locking position, obtain the batch number of the steel strand pay-off reel or grouting pipe pay-off reel, bind the batch number with the unique ID of the corresponding servo driver, store it in the database, initialize the servo driver of the steel strand pay-off reel or grouting pipe pay-off reel; and record the material batch information, establish the starting point of the material traceability chain, update the inventory data, reduce the inventory quantity of the corresponding material, and provide a data foundation for subsequent quality traceability. The process monitoring layer displays in real time: the operating status of the loading area, batch number and binding status, communication status and enable status of each servo driver.
4. The intelligent manufacturing control system for prestressed anchor cables according to claim 2, characterized in that, The production management layer is equipped with a branch selection module, which receives the steel strand feeding production line or grouting pipe feeding production line selected by the operator, activates all equipment on the corresponding branch, and closes the subsequent process channels of the unselected branch to prevent misoperation.
5. The intelligent manufacturing control system for prestressed anchor cables according to claim 2, characterized in that, The production management layer is equipped with a wire feeding module, which controls the wire feeding process of the steel strand feeding production line and the grouting pipe feeding production line. It can realize parallel wire feeding of steel strands and grouting pipes. During the wire feeding process, batch information is called to generate QR code data, which is sent to the laser marking machine to trigger marking. Then, the vision camera is triggered to read the code. After successful verification, the material is released. The marking is obtained in real time and used to bind it to the material for life. During the wire laying process, the cutting pressure and time are dynamically adjusted according to the material diameter, and the cut quality is verified through a vision system. The wear of the cutting blade can be judged and an early warning can be issued by judging the cutting current or the usage time of the cutting blade, so as to prompt replacement in advance; Record the coding information, length data, cutting time, and stripping parameters of each steel strand to establish a quality file for each steel strand, providing data support for subsequent traceability, statistically analyze the service life of cutting blades and stripping blades, and optimize spare parts management.
6. The intelligent manufacturing control system for prestressed anchor cables according to claim 2, characterized in that, The production management layer is equipped with a threading module, which is used to control the movement of the mobile unloading platform and the alignment of the hole. The specific process is as follows: according to the product model and the current production progress, the target hole coordinates are calculated, the mobile unloading platform is controlled to accurately position to the target hole, a secondary positioning correction is performed through the vision system to ensure the hole alignment accuracy, a "hole ready" signal is sent to the threading mechanism, and the traction machine is used to push the grouting pipe or steel strand to cooperate with the threading mechanism for threading. During the threading process, the threading resistance F is monitored in real time; If F ≤ F_max, continue threading; stop after detecting the "threading in place" signal, and record the threading time and resistance data; repeat the threading action according to the number of holes of the anchor cable product until the threading task of the current workpiece is completed; If F > F_max, immediately pause the traction machine, record the current resistance value and position; the traction machine should retreat 5cm, then advance at 0.5 times the speed; if the resistance returns to normal, continue threading the cable. If the problem persists, a "critical fault" alarm will be triggered and the system will be shut down.
7. The intelligent manufacturing control system for prestressed anchor cables according to claim 2, characterized in that, The production management layer is equipped with a production line scheduling module, which is used to arrange the production of two sub-production lines according to the number and sequence of holes in the product, and to control the mobile unloading platform to distribute materials to the two sub-production lines. The specific process is as follows: Determine the sub-production line to which the current material should be allocated according to the production plan; adopt a cross-allocation strategy: first feed the material of the lower part of the workpiece to the first sub-production line, then feed the material of the lower part of the workpiece to the second sub-production line, and then alternate the material of the middle part of the hole and the upper part of the hole; through cross-allocation, robots 1 and 2 can work cross-operate between the two sub-production lines to maximize equipment utilization. Real-time monitoring of the production status of the two production lines and dynamic adjustment of production task allocation, taking into account factors such as equipment maintenance and material supply to optimize production scheduling; conducting balance analysis of the entire production line, identifying bottleneck processes and proposing optimization suggestions.
8. The intelligent manufacturing control system for prestressed anchor cables according to claim 2, characterized in that, The production management layer is equipped with an intelligent extrusion module, which is used to determine the extrusion position according to the process instructions and the number of holes in the workpiece, and send the extrusion position and process requirements to Robot 1 and Robot 2. Robot 1 and Robot 2 move to the extrusion position to jointly complete the extrusion operation of the extrusion sleeve. During the extrusion operation, the extrusion sleeve release robot of the corresponding sub-production line automatically feeds the extrusion sleeve. Monitor the extrusion pressure curve in real time, compare it with the standard curve, and calculate the similarity coefficient R; If R ≥ 0.95, it is judged as qualified; if R < 0.8, it is judged as unqualified and the product is marked; otherwise, it is marked for manual review; Record the pressure curve, position data, and timestamp of each extrusion to form an extrusion process file.
9. The intelligent manufacturing control system for prestressed anchor cables according to claim 2, characterized in that, The production management layer is equipped with a binding module, which is used to send a binding signal to the binding machine to automatically bind the isolation frame and the bearing plate after all the steel strands and grouting pipes are threaded and the extrusion process is completed; After the binding is completed, a jacking signal is sent to the jacking and pushing module. The multiple jacking units of the jacking and pushing module jack strictly synchronously. After jacking in place, the side pushing unit pushes the anchor cable onto the conveying plate chain, and then the jacking and pushing module descends and resets; After the anchor cable is pushed onto the conveying plate chain, start the conveying plate chain and adjust the speed of the conveying plate chain according to the status of the downstream coiling machine to ensure that the anchor cable can be coiled immediately after being conveyed to the coiling machine; The coiled anchor cable is manually lifted and transported to the packaging machine for packaging; Record the binding data, coiling data, and packaging data, and complete the product assembly record to generate a complete quality data package for the final product, including the key parameters and quality inspection results of all processes; associate the complete quality data package with the unique QR code of the product so that customers can obtain the complete production data and quality report by scanning.
10. The intelligent manufacturing control system for prestressed anchor cables according to claim 2, characterized in that, The production management layer is equipped with a fault prediction and handling module, which is used to continuously collect the operating current, temperature, and vibration data of key equipment, establish an equipment health model, analyze the data change trend, and issue an "early warning" level alarm before the equipment fails completely to prompt preventive maintenance; The early warning levels include: yellow early warning, suggesting inspection; orange early warning, suggesting recent maintenance; red early warning, suggesting immediate maintenance; Establish a three-level alarm system of "emergency-stop", "serious-pause", and "warning-tip"; any safety signal or key actuator failure will trigger the highest-level alarm and the hard-wired safety circuit to ensure immediate shutdown; Automatically push the alarm information to the mobile devices of relevant personnel; When an alarm or fault occurs, display the alarm code on the human-machine interface and pop up a "diagnosis wizard" window, which is used to guide the operator to perform fault troubleshooting step by step according to the interface prompts; Store all fault records, including the occurrence time, handling process, and recovery time, automatically generate fault statistical analysis, identify high-frequency fault points and root causes, and remind preventive maintenance in advance based on the equipment operation time and usage frequency.