Intelligent automatic assembly production line operation system and control method

Abstract

The application provides an intelligent automatic assembly production line operation system and a control method, and belongs to the technical field of industrial automation control. The system comprises a ground type master console, a PLC, a communication module and an execution module. A touch screen and a physical safety button box are arranged on the ground type master console. The touch screen is used for displaying a dynamically configurable virtual operation panel, and the virtual operation panel is integrated with a virtual function button. The PLC is configured with the following functions: receiving an assembly task identifier, dynamically loading a virtual operation panel configuration for the touch screen, setting a standard process parameter set and a parameter monitoring weight; real-time acquisition of the actual value of the running parameter of the execution module, calculation of the comprehensive deviation index from the standard process parameter set of the current task, comparison with the early warning threshold and the intervention threshold, decision-making according to the comparison result, and driving the execution module to act. The application improves production efficiency, optimizes human-computer interaction, enhances operation safety and reduces maintenance cost.

Description

Technical Field

[0001] This application belongs to the field of industrial automation control technology, specifically relating to an intelligent automatic assembly line operating system and control method. Background Technology

[0002] In the field of industrial automated assembly, automated assembly lines have been widely used in the manufacturing of automotive parts, electronic components, and home appliances. Besides improving efficiency, the structural design and functional intelligence level of automated assembly lines directly impact production efficiency, personnel safety, and product quality.

[0003] In existing technologies, automated assembly lines mainly suffer from the following limitations: First, they are passive monitoring and have delayed responses. Current systems primarily implement parameter setting, status monitoring, and fault alarms, operating on a monitoring-response model. By the time sensors detect that a parameter (such as assembly force) exceeds the limit, a batch of defective products has often already been produced, resulting in wasted materials and time. They lack the ability to analyze and predictively adjust parameter trends in advance. Second, the user interface is rigid and lacks human-machine adaptability. Existing systems' human-machine interfaces (HMIs) are mostly statically designed, unable to dynamically adjust based on operator skill levels, current production tasks, or fatigue levels. For example, new operators face complex parameter setting interfaces, while experienced operators may find the interface too cumbersome, reducing efficiency. This integrated interface design leads to high learning costs, frequent misoperations, a high monthly accidental touch rate, and is prone to causing muscle fatigue. Finally, safety protection and operational processes are disconnected; physical safety buttons (such as emergency stop and reset) are independent of the process control logic within the touchscreen. While it facilitates rapid response in emergencies, it cannot prevent accidental activation of safety buttons at the wrong time, leading to production interruptions or the omission of necessary safety confirmation steps in routine, complex processes.

[0004] Therefore, there is an urgent need for an intelligent assembly line operating system that can proactively predict and adjust production status, dynamically adapt to operators, and achieve deep integration of safety and processes, in order to further improve the overall efficiency of the production line, product qualification rate, and operational safety. Summary of the Invention

[0005] In a first aspect, embodiments of this application provide an intelligent automated assembly line operating system, including a ground-based central control console, a PLC controller, a communication module, and an execution module; The ground-based central control panel is equipped with a touch screen and a physical safety button box; the touch screen is used to display a dynamically configurable virtual operation panel, which integrates at least virtual function buttons for starting and stopping the equipment; The PLC controller is connected to the touch screen, physical safety button box, and communication module. The communication module is used to establish data communication between the PLC controller and the execution module; The PLC controller is configured with the following functions: Receive assembly task identifier, dynamically load the corresponding virtual operation panel configuration for the touch screen based on the assembly task identifier, and set the standard process parameter set and parameter monitoring weight associated with the assembly task. The actual values ​​of the operating parameters of the execution module are obtained in real time through the communication module, and the comprehensive deviation index between the actual values ​​of the operating parameters and the current task standard process parameter set is calculated. The comprehensive deviation index is compared with the warning threshold and intervention threshold under the current task, and a decision is made based on the comparison results to drive the execution of at least one of the following operations: Display warning information on the touchscreen, send parameter fine-tuning instructions to the execution module through the communication module, trigger alarms and lock relevant virtual function buttons on the touchscreen, or record system event logs.

[0006] Furthermore, the virtual function buttons integrated on the virtual operation panel include one or more combinations of pump station start / stop, drive on / stop, and servo on / stop.

[0007] Furthermore, the cabinet height of the ground-mounted central control console meets the preset height range; The ground control console includes an operation panel and outriggers. The operation panel is tilted backward at a set angle relative to the vertical surface of the outriggers. The touchscreen is located on the surface of the control panel; The physical safety button box is embedded in the upper part of the support leg; The physical safety button box is equipped with an emergency stop button, a reset button, an enable switch, and a padlock switch.

[0008] Furthermore, the PLC controller is also configured with the following functions: When any process stage is started via the touchscreen, the function of the reset button in the physical safety button box is dynamically disabled until the corresponding process stage is completed.

[0009] Secondly, embodiments of this application also provide a control method based on the intelligent automated assembly line operating system described in the first aspect, comprising the following steps: The S1.PLC controller receives the assembly task identifier, dynamically loads the corresponding virtual operation panel configuration for the touch screen based on the assembly task identifier, and sets the standard process parameter set and parameter monitoring weight associated with the assembly task. The S2.PLC controller obtains the actual values ​​of the operating parameters of the execution module in real time through the communication module; The S3.PLC controller calculates the comprehensive deviation index between the actual values ​​of the operating parameters and the standard process parameter set for the current task, compares the comprehensive deviation index with the warning threshold and intervention threshold under the current task, and generates decision instructions based on the comparison results. The S4 PLC controller executes decision instructions, driving at least one of the following operations: Display warning information on the touchscreen, send parameter fine-tuning instructions to the execution module through the communication module, trigger alarms and lock relevant virtual function buttons on the touchscreen, or record system event logs.

[0010] Furthermore, the specific steps of step S1 are as follows: S11. Receive assembly task identifiers obtained from an external production management system or entered by the operator on a touchscreen; S12. Based on the assembly task identifier, retrieve the corresponding virtual operation panel configuration file and standard process parameter set from the preset process database; S13. Send the virtual operation panel configuration file to the touch screen for rendering and display, and set the target values ​​of each operating parameter and its monitoring weight in the current task according to the standard process parameter set.

[0011] Furthermore, the specific steps of step S2 are as follows: The S21.PLC controller sends data request commands to each sensor and driver in the execution module through the communication module according to the preset sampling period, and receives feedback data packets containing the actual values ​​of the operating parameters returned by the execution module. The S22.PLC controller parses and converts the feedback data packets to obtain a structured set of actual operating parameter values.

[0012] Furthermore, the specific steps of step S3 are as follows: S31. Calculate the comprehensive deviation index using the following formula. :

[0013] in, For the first The actual values ​​of each operating parameter; For the first standard process parameter set Standard values ​​for each operating parameter; The monitoring weights for the corresponding parameters; This represents the total number of parameters. S32. Calculate the comprehensive deviation index. Compared with the pre-stored warning threshold under the current task and intervention threshold Comparison; among which ; S33. Generate decision instructions based on the comparison results: like Generate normal operation instructions; like Generate early warnings and fine-tune instructions; like Generate an alarm and lock command.

[0014] Furthermore, the specific steps of step S4 are as follows: S41. PLC controller analyzes decision instruction types; If the instruction is a warning and fine-tuning instruction, proceed to step S42; If it is an alarm and lock command, proceed to step S43; S42. Drive the touchscreen to display a high-brightness warning message in the corresponding parameter area; The parameter fine-tuning value is generated based on the preset fine-tuning algorithm, and the parameter fine-tuning value is sent to the corresponding controller of the execution module through the communication module; S43. Trigger the audible and visual alarm and drive the touchscreen to switch to the full-screen alarm page; A lock command is sent to the touchscreen to disable the relevant virtual function buttons on the touchscreen. At the same time, a system event log containing timestamps, a comprehensive deviation index, and snapshots of key parameters is recorded to the storage unit.

[0015] Furthermore, between step S1 and step S2, a safety interlock initialization step is also included: After the touch screen finishes loading the virtual operation panel, the PLC controller checks whether the current task configuration includes a process stage that requires safety interlocking. If so, a disabled flag is set for the reset button in the physical safety button box, and the flag is cleared to restore the reset button function after a signal indicating the completion of the corresponding process stage is received.

[0016] As can be seen from the above technical solutions, this application has the following advantages: The intelligent automated assembly line operating system and control method provided in this application, through a dynamically configurable virtual operation panel and real-time parameter monitoring and adjustment, can quickly adapt to different assembly tasks, reduce production interruptions and defect rates caused by improper parameter settings, thereby improving production efficiency and product quality. The combination of physical safety button boxes and touchscreen operation, along with the application of a safety interlock mechanism, effectively prevents misoperation and improper operation in emergency situations, ensuring operator safety and stable production line operation. The ergonomic design of the ground-mounted central control console and the dynamic loading of the virtual operation panel enable operators to operate more comfortably and conveniently, reducing operator fatigue and improving work efficiency. This application has real-time monitoring and early warning functions, enabling early detection of potential problems and fine-tuning, reducing equipment failures and downtime, extending equipment lifespan, and reducing maintenance costs. This application supports multiple industrial communication protocols, can adapt to different types of assembly line equipment, and has strong versatility and scalability, adapting to different scales and types of production scenarios. Attached Figure Description

[0017] To more clearly illustrate the technical solution of this application, the accompanying drawings used in the description will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the automated assembly line operating system of the present invention.

[0019] Figure 2 This is a front structural diagram of the ground-mounted central control console of the present invention.

[0020] Figure 3 This is a three-dimensional structural diagram of the ground-mounted central control console of the present invention.

[0021] Figure 4 This is a structural schematic diagram of the physical safety button box of the present invention.

[0022] Figure 5 This is a schematic diagram of the virtual operation panel of the present invention.

[0023] Figure 6 This is a flowchart illustrating the control method of the automatic assembly line operating system of the present invention.

[0024] The components are as follows: 1-Ground control console; 1.1-Operation panel; 1.2-Outrigger; 2-PLC controller; 3-Communication module; 4-Execution module; 5-Touch screen; 6-Physical safety button box; 6.1-Emergency stop button; 6.2-Reset button; 6.3-Enable switch; 6.4-Padlock switch; 7-Virtual operation panel; 8-Operator. Detailed Implementation

[0025] The various embodiments of this disclosure will be described more fully in the following detailed description of the intelligent automated assembly line operating system. This disclosure may have various embodiments, and adjustments and changes may be made therein. However, it should be understood that there is no intention to limit the various embodiments of this disclosure to the specific embodiments disclosed herein, but rather this disclosure should be understood to cover all adjustments, equivalents, and / or alternatives falling within the spirit and scope of the various embodiments of this disclosure.

[0026] This embodiment provides an intelligent automated assembly line operating system that improves production efficiency and quality, optimizes human-machine interaction, enhances operational safety, and reduces equipment maintenance costs.

[0027] 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. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] Please see Figure 1 The diagram shown is a schematic of an intelligent automated assembly line operating system in a specific embodiment. The system includes a ground-mounted central control console 1, a PLC controller 2, a communication module 3, and an execution module 4. like Figure 2 and Figure 3 As shown, the ground-mounted central control console 1 is equipped with a touch screen 5 and a physical safety button box 6; the touch screen 5 is used to display a dynamically configurable virtual operation panel 7, such as... Figure 5 As shown, the virtual operation panel 7 integrates at least a virtual function button for starting and stopping the device; PLC controller 2 is connected to touch screen 5, physical safety button box 6 and communication module 3; Communication module 3 is used to establish data communication between PLC controller 2 and execution module 4; PLC controller 2 is configured with the following functions: Receive the assembly task identifier and dynamically load the corresponding virtual operation panel 7 configuration for the touch screen 5 based on the assembly task identifier, while setting the standard process parameter set and parameter monitoring weight associated with the assembly task. The communication module 3 obtains the actual values ​​of the operating parameters of the execution module 4 in real time, and calculates the comprehensive deviation index between the actual values ​​of the operating parameters and the current task standard process parameter set. The comprehensive deviation index is compared with the warning threshold and intervention threshold under the current task, and a decision is made based on the comparison results to drive the execution of at least one of the following operations: Display warning information on touch screen 5, send parameter fine-tuning instructions to execution module 4 through communication module 3, trigger alarm and lock relevant virtual function buttons on touch screen 5 or record system event logs; It should be noted that the ground-mounted central control console 1 adopts a floor-standing structure, requiring no additional support, maximizing space utilization, and is easy to install; its height and the tilt angle of the operation panel 1.1 are ergonomically designed, reducing operator fatigue and improving operational comfort and work efficiency.

[0029] As the core control unit, PLC controller 2 can receive assembly task identifiers and dynamically load the configuration of virtual operation panel 7, set standard process parameter sets and parameter monitoring weights, obtain the actual values ​​of the operating parameters of execution module 4 in real time, and perform comprehensive deviation index calculation and decision-making, thereby realizing intelligent control and optimization management of the production line and improving the automation level and operating efficiency of the system. Communication module 3 establishes stable data communication between PLC controller 2 and execution module 4, ensuring fast and accurate transmission of control signals and data. This enables the system to monitor the operating status of execution module 4 in real time and perform precise control of the equipment, improving the system's response speed and reliability. Execution module 4 receives instructions from PLC controller 2 and executes corresponding actions to complete assembly tasks. It is the actual operation execution part of the production line. Its collaborative work with PLC controller 2 and communication module ensures the normal operation of the production line and the smooth completion of production tasks. The touch screen 5 displays a dynamically configurable virtual operation panel 7, providing an intuitive and convenient human-machine interface, enabling operators 8 to easily start and stop the equipment through virtual function buttons. It can also display warning information and system event logs in real time, improving the convenience of operation and the visualization of information. The embedded installation method of the physical safety button box 6 also enhances its own protective performance and reduces the risk of damage caused by external forces such as collisions; The virtual operation panel 7 is integrated into the touch screen and is dynamically configurable. It can load the corresponding operation interface and function buttons according to different assembly tasks, making the system more adaptable and flexible, meeting the operation needs of different production scenarios, and improving the system's versatility and operational efficiency.

[0030] This embodiment improves production efficiency and product quality, optimizes the human-machine interaction experience, and reduces operator fatigue. It also enhances operational safety, reduces the risk of misoperation, lowers equipment maintenance costs, and improves system versatility.

[0031] Furthermore, as a refinement and extension of the specific implementation of the above embodiments, in order to fully illustrate the specific implementation process in this embodiment, another intelligent automatic assembly line operating system is provided. This system includes a ground-mounted central control console 1, a PLC controller 2, a communication module 3, and an execution module 4. like Figure 2 and Figure 3 As shown, the ground-mounted central control console 1 is equipped with a touch screen 5 and a physical safety button box 6; the touch screen 5 is used to display a dynamically configurable virtual operation panel 7, such as... Figure 5 As shown, the virtual operation panel 7 integrates at least a virtual function button for starting and stopping the device; The ground-based central control console 1 is the interface for human-machine interaction with the 8 operators; PLC controller 2 is connected to touch screen 5, physical safety button box 6 and communication module 3; Communication module 3 is used to establish data communication between PLC controller 2 and execution module 4; PLC controller 2 is configured with the following functions: Receive the assembly task identifier and dynamically load the corresponding virtual operation panel 7 configuration for the touch screen 5 based on the assembly task identifier, while setting the standard process parameter set and parameter monitoring weight associated with the assembly task. The communication module 3 obtains the actual values ​​of the operating parameters of the execution module 4 in real time, and calculates the comprehensive deviation index between the actual values ​​of the operating parameters and the current task standard process parameter set. The comprehensive deviation index is compared with the warning threshold and intervention threshold under the current task, and a decision is made based on the comparison results to drive the execution of at least one of the following operations: Display warning information on touch screen 5, send parameter fine-tuning instructions to execution module 4 through communication module 3, trigger alarm and lock relevant virtual function buttons on touch screen 5 or record system event logs; The virtual function buttons integrated on the virtual operation panel 7 include one or more combinations of pump station start / stop, drive on / stop, and servo on / stop; like Figure 2 and Figure 3 As shown, the cabinet height of the ground-mounted central control console 1 meets the preset height range (e.g., 1.2-1.5 meters). The ground control console 1 includes an operation panel 1.1 and a support leg 1.2. The operation panel 1.1 is tilted backward relative to the vertical surface of the support leg 1.1 at a set angle (e.g., 15-30 degrees). Touchscreen 5 is mounted on the surface of operation panel 1.1; The physical safety button box 6 is installed in an embedded manner on the upper part of the support leg 1.2; like Figure 4As shown, the physical safety button box 6 is fixedly equipped with an emergency stop button 6.1, a reset button 6.2, an enable switch 6.3, and a padlock switch 6.4; the PLC controller 2 is also configured with the following functions: When any process stage is started via touch screen 5, the function of reset button 6.2 in physical safety button box 6 is dynamically disabled until the corresponding process stage is completed. For example, the ground-mounted central control console 1 adopts a floor-standing cabinet structure, abandoning the traditional console and hanging design. The cabinet is made of 1.5mm thick cold-rolled steel plate and the surface is sprayed with gray anti-static powder, which has good anti-interference and environmental adaptability and can be adapted to the complex working conditions of industrial assembly workshops. The core dimensions of the cabinet are as follows: Cabinet height: 1.3m (in line with the preset height range of 1.2-1.5m), suitable for operators to work standing or sitting, without having to bend over or stand on tiptoe; Cabinet width: 0.5m, depth: 0.5m, the total floor space occupied is only 0.25㎡, which is much smaller than the traditional piano-style control panel of 1.5m×0.8m, greatly improving the space utilization rate; The control panel 1.1 is tilted 20° backward relative to the vertical of the outrigger (within the preset tilt angle range of 15-30°), which conforms to the ergonomic design. When the operator 8 is standing, their line of sight can naturally be aligned with the screen, without having to bend over more than 45° to view the panel information, effectively reducing the risk of lumbar muscle strain. The 1.2 outriggers are made of square steel tubing and are equipped with anti-slip rubber pads and fixing bolt holes on the bottom to ensure that the control panel is placed stably and there is no risk of shaking. The physical safety button box 6 is installed in an embedded manner on the upper part of the support leg to avoid protruding collisions. The box size is 150mm×80mm×50mm. It is equipped with a waterproof and dustproof sealing ring on the outside, with a protection level of IP65, which can effectively resist workshop dust, oil stains and small amounts of liquid corrosion. The physical safety button box 6 is equipped with key safety buttons such as an emergency stop button 6.1, a reset button 6.2, an enable switch 6.3, and a padlock switch 6.4, which provide necessary safety protection measures for the system, enabling a rapid response in emergency situations and ensuring the safety of operators and the stable operation of the production line. The touchscreen 5 uses a 32-inch industrial capacitive screen with a resolution of 1920×1080 and a 16:9 aspect ratio. It supports multi-touch operation and is installed in the center of the operation panel 1.1, which is convenient for operators to operate with both hands. The screen response time is ≤5ms, and it has anti-scratch and anti-interference characteristics, and can operate stably in industrial environments for a long time. The physical safety button box 6 integrates four core buttons, with functions clearly distinguished by color and structure, reducing the probability of accidental operation: The emergency stop button 6.1 features a red mushroom-shaped design. It automatically locks when pressed and needs to be rotated to reset, ensuring that the power to the equipment can be quickly cut off in an emergency. The reset button 6.2 is a blue circular button that can only be operated during non-process execution phases; The enable switch 6.3 uses a green rotary switch, which must be kept pressed to start the equipment, preventing accidental start when unattended. The 6.4 padlock switch adopts an ECPL type padlock design, which can lock the switch status during equipment maintenance to prevent others from accidentally starting the equipment.

[0032] PLC controller 2 uses a Siemens S7-1500F series PLC, which has high computing speed and reliability, supports multi-task parallel processing, and has a built-in safety function module to meet industrial safety level requirements; it is equipped with an 8GB industrial SD card as a data storage unit, which supports timed backup and long-term storage of operating parameters and event logs, facilitating later traceability and maintenance. Communication module 3 supports multiple industrial communication protocols such as TCP / IP and PROFINET. The communication interface panel has two RJ45 interfaces and one aviation plug interface. The grounding terminal is made of copper to ensure that the grounding resistance is ≤4Ω, thereby improving the anti-interference capability. Communication module 3 has a maximum transmission rate of 100Mbps, ensuring that control signals and data transmission are real-time, stable, and without delay. The execution module 4 includes assembly robots, press machines, conveyor lines, sensor groups (force sensors, displacement sensors, speed sensors, etc.) and drivers at each workstation of the production line. Each device establishes a data connection with the PLC controller 2 through the communication module 3, receives control commands and provides feedback on the operating status. The preset process database is stored in the SD card of PLC controller 2. For different assembly tasks (such as the assembly of different models of engine cylinder blocks), it stores the corresponding virtual operation panel configuration file, standard process parameter set, parameter monitoring weight, early warning threshold, and intervention threshold. For example, for the assembly task of engine cylinder block of model A, the standard process parameter set includes: standard value of assembly force 5000N, standard value of assembly speed 1.2m / s, standard value of press displacement 10mm, etc., where the assembly force monitoring weight is set to 0.4, the assembly speed monitoring weight is set to 0.3, the press displacement monitoring weight is set to 0.3, the early warning threshold is set to 0.1, and the intervention threshold is set to 0.3. The virtual operation panel 7 is rendered and displayed via the touchscreen 5. It dynamically loads corresponding configurations based on the assembly task identifier. The interface layout is simple and clear, integrating core virtual function buttons without redundant operation elements. For engine block assembly tasks, the virtual operation panel 7 mainly includes: Equipment control area: integrates virtual function buttons for pump station start / stop, drive on / stop, servo on / stop, production line start / pause, etc. The buttons are distinguished by different colors (green for start and red for stop), and there is a clear feedback animation after clicking, which makes it easy for operators to confirm the operation status; Parameter display area: Real-time display of the actual values ​​of the operating parameters of the execution module 4, including assembly force, assembly speed, press displacement, and station completion status. The parameter values ​​are displayed in large font and automatically change color to indicate when they exceed the normal range. Warning and alarm zone: Used to display warning information, alarm codes and handling suggestions. Warning information is highlighted in yellow and alarm information is displayed in a red full-screen pop-up window, accompanied by audible and visual alarm prompts. Task configuration area: Supports operators to input assembly task identifiers, select production batches, and view process requirements. The interface has a data input verification function to avoid invalid parameter input. The PLC controller 2 has a built-in safety interlock logic. After the virtual operation panel is loaded on the touch screen 5, it automatically detects whether the current task configuration includes a process stage that requires safety interlock (such as cylinder pressing, bolt tightening, and other critical processes). If it does, it sets a disabled flag for the reset button 6.2 in the physical safety button box 6. At this time, even if the reset button 6.2 is pressed, the PLC controller 2 will not respond to its operation. Until the process stage is completed, the PLC controller 2 receives the station completion signal, clears the disabled flag, and restores the function of the reset button 6.2. For example, during the cylinder pressing process, the reset button 6.2 is in a disabled state to prevent the operator from accidentally touching it and causing the pressing process to be interrupted, resulting in damage to the workpiece.

[0033] It should be understood that the sequence number of each step in the above embodiments does not imply the order of execution. The execution order of each process should be determined by its function and internal logic, and should not constitute any limitation on the implementation process of the embodiments of the present invention.

[0034] like Figure 2 As shown, the following are embodiments of the control method for the intelligent automatic assembly line operating system provided in this disclosure. This system belongs to the same inventive concept as the intelligent automatic assembly line operating system in the above embodiments. For details not described in detail in the embodiments of the control method for the intelligent automatic assembly line operating system, please refer to the embodiments of the intelligent automatic assembly line operating system described above.

[0035] The method includes the following steps: The S1.PLC controller receives the assembly task identifier, dynamically loads the corresponding virtual operation panel configuration for the touch screen based on the assembly task identifier, and sets the standard process parameter set and parameter monitoring weight associated with the assembly task. It should be noted that the PLC controller receives the assembly task identifier and dynamically loads the virtual operation panel configuration and sets the standard process parameter set and parameter monitoring weights accordingly. This enables the system to quickly adjust the operation interface and parameter settings according to different assembly tasks, improving the system's adaptability and response speed, and providing operation guidance and monitoring basis for the subsequent production process. The S2.PLC controller obtains the actual values ​​of the operating parameters of the execution module in real time through the communication module; It should be noted that the PLC controller obtains the actual values ​​of the operating parameters of the execution module in real time through the communication module, ensuring that the system can grasp the real-time operating status of the production line in a timely and accurate manner, providing reliable data support for deviation index calculation and decision-making, and enabling the system to effectively monitor and adjust the production process; The S3.PLC controller calculates the comprehensive deviation index between the actual values ​​of the operating parameters and the standard process parameter set for the current task, compares the comprehensive deviation index with the warning threshold and intervention threshold under the current task, and generates decision instructions based on the comparison results. It should be noted that this step enables real-time evaluation and intelligent decision-making of the production process, allowing the system to take timely measures based on the degree of deviation, such as early warning, parameter fine-tuning, or alarm locking, thus avoiding production problems caused by excessive parameter deviation and improving the stability of the production process and product quality. The S4 PLC controller executes decision instructions, driving at least one of the following operations: Display warning information on the touch screen, send parameter fine-tuning instructions to the execution module through the communication module, trigger alarms and lock relevant virtual function buttons on the touch screen or record system event logs; It should be noted that this step can promptly remind operators to pay attention to abnormal situations in the production process and take corresponding measures to deal with them. At the same time, through the functions of parameter fine-tuning and alarm locking, it can automatically adjust and protect the production process to ensure the safe, stable and efficient operation of the production process.

[0036] This embodiment improves production efficiency and product quality, optimizes human-machine interaction, reduces operator fatigue, enhances operational safety, reduces the risk of misoperation, lowers equipment maintenance costs, and improves system versatility.

[0037] Furthermore, as a refinement and extension of the specific implementation of the above embodiments, in order to fully illustrate the specific implementation process in this embodiment, another control method for an intelligent automatic assembly line operating system is provided. Taking the assembly task of engine block model A as an example, the method includes the following steps: S1. The PLC controller receives the assembly task identifier, dynamically loads the corresponding virtual operation panel configuration for the touch screen based on the assembly task identifier, and sets the standard process parameter set and parameter monitoring weights associated with the assembly task; the specific steps of step S1 are as follows: S11. Receive assembly task identifiers obtained from an external production management system or entered by the operator on a touchscreen; S12. Based on the assembly task identifier, retrieve the corresponding virtual operation panel configuration file and standard process parameter set from the preset process database; S13. Send the virtual operation panel configuration file to the touch screen for rendering and display, and set the target values ​​of each operating parameter and its monitoring weight in the current task according to the standard process parameter set; For example, the PLC controller receives the assembly task identifier "engine block A" sent from an external production management system, or the identifier entered by the operator through the task configuration area of ​​the touch screen; Based on the task identifier "Engine Cylinder Block A", the PLC controller retrieves the corresponding virtual operation panel configuration file, standard process parameter set (assembly force 5000N, assembly speed 1.2m / s, press-fit displacement 10mm), parameter monitoring weights (0.4, 0.3, 0.3), early warning threshold 0.1, and intervention threshold 0.3 from the process database; The PLC controller sends the virtual operation panel configuration file to the touch screen, which then renders and displays the corresponding operation interface. Simultaneously, it sets the target values ​​for each operating parameter according to the standard process parameter set and stores the monitoring weights of each parameter, thus completing system initialization. The PLC controller detects that the current task includes process stages that require safety interlocking, such as pressing and tightening, and sets a disabled flag for the reset button in the physical safety button box, temporarily disabling the reset button function; S2. The PLC controller obtains the actual values ​​of the operating parameters of the execution module in real time through the communication module; the specific steps of step S2 are as follows: The S21.PLC controller sends data request commands to each sensor and driver in the execution module through the communication module according to the preset sampling period, and receives feedback data packets containing the actual values ​​of the operating parameters returned by the execution module. The S22.PLC controller parses and converts the feedback data packets to obtain a structured set of actual values ​​of operating parameters. For example, the PLC controller sends data request commands to the force sensor, speed sensor, displacement sensor and each driver in the execution module through the communication module according to a preset sampling period (100ms); after receiving the command, each sensor and driver collects the actual value of the current operating parameters, generates a feedback data packet and returns it to the PLC controller. The PLC controller parses and converts the feedback data packets to obtain a structured set of actual values ​​of operating parameters, such as: actual assembly force 4900N, actual assembly speed 1.15m / s, and actual pressing displacement 9.8mm. S3. The PLC controller calculates the comprehensive deviation index between the actual values ​​of the operating parameters and the standard process parameter set for the current task. It then compares this comprehensive deviation index with the warning and intervention thresholds for the current task and generates decision instructions based on the comparison results. The specific steps of step S3 are as follows: S31. Calculate the comprehensive deviation index using the following formula. :

[0038] in, For the first The actual values ​​of each operating parameter; For the first standard process parameter set Standard values ​​for each operating parameter; The monitoring weights for the corresponding parameters; This represents the total number of parameters. S32. Calculate the comprehensive deviation index. Compared with the pre-stored warning threshold under the current task and intervention threshold Comparison; among which ; S33. Generate decision instructions based on the comparison results: like Generate normal operation instructions; like Generate early warnings and fine-tune instructions; like Generate an alarm and lock command; For example, the PLC controller calculates the comprehensive deviation index according to the following formula:

[0039] in, The actual value of the i-th running parameter. Let i be the standard value of the i-th running parameter. Let n be the monitoring weight of the i-th parameter, and n be the total number of parameters. Substituting the current parameter values, the assembly force deviation is calculated as follows: 0.4 × |(4900-5000) / 5000| = 0.4 × 0.02 = 0.008 Assembly speed deviation: 0.3 × |(1.15-1.2) / 1.2| ≈ 0.3 × 0.0417 ≈ 0.0125 Press-fit displacement deviation: 0.3 × |(9.8-10) / 10| = 0.3 × 0.02 = 0.006 The overall deviation index Δ = 0.008 + 0.0125 + 0.006 = 0.0265 The current task's warning threshold is 0.1, the intervention threshold is 0.3, and the calculated comprehensive deviation index is 0.0265 < warning threshold 0.1; Based on the comparison results, the PLC controller generates normal operation instructions; If, during subsequent operation, equipment wear causes the actual assembly force to change to 5600N, while other parameters remain unchanged, then: Assembly force deviation: 0.4 × |(5600-5000) / 5000| = 0.4 × 0.12 = 0.048 Assembly speed deviation: 0.3 × |(1.15-1.2) / 1.2| ≈ 0.0125 Press-fit displacement deviation: 0.3 × |(9.8-10) / 10| = 0.006 The overall deviation index Δ = 0.048 + 0.0125 + 0.006 = 0.0665. At this point, the warning threshold 0.1 > Δ > the normal range, and the PLC controller generates a warning and fine-tunes the command. If the actual assembly force continues to increase to 6500N, while other parameters remain unchanged: Assembly force deviation: 0.4 × |(6500-5000) / 5000| = 0.4 × 0.3 = 0.12 The overall deviation index Δ = 0.12 + 0.0125 + 0.006 = 0.1385 > the warning threshold of 0.1 and < the intervention threshold of 0.3, so a warning is still generated and a fine-tuning instruction is given; When the actual assembly force reaches 7000N: Assembly force deviation: 0.4 × |(7000-5000) / 5000| = 0.4 × 0.4 = 0.16 The overall deviation index Δ = 0.16 + 0.0125 + 0.006 = 0.1785, which is still within the warning fine-tuning range; If the actual assembly force suddenly changes to 8000N: Assembly force deviation: 0.4 × |(8000-5000) / 5000| = 0.4 × 0.6 = 0.24 The overall deviation index Δ = 0.24 + 0.0125 + 0.006 = 0.2585, which is close to the intervention threshold; When the actual assembly force reaches 8500N: Assembly force deviation: 0.4 × |(8500-5000) / 5000| = 0.4 × 0.7 = 0.28 The overall deviation index Δ = 0.28 + 0.0125 + 0.006 = 0.2985, which still does not exceed the intervention threshold; Until the actual assembly force reaches 9000N: Assembly force deviation: 0.4 × |(9000-5000) / 5000| = 0.4 × 0.8 = 0.32 The overall deviation index Δ = 0.32 + 0.0125 + 0.006 = 0.3385 > the intervention threshold of 0.3, so the PLC controller generates an alarm and locks the device. The S4 PLC controller executes decision instructions, driving at least one of the following operations: The steps of step S4 are as follows: displaying warning information on the touchscreen, sending parameter fine-tuning instructions to the execution module via the communication module, triggering an alarm and locking the relevant virtual function buttons on the touchscreen, or recording system event logs. S41. PLC controller analyzes decision instruction types; If the instruction is a warning and fine-tuning instruction, proceed to step S42; If it is an alarm and lock command, proceed to step S43; S42. Drive the touchscreen to display a high-brightness warning message in the corresponding parameter area; The parameter fine-tuning value is generated based on the preset fine-tuning algorithm, and the parameter fine-tuning value is sent to the corresponding controller of the execution module through the communication module; S43. Trigger the audible and visual alarm and drive the touchscreen to switch to the full-screen alarm page; Send a lock command to the touchscreen to disable the relevant virtual function buttons on the touchscreen. At the same time, record the system event log, which includes timestamps, comprehensive deviation index and snapshots of key parameters, to the storage unit. For example, normal operation of instruction execution: The PLC controller maintains the current operating status, the touch screen parameter display area displays the actual values ​​of each operating parameter normally, there are no warning prompts, and all virtual function buttons can be operated normally; Warning and fine-tuning of command execution: The touchscreen displays a bright yellow warning message next to the assembly force value in the parameter display area: "Assembly force is too high, automatic fine-tuning has been performed." The PLC controller generates parameter fine-tuning values ​​based on a preset fine-tuning algorithm (proportional-integral control algorithm) and the comprehensive deviation index and the degree of deviation of each parameter. For example, when the actual assembly force is 5600N, the calculated fine-tuning value is -300N. The PLC controller sends the assembly force fine-tuning command to the press machine's driver through the communication module. After receiving the instruction, the driver adjusts the output force of the press to 5300N, and then continuously monitors the parameter changes until the actual value of the operating parameters returns to a reasonable range, at which point the warning information is automatically eliminated.

[0040] Alarm and lock command execution: The PLC controller triggers the audible and visual alarm, emitting a continuous audible and visual alarm signal. At the same time, it drives the touch screen to switch to a full-screen red alarm page, displaying the alarm code "ALM-001", the alarm cause "assembly force seriously exceeded the standard", and the handling suggestion "check the hydraulic system of the press machine, and reset it after troubleshooting". Send a lock command to the touchscreen to make the virtual function buttons related to device start / stop, parameter adjustment, etc. grayed out and inoperable to prevent operator error. Record system event logs to the storage unit. The log content includes alarm timestamps (accurate to milliseconds), comprehensive deviation index of 0.3385, actual values ​​of each parameter (assembly force 8500N, assembly speed 1.15m / s, press displacement 9.8mm) and snapshots of key parameters, which facilitates troubleshooting in the future. Once all process stages of the engine block assembly task are completed, the PLC controller receives the completion signal from each workstation, clears the disabled flag of the reset button in the physical safety button box, and the operator can press the reset button to reset the equipment status to the initial state. The data storage unit automatically records statistical information such as the pass rate and production time of this production batch, and the system waits for the input of the next assembly task identifier.

[0041] In some embodiments, unlike the embodiments described above, a safety interlock initialization step is included between step S1 and step S2: After the touch screen finishes loading the virtual operation panel, the PLC controller checks whether the current task configuration includes a process stage that requires safety interlocking. If so, a disabled flag is set for the reset button in the physical safety button box, and the flag is cleared to restore the reset button function after a signal indicating the completion of the corresponding process stage is received.

[0042] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An intelligent automated assembly line operating system, characterized in that, It includes a ground-mounted central control console (1), a PLC controller (2), a communication module (3), and an execution module (4); The ground-based central control console (1) is equipped with a touch screen (5) and a physical safety button box (6); the touch screen (5) is used to display a dynamically configurable virtual operation panel (7), which integrates at least virtual function buttons for starting and stopping the equipment; The PLC controller (2) is connected to the touch screen (5), the physical safety button box (6), and the communication module (3); The communication module (3) is used to establish data communication between the PLC controller (2) and the execution module (4); The PLC controller (2) is configured with the following functions: Receive assembly task identifier and dynamically load the corresponding virtual operation panel (7) configuration for touch screen (5) based on assembly task identifier, while setting the standard process parameter set and parameter monitoring weight associated with assembly task; The actual values ​​of the operating parameters of the execution module (4) are obtained in real time through the communication module (3), and the comprehensive deviation index between the actual values ​​of the operating parameters and the current task standard process parameter set is calculated. The comprehensive deviation index is compared with the warning threshold and intervention threshold under the current task, and a decision is made based on the comparison results to drive the execution of at least one of the following operations: Display warning information on the touch screen (5), send parameter fine-tuning instructions to the execution module (4) through the communication module (3), trigger an alarm and lock the relevant virtual function buttons on the touch screen (5) or record system event logs.

2. The intelligent automatic assembly line operating system according to claim 1, characterized in that, The virtual function buttons integrated on the virtual operation panel (7) include one or more combinations of pump station start / stop, drive on / stop, and servo on / stop.

3. The intelligent automatic assembly line operating system according to claim 1, characterized in that, The cabinet height of the ground-mounted central control console (1) meets the preset height range; The ground control console (1) includes an operation panel (1.1) and a support leg (1.2). The operation panel (1.1) is tilted backward relative to the support leg (1.2) at a set angle. The touchscreen (5) is mounted on the surface of the operation panel (1.1); The physical safety button box (6) is installed in an embedded manner on the upper part of the support leg (1.2); The physical safety button box (6) is fixedly equipped with an emergency stop button (6.1), a reset button (6.2), an enable switch (6.3), and a padlock switch (6.4).

4. The intelligent automated assembly line operating system according to claim 3, characterized in that, The PLC controller (2) is also configured with the following functions: When any process stage is started via the touch screen (5), the function of the reset button (6.2) in the physical safety button box (6) is dynamically disabled until the corresponding process stage is completed.

5. A control method based on the intelligent automatic assembly line operating system according to any one of claims 1-4, characterized in that, Includes the following steps: The S1.PLC controller receives the assembly task identifier, dynamically loads the corresponding virtual operation panel configuration for the touch screen based on the assembly task identifier, and sets the standard process parameter set and parameter monitoring weight associated with the assembly task. The S2.PLC controller obtains the actual values ​​of the operating parameters of the execution module in real time through the communication module; The S3.PLC controller calculates the comprehensive deviation index between the actual values ​​of the operating parameters and the standard process parameter set for the current task, compares the comprehensive deviation index with the warning threshold and intervention threshold under the current task, and generates decision instructions based on the comparison results. The S4 PLC controller executes decision instructions, driving at least one of the following operations: Display warning information on the touchscreen, send parameter fine-tuning instructions to the execution module through the communication module, trigger alarms and lock relevant virtual function buttons on the touchscreen, or record system event logs.

6. The control method according to claim 5, characterized in that, The specific steps of step S1 are as follows: S11. Receive assembly task identifiers obtained from an external production management system or entered by the operator on a touchscreen; S12. Based on the assembly task identifier, retrieve the corresponding virtual operation panel configuration file and standard process parameter set from the preset process database; S13. Send the virtual operation panel configuration file to the touch screen for rendering and display, and set the target values ​​of each operating parameter and its monitoring weight in the current task according to the standard process parameter set.

7. The control method according to claim 5, characterized in that, The specific steps of step S2 are as follows: The S21.PLC controller sends data request commands to each sensor and driver in the execution module through the communication module according to the preset sampling period, and receives feedback data packets containing the actual values ​​of the operating parameters returned by the execution module. The S22.PLC controller parses and converts the feedback data packets to obtain a structured set of actual operating parameter values.

8. The control method according to claim 5, characterized in that, The specific steps of step S3 are as follows: S31. Calculate the comprehensive deviation index using the following formula. : in, For the first The actual values ​​of each operating parameter; For the first standard process parameter set Standard values ​​for each operating parameter; The monitoring weights for the corresponding parameters; This represents the total number of parameters. S32. Calculate the comprehensive deviation index. Compared with the pre-stored warning threshold under the current task and intervention threshold Comparison; among which ; S33. Generate decision instructions based on the comparison results: like Generate normal operation instructions; like Generate early warnings and fine-tune instructions; like Generate an alarm and lock command.

9. The control method according to claim 8, characterized in that, The specific steps of step S4 are as follows: S41. PLC controller analyzes decision instruction types; If the instruction is a warning and fine-tuning instruction, proceed to step S42; If it is an alarm and lockout command, proceed to step S43; S42. Drive the touchscreen to display a high-brightness warning message in the corresponding parameter area; The parameter fine-tuning value is generated based on the preset fine-tuning algorithm, and the parameter fine-tuning value is sent to the corresponding controller of the execution module through the communication module; S43. Trigger the audible and visual alarm and drive the touchscreen to switch to the full-screen alarm page; A lock command is sent to the touchscreen to disable the relevant virtual function buttons on the touchscreen. At the same time, a system event log containing timestamps, a comprehensive deviation index, and snapshots of key parameters is recorded to the storage unit.

10. The control method according to claim 5, characterized in that, Between step S1 and step S2, a safety interlock initialization step is also included: After the touch screen finishes loading the virtual operation panel, the PLC controller checks whether the current task configuration includes a process stage that requires safety interlocking. If so, a disabled flag is set for the reset button in the physical safety button box, and the flag is cleared to restore the reset button function after a signal indicating the completion of the corresponding process stage is received.

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