A shower curtain buckle automatic processing production line program control method

Abstract

The application relates to the technical field of automatic processing control, and discloses a program control method for an automatic processing production line of a shower curtain buckle ring, which comprises the following steps: establishing a processing technology table, a station type table, a control parameter table and a defect back-checking table before production is started, confirming the initial state of each station, assigning a virtual number to the buckle ring after the buckle ring enters the production line, forming a station processing record according to the number, generating a release permission mark according to the station processing record, distributing the beat deviation amount to an adjustable waiting station after the beat deviation amount is calculated according to the station stay time, generating a complete production record after detecting a defect code output by the station, determining a candidate back-checking station and correcting the amplitude according to the defect back-checking table, determining a sorting path and saving production data. The buckle ring cross-station data is associated with the virtual number and the station processing record, the station stay time, the positioning state value, the processing state value and the station abnormal code are used for release judgment, beat deviation amount calculation and defect back-checking, and the production data is used for control.

Description

Technical Field

[0001] This invention relates to the field of automated processing control technology, specifically to a program control method for an automated processing production line for shower curtain buckles. Background Technology

[0002] An automated production line for shower curtain fasteners typically includes stages such as material feeding and sequencing, conveying and positioning, processing execution, inspection and sorting, and control. The fasteners continuously flow between different workstations, and the workstation dwell time, positioning status values, processing status values, and workstation exception codes generated at each workstation need to maintain a corresponding relationship with the same fastener. Existing control methods, during the fastener's cross-workstation flow, usually rely on the current signal or partial record of the workstation for control. The data association formed by the fastener passing through different workstations is incomplete, making it difficult to use the same set of workstation processing records for release judgment, cycle time deviation calculation, and defect review.

[0003] During the manufacturing process of shower curtain fasteners, some stations directly affect the forming or fastening state of the fasteners. These forming protection stations need to meet the minimum allowable processing time requirements. Existing control methods often struggle to accurately distinguish between forming protection stations and adjustable waiting stations when processing cycle time. Cycle time deviations cannot be stably allocated to currently adjustable waiting stations, easily leading to a lack of clear data boundaries between cycle time adjustments and forming protection constraints. This affects the release determination and flow path determination of the fasteners in subsequent stations.

[0004] After the inspection station outputs a defect code, existing control methods often struggle to establish a correspondence between the defect code and the processing records of the preceding station based on a defect lookup table. Control parameter corrections are prone to detaching from the station dwell time, positioning status value, processing status value, and station anomaly code of the candidate lookup station. Furthermore, the parameter correction amount lacks constraints on control parameter boundaries and single correction limits, resulting in insufficient correlation between parameter correction records and the complete production record. Therefore, establishing a program control method that combines cross-station recording of shower curtain buckles, cycle time allocation, and defect lookup correction in an automated shower curtain buckle production line is a problem that needs to be solved in this field. Summary of the Invention

[0005] To address the shortcomings of existing technologies, this invention provides a program control method for an automated production line for shower curtain buckles. This method solves the problems of incomplete cross-station data association for buckles, difficulty in limiting and allocating cycle time deviation to adjustable waiting stations, and insufficient association between defect detection codes and control parameter correction for candidate back-check stations, which leads to a lack of unified data foundation for release judgment, cycle time processing, and parameter correction.

[0006] To address the above problems, the present invention provides the following technical solution: This invention provides a program control method for an automated production line for shower curtain fasteners, employing the following technical solution: A program control method for an automated production line for shower curtain fasteners includes: Before production starts, establish a processing technology table, workstation type table, control parameter table, and defect review table, and confirm the initial status of each workstation. After the buckle enters the production line, a virtual number is assigned, and the workstation processing record formed by the buckle passing through each workstation is recorded according to the virtual number. Based on the processing record of the workstation, the release judgment is made on the status of the buckle in the forming protection workstation to generate a release permission mark, and the cycle deviation is calculated based on the workstation dwell time and then allocated to an adjustable waiting workstation. After the detection station outputs the detection defect code, a complete production record is generated. Based on the defect back-check table, candidate back-check stations are determined and back-check judgment values ​​are calculated. When the back-check judgment value meets the correction conditions, the control parameters of the candidate back-check stations are limited and corrected, and a parameter correction record is generated. The sorting path is determined based on the detected defect code, the release permission mark, and the workstation exception code, and the production data is saved.

[0007] By adopting the above technical solution, the control process first establishes a correspondence between the buckle and the processing records of each workstation through the virtual number, and then uses the workstation processing records as the data basis for release judgment, cycle time allocation and defect review and correction, so that the time status, positioning status, processing status and abnormal status of the buckle in the cross-workstation flow can be continuously called.

[0008] The release decision of the molding protection station, the cycle time processing of the adjustable waiting station, and the back-check of the preceding station corresponding to the defect code are all incorporated into the same control process. This allows for cycle time adjustment of waiting stations without compressing the necessary processing conditions of the molding protection station, and restrictive correction of relevant control parameters after abnormality detection.

[0009] Furthermore, the processing schedule includes the standard processing time, minimum allowable processing time, maximum allowable waiting time, allowable range of process status, and release conditions for each station; The workstation type table divides the workstations in the production line into material loading and sorting workstations, forming protection workstations, adjustable waiting workstations, inspection workstations, and sorting workstations. The control parameter table includes the adjustable control parameters and corresponding parameter boundaries for each workstation. The defect lookup table includes the correspondence between the detected defect code and the previous workstation, the data type to be read for processing, and the control parameters that allow for correction.

[0010] By adopting the above technical solution, a unified configuration basis is established before production starts, including workstation types, processing times, control parameter boundaries, and defect backtracking relationships. The roles of different workstations in the control process are distinguished, and subsequent cycle time allocation and parameter correction can be executed according to preset workstation attributes and parameter boundaries.

[0011] Furthermore, the step of confirming the initial state of each workstation is as follows: Perform legality checks on processing time parameters and control parameters; Perform execution status confirmation, detection status confirmation, and communication status confirmation for each workstation; When all workstations meet the initial state requirements, the production line is allowed to enter automatic operation mode; if any workstation fails to meet the initial state requirements, automatic operation is prohibited and the corresponding workstation's initial state abnormality information is output.

[0012] By adopting the above technical solution, the production line completes parameter validity and workstation status confirmation before entering automatic operation, which can avoid directly starting processing when processing time parameters, control parameters, or workstation status are out of bounds. Initial state anomaly information is associated with the corresponding workstation, making it easier for the control program to locate the source of the anomaly.

[0013] Furthermore, the step of assigning a virtual number to the buckle after it enters the production line, and recording the station processing records formed by the buckle passing through each station based on the virtual number, is as follows: The virtual number is generated after the buckle entry signal is detected; Maintain a numbered queue for each workstation according to the workstation flow direction, and update the numbered queue synchronously after the buckle transfer signal is confirmed; The entry and exit times of the buckle are recorded when it enters and leaves each workstation. The dwell time at the workstation is calculated. The positioning status value, processing status value and the workstation error code are collected simultaneously to form the processing record of the workstation.

[0014] By adopting the above technical solution, the virtual number moves between workstations along with the buckle, and the numbering queue is updated synchronously with the buckle transfer signal, enabling data generated by the same buckle at different workstations to be grouped into the same record. The entry time, exit time, and workstation status data together form the workstation processing record, providing process data for subsequent judgment.

[0015] Furthermore, the generation process of the workstation processing record and the complete production record is as follows: When the entry time is earlier than or equal to the exit time, and the workstation exception code is not a data missing exception code, the corresponding workstation processing record is written into the valid record area. When the entry time is later than the exit time, or when the workstation exception code is a data missing exception code, the corresponding workstation processing record will be written into the exception record area. After the buckle is inspected, the virtual number, the processing records of each workstation, and the inspection defect code are associated to generate the complete production record.

[0016] By adopting the above technical solution, the workstation processing records are validally distinguished during generation, and abnormal time relationships and missing data states will not be mixed into normal records. The complete production record associates and saves the virtual number, processing records of each workstation, and the detected defect code, so that release control, cycle time processing, and defect review have the same data source.

[0017] Further, the step of determining the release status of the buckle at the forming protection station based on the processing record of the workstation and generating a release permission mark is as follows: The station dwell time is compared with the shortest allowable processing time, the positioning status value is compared with the allowable positioning status set, the processing status value is compared with the allowable processing status set, and it is determined whether the station abnormality code is an abnormality code. Based on the comparison results, a release decision quantity is generated, and the release decision quantity is compared with the release threshold to generate the release permission mark; When the release determination quantity reaches the release threshold, the buckle is allowed to enter the next work station; when the release determination quantity does not reach the release threshold, the flow path is determined according to the type of unmet condition.

[0018] By adopting the above technical solution, the release determination simultaneously considers dwell time, positioning status, processing status, and abnormal status, and does not directly replace the workstation status judgment with a fixed waiting time. When the buckle does not meet the release conditions, the control program can determine the flow path of waiting, repositioning, rework, manual confirmation, or abnormal handling based on different unmet conditions.

[0019] Furthermore, the step of calculating the cycle time deviation based on the station dwell time and then allocating it to an adjustable waiting station is as follows: The cycle time deviation is calculated based on the dwell time and standard processing time of the buckle at each workstation. Select the currently adjustable waiting workstation from the adjustable waiting workstations as the cycle processing object; Based on the current waiting state of each of the aforementioned beat processing objects, the beat deviation is allocated to the corresponding beat processing object to obtain the beat processing amount; The beat processing volume is limited according to the single wait adjustment limit value, and the waiting time of the corresponding beat processing object is adjusted according to the actual write value after the limit. During the cycle time allocation process, the actual operating time of the forming protection station is limited to be no less than the minimum allowable processing time.

[0020] By adopting the above technical solution, the cycle time deviation is limited to the adjustable waiting station, and the forming protection station does not participate in the compression processing time. The cycle time processing object undertakes the corresponding adjustment amount according to the current waiting state, and the adjustment range is limited by the single waiting adjustment limit value, so that cycle time adjustment and forming protection constraints are retained simultaneously.

[0021] Further, the step of determining candidate review stations and calculating review judgment values ​​based on the defect review table is as follows: Read the preceding workstation associated with the detected defect code from the defect lookup table as the candidate lookup workstation; Read the station dwell time, positioning status value, processing status value, and station exception code of the candidate retrospective station from the complete production record; The back-check judgment value is determined based on the deviation of workstation dwell time, deviation of positioning status, deviation of processing status, and abnormal status. When the back-check judgment value reaches the back-check judgment threshold, the corresponding candidate back-check workstation is determined as the workstation to be corrected.

[0022] By adopting the above technical solution, the detected defect code will not directly trigger arbitrary parameter changes. Instead, it first determines the candidate back-check station based on the defect back-check table, and then calculates the back-check judgment value in conjunction with the complete production record. The parameter correction object is determined by the comparison result between the back-check judgment value and the back-check judgment threshold, which can reduce the involvement of station parameters unrelated to the current detected defect in the correction.

[0023] Furthermore, the step of performing amplitude limiting correction and generating parameter correction records is as follows: The parameter correction amount is determined based on the detected defect code, the station to be corrected, the control parameter boundary, and the single correction limit value. Based on the parameter correction amount and parameter correction direction, the control parameters that can be corrected in the station to be corrected are increased or decreased to obtain updated values. Apply parameter boundary constraints to the updated value so that the updated control parameter is greater than or equal to the lower limit of the control parameter boundary and less than or equal to the upper limit of the control parameter boundary. Write the updated control parameters into the corresponding workstation parameter area, and record the detected defect code, the workstation number to be corrected, the back-check judgment value, the parameter correction amount, and the updated control parameters to generate the parameter correction record.

[0024] By adopting the above technical solution, parameter updates are simultaneously constrained by the allowable correction range, parameter correction direction, single correction limit, and control parameter boundaries. The parameter correction record retains the detected defect code, the station to be corrected, the retrospective judgment value, and the updated control parameters, facilitating subsequent data retrospective review and production formula update judgment.

[0025] Further, the step of determining the sorting path based on the detected defect code, the release permission mark, and the workstation exception code, and saving the production data, is as follows: When the detected defect code is a defect-free code, the release permission mark is 1, and the station abnormality codes of each station are all defect-free codes, the sorting path is determined as a qualified product path. When the detected defect code belongs to the rework defect code registered in the production formula, and there is no abnormal code at each workstation that affects the rework judgment, the sorting path is determined as the rework path. When the detected defect code belongs to the scrap defect code registered in the production formula, the sorting path is determined as the scrap path; When there is an inconsistency between the detected defect code, the release permission mark, or the workstation abnormality code, the sorting path will be determined as a manual confirmation path; When an abnormality occurs on the production line, the abnormal workstation number and abnormality type are recorded, material discharge and reset control are executed, and the production data is saved after sorting is completed, abnormality handling is completed, or parameter correction is completed.

[0026] By adopting the above technical solution, the sorting path is jointly determined by the defect code, release permission mark, and workstation anomaly code, avoiding the misclassification of buckles with abnormal records as qualified products based solely on inspection results. When an anomaly occurs in the production line, the abnormal workstation number, anomaly type, material discharge reset process, and production data are saved, forming a queryable operation record.

[0027] This invention provides a program control method for an automated production line for shower curtain fasteners. It offers the following advantages: 1. This invention records the processing records of the buckle at each workstation through virtual numbering, and uses the workstation dwell time, positioning status value, processing status value and workstation abnormal code for release judgment, cycle deviation calculation and defect review, so that the buckle cross-workstation data can be associated with the complete production record, release permission mark and sorting path and used for subsequent control.

[0028] 2. This invention distinguishes between molding protection stations and adjustable waiting stations through a station type table, allocates the cycle time deviation to the currently adjustable waiting stations, and performs limit processing according to the single waiting adjustment limit value. At the same time, it restricts the actual running processing time of the molding protection station to not be less than the minimum allowable processing time, thus making the cycle time processing object clear.

[0029] 3. This invention determines the candidate back-check station associated with the detected defect code through a defect back-check table, and calculates the back-check judgment value in combination with the complete production record. When the back-check judgment value meets the correction conditions, the limit correction is performed according to the control parameter boundary and the single correction limit value, generating a parameter correction record containing the station number to be corrected, the parameter correction amount, and the updated control parameters. Attached Figure Description

[0030] Figure 1 This is a diagram of the program control system architecture for the automated production line of shower curtain buckles according to the present invention. Figure 2 This is a flowchart of the automated production line control method for shower curtain fasteners according to the present invention; Figure 3 This is a flowchart of the process configuration data establishment and initial state confirmation process of the present invention. Figure 4 This is a flowchart illustrating the generation process of virtual numbering and workstation processing records for this invention. Figure 5 This is a flowchart of the process release determination and cycle time allocation of the present invention; Figure 6 This is a flowchart of the defect review and control parameter limiting correction process of the present invention; Figure 7 This is a flowchart illustrating the sorting path determination, anomaly recovery, and data saving processes of the present invention. Figure 8 This is the power spectrum of the beat deviation sequence of the present invention; Figure 9 The key control parameter of this invention is the logarithmic amplitude spectrum of the corrected sequence. Detailed Implementation

[0031] The technical solutions in 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.

[0032] This invention relates to a program control method for an automated production line for shower curtain fasteners. The method is applied to an automated production line for shower curtain fasteners, which includes a feeding section, a conveying and positioning section, a processing execution section, an inspection and sorting section, and a control section.

[0033] The feeding section feeds shower curtain button ring blanks or semi-finished buttons into the production line and guides them to subsequent workstations according to processing requirements. The conveying and positioning section moves the buttons between workstations on the production line and confirms their positions before processing. The processing execution section performs corresponding processing actions on the buttons according to set process parameters. The detection and sorting section acquires the status information of the processed buttons and controls them to enter the corresponding feeding path based on the detection results. The control section receives status signals from each workstation, outputs corresponding control commands, and stores process parameters, processing records, detection results, and parameter correction records.

[0034] See attached document Figure 1 This invention provides a program control system for an automated production line for shower curtain buckles, which may include: a process configuration module, a process recording module, a release control module, a cycle time allocation module, and a backtracking and correction module. The process configuration module is used to establish basic process data for the production line; the process recording module is used to generate cross-station processing records for the buckles; the release control module is used to determine the process flow path based on the buckle processing status; the cycle time allocation module is used to handle cycle time deviations in the production line; and the backtracking and correction module is used to backtrack to previous stations and correct corresponding control parameters based on the detection results.

[0035] The process configuration module is used to establish the basic process data for the automated production line of shower curtain fasteners, enabling the control program to identify the functional attributes, processing time requirements, inspection conditions, and adjustable control parameters of each workstation. The process configuration module includes a workstation type configuration unit, a process parameter configuration unit, a control parameter configuration unit, and a defect review configuration unit.

[0036] The workstation type configuration unit is used to divide the production line workstations into loading and sorting workstations, forming protection workstations, adjustable waiting workstations, inspection workstations, and sorting workstations. Forming protection workstations directly affect the forming or engaging state of the fasteners. Adjustable waiting workstations are used for buffering, waiting, or conveying transitions. The control program uses the workstation type configuration unit to distinguish between workstations limited by minimum processing time and waiting workstations involved in cycle time adjustment.

[0037] The process parameter configuration unit is used to configure the standard processing time, minimum allowable processing time, maximum allowable waiting time, allowable range of process status, and release conditions for each station. The process parameter configuration unit saves the corresponding parameters according to the buckle specification, material batch, and processing method, and writes them into the control program of the corresponding station before production starts.

[0038] The control parameter configuration unit is used to configure the adjustable control parameters for each workstation. These adjustable control parameters include feeding control parameters, positioning control parameters, processing control parameters, cooling and holding parameters, detection and judgment parameters, and sorting control parameters. The control parameter configuration unit establishes a correspondence between the adjustable control parameters and the workstation numbers, enabling subsequent parameter corrections to be written to the corresponding workstation parameter area.

[0039] The defect backtracking configuration unit is used to establish the correspondence between detected defect codes and preceding workstations, and to configure the candidate backtracking workstations, data to be judged, and correctable parameters corresponding to each defect code. The correspondence saved in the defect backtracking configuration unit is used to support the backtracking processing of the processing records of preceding workstations based on the detection results.

[0040] The process recording module is used to establish process data records for fasteners or fastener groups during the fastener production process. The process recording module includes a virtual numbering unit, a workstation entry / exit recording unit, a processing status acquisition unit, and a production record generation unit.

[0041] The virtual numbering unit is used to assign virtual numbers to buckles or buckle groups based on their triggering sequence upon entering the production line, fixture position, conveyor position, or material channel queue sequence. The virtual number circulates with the buckle between different workstations, enabling the control program to associate the processing data of the same buckle generated at different workstations.

[0042] The station entry / exit recording unit records the time when the buckle enters and leaves each station, and calculates the actual dwell time of the buckle at each station. The station entry / exit recording unit uses station arrival signals, station departure signals, conveyor position signals, or fixture position signals as triggering criteria.

[0043] The processing status acquisition unit is used to collect the action completion status, processing status signals, number of secondary positioning attempts, material feeding waiting status, and abnormal status of each workstation. The processing status acquisition unit collects corresponding data according to workstation type, enabling the processing of the fastener at different workstations to be recorded.

[0044] The production record generation unit combines virtual numbers, workstation numbers, entry / exit times, dwell time, processing status data, and inspection results into a complete production record. This complete production record serves as the data foundation for the release control module, cycle time allocation module, and backtracking / correction module.

[0045] The release control module determines whether the fastener should proceed to the next station based on its actual processing status in the forming protection station. The release control module includes a forming protection judgment unit, a release judgment quantity calculation unit, and a path selection unit.

[0046] The forming protection judgment unit is used to determine whether the retaining ring meets the minimum allowable processing time and the allowable range of process status in the forming protection station. The forming protection judgment unit receives the actual dwell time and processing status data output by the process recording module and compares it with the corresponding parameters in the process configuration module.

[0047] The release judgment quantity calculation unit is used to calculate the release judgment quantity of the fastener based on the processing time judgment item, process status judgment item, and positioning status judgment item. The release judgment quantity is used to convert the fastener processing status into a release condition that the program can judge.

[0048] The path selection unit is used to determine the subsequent path of the locking ring based on the release judgment result. When the locking ring meets the release conditions, the path selection unit controls the locking ring to enter the next work station; when the locking ring does not meet the release conditions, the path selection unit controls the locking ring to enter the waiting, rework, manual confirmation, or scrap path.

[0049] The cycle time allocation module is used to calculate the cycle time deviation of the production line and allocate the deviation to adjustable waiting stations. The cycle time allocation module includes a cycle time deviation calculation unit, a waiting station identification unit, a deviation allocation unit, and a protection limit unit.

[0050] The cycle time deviation calculation unit is used to calculate the cycle time deviation of the buckle or buckle group based on the actual dwell time of the buckle at each station and the standard processing time. The cycle time deviation calculation unit receives the actual dwell time of the station output by the process recording module and uses the standard processing time in the process configuration module as the basis for calculation.

[0051] The waiting station identification unit is used to identify adjustable waiting stations that can participate in cycle time adjustment. Based on the station type configuration results, the waiting station identification unit selects the currently adjustable waiting station as the cycle time processing object.

[0052] The deviation allocation unit is used to allocate cycle time deviations to the corresponding workstations based on the current adjustable capacity of each adjustable waiting workstation. The deviation allocation unit determines the processing capacity based on the current waiting status of the adjustable waiting workstations and does not use the same time adjustment method for all workstations.

[0053] The protection limit unit is used to restrict the processing time of the molding protection station to a minimum preset allowable processing time. The protection limit unit ensures that the cycle time processing does not change the minimum processing constraint of the molding protection station.

[0054] The retrospective correction module is used to retrospectively check the processing records of previous workstations based on the defect codes output by the inspection workstations, and to perform limit corrections on the control parameters of the corresponding workstations. The retrospective correction module includes a defect code identification unit, a candidate workstation determination unit, a correction judgment calculation unit, and a parameter limit correction unit.

[0055] The defect code recognition unit is used to identify the defect codes output by the inspection station. The defect codes characterize the inspection status after the buckle is processed and serve as input for subsequent back-checking.

[0056] The candidate workstation determination unit is used to determine the preceding workstations related to the current defect code based on the correspondence in the defect lookup configuration unit. After the detection results are generated, the candidate workstation determination unit associates the defect code with the processing records of the preceding workstations.

[0057] The correction judgment calculation unit is used to calculate the correction judgment value for each candidate station based on the dwell time deviation, processing status deviation, and positioning status deviation. The correction judgment value is used to determine whether the corresponding station enters the parameter correction process.

[0058] The parameter limiting correction unit is used to update the control parameters of the station to be corrected according to the preset correction direction and single correction limit value. The parameter limiting correction unit writes the updated control parameters into the corresponding station parameter area and uses them for subsequent buckle processing.

[0059] Through the coordination of the feeding section, conveying and positioning section, processing execution section, inspection and sorting section, and control section, this invention forms the program control foundation for an automated production line for shower curtain buckles. The process configuration module provides process constraints and parameter boundaries, the process recording module provides buckle cross-station process data, the release control module controls the buckle flow according to the actual processing status, the cycle time allocation module performs cycle time processing for adjustable waiting stations, and the back-check correction module performs restricted corrections to the parameters of the preceding station based on detected defects.

[0060] See attached document Figure 2 This invention provides a program control method for an automated production line for shower curtain fasteners, comprising the following steps: S100. Before production starts, establish a shower curtain buckle processing process table, workstation type table, control parameter table, and defect review table, and confirm the initial status of the material supply, conveying, processing, inspection, sorting, and control parts of the production line to ensure that the production line has the basic conditions to execute automated processing procedures.

[0061] S200. After the buckle enters the production line, a virtual number is assigned to the buckle or buckle group according to the buckle entry sequence, fixture position, conveying position or material channel queue sequence. When the buckle passes through each station, the entry time, exit time, station dwell time, positioning status, processing status data and exception code are recorded, thereby forming a station processing record corresponding to the virtual number.

[0062] S300: Calculate the release judgment quantity based on the actual processing time, process status data and positioning status of the buckle in the forming protection station, and determine the buckle's entry into the next station, waiting path, rework path or abnormal handling path based on the release judgment result. At the same time, calculate the cycle deviation based on the actual dwell time of each station, and allocate the cycle deviation to the adjustable waiting station.

[0063] S400 After the defect code is output at the inspection station, the candidate back-check station related to the defect code is determined according to the defect back-check table. The correction judgment amount of the candidate back-check station is calculated in combination with the complete production record of the buckle. When the correction judgment amount meets the correction condition, the control parameters of the corresponding station are limited and corrected so that the corrected control parameters can be used for subsequent buckle processing.

[0064] S500 controls the buckle to enter the corresponding feeding path based on the final inspection results, release judgment results and workstation abnormality codes. When material blockage occurs on the production line, the actuator is not in place, the temperature is abnormal or the positioning fails, the abnormal shutdown recovery process is executed. At the same time, production records, inspection records, sorting records and parameter correction records are saved.

[0065] The following describes steps S100 to S500 in detail, taking into account the operation process of the automated production line for shower curtain buckles.

[0066] See attached document Figure 3 Step S100 is used to generate process configuration data that the controller can call before production starts and to complete the status confirmation before automatic operation. The controller writes the station configuration, process parameters, control parameters, defect backtracking relationship and initial status flag into the corresponding data area, so that the virtual number, station processing record, process release, cycle time allocation and defect backtracking in operation are executed based on the same set of configuration data.

[0067] S101. The controller numbers the workstations on the production line according to the actual flow sequence of the shower curtain buckle from entering the production line to completing the unloading process. The workstation numbers are assigned sequentially according to the buckle's flow direction, and the same workstation maintains a unique number during the production process. When there are parallel material channels or parallel processing positions on the production line, the controller sets the parallel positions to different workstation numbers, or sets a position sequence number under the same workstation number, so that the processing positions passed by the buckle can be recorded and recalled.

[0068] The controller configures the station type code, processing time parameters, and control parameters for each workstation, and writes the configuration results into the process configuration data. The process configuration data for each workstation is represented as follows: ; in, For the first Process configuration data for each workstation; Assign workstation numbers; For the first Workstation type code; For the first Standard processing time for each workstation; For the first The minimum allowable processing time for each workstation; For the first The maximum allowed waiting time for each workstation; For the first The first workstation One control parameter; For the first The first workstation The lower limit of each control parameter; For the first The first workstation The upper limit of each control parameter; This refers to the control parameter number.

[0069] The control parameters include feeding control parameters, positioning control parameters, processing control parameters, cooling and holding parameters, detection and judgment parameters, and sorting control parameters. The controller binds each control parameter to the corresponding workstation number and saves the binding relationship to the process configuration data.

[0070] The controller performs validity checks on the processing time parameters and control parameters. The standard processing time for each workstation needs to be within the [number]th [timeframe]. The shortest allowed processing time for each workstation and the first Between the longest allowed waiting times for each workstation, the first... The first workstation The control parameter needs to be located in the first position. The first workstation The lower limit of the first control parameter and the first The first workstation The upper limit of each control parameter. If any workstation fails to meet the processing time parameter verification condition, the controller prohibits the production line from entering automatic operation mode and outputs a parameter configuration abnormality status. If any control parameter fails to meet the boundary verification condition, the controller prohibits that parameter from being written to the corresponding workstation parameter area and outputs a control parameter out-of-bounds status.

[0071] S102. The controller, based on the impact of each workstation on the forming, fastening, and detection states of the shower curtain fasteners, assigns workstation type codes. Write the process configuration data. Station type codes include material loading and sorting station, forming protection station, adjustable waiting station, inspection station, and sorting station.

[0072] The forming protection station is a station that needs to maintain set processing conditions during the processing. The actual processing time of this type of station must not be less than the minimum allowable processing time. The adjustable waiting station is used for temporary storage, waiting, buffering, or conveying of buckles; this type of station participates in cycle time management. The detection station outputs the buckle detection status. The sorting station controls the buckles to enter the corresponding feeding path based on the detection results.

[0073] The set of workstation numbers, the set of molding protection workstation numbers, and the set of adjustable waiting workstation numbers are represented as follows: ; in, A set of workstation numbers; This represents the total number of workstations on the production line. This is a set of numbers for the molding protection workstations; This is a set of adjustable waiting workstation numbers; Indicates the first Each workstation is a molding protection workstation; Indicates the first Each workstation is an adjustable waiting workstation. The vertical lines in the formula represent set filtering conditions.

[0074] The controller writes protection constraints to the forming protection station. These constraints include prohibiting actual processing time from being compressed below the minimum allowable processing time and excluding compression operations on the forming protection station during cycle time allocation. The controller writes cycle time participation flags to the adjustable waiting station. The adjustable waiting station is used as a waiting time adjustment object in cycle time allocation; the controller adjusts its waiting time based on the current waiting status. The adjustable waiting station is still subject to the first... Maximum allowed waiting time per workstation , No. The first workstation Lower limit of each control parameter and the The first workstation Upper limit of each control parameter limit.

[0075] S103. The controller establishes a defect code set and converts the buckle status output by the inspection station into the corresponding defect code. The defect codes include no-defect codes and defect codes indicating abnormal buckle inspection states. The names and number of defect codes are determined based on the inspection station configuration and are consistent with the buckle inspection items.

[0076] The controller establishes a mapping between defect codes and preceding candidate workstations. For any defect code, during the configuration phase, the controller specifies the preceding workstation to be checked, the data type of processing to be read, and the control parameters that can be corrected. Data types of processing include workstation dwell time, positioning status, action completion status, pressure status, displacement status, temperature status, feeding waiting status, and workstation abnormal status. The control parameters that can be corrected are those already registered in the control parameter configuration for the corresponding workstation; unregistered parameters are not included in parameter correction.

[0077] Detect defect codes Corresponding to the The first workstation The configuration data for each control parameter is represented as follows: ; in, To detect defect codes Corresponding to the The first workstation The configuration data for each control parameter was retrieved. For the first Defect codes for each buckle; This is a virtual number; To detect defect codes With the The associated tags for each workstation; To detect defect codes Corresponding to the The first workstation The direction of correction for each control parameter; To detect defect codes Corresponding to the The first workstation The single correction limit value of each control parameter.

[0078] when At the time, detect defect codes Need to check the first Each workstation; when At the time, detect defect codes No backtracking Each workstation. When When the controller makes a correction, it adds the first... The first workstation One control parameter; when At that time, the controller maintains the first The first workstation Each control parameter remains unchanged; when When the controller makes a correction, it reduces the first... The first workstation One control parameter.

[0079] The controller stores the single-correction limit value in the defect backlog relationship. The single-correction limit value is set corresponding to the control parameter boundary and is used to limit the adjustment range of control parameters within the same processing cycle. Through this configuration, the defect code, candidate backlog station, processing data to be read, allowed control parameters for correction, parameter correction direction, and single-correction limit value are all clearly defined before production operation.

[0080] S104. The controller reads the production formula before starting automatic operation. The production formula includes process configuration data, a set of molding protection station numbers, a set of adjustable waiting station numbers, defect backtracking relationships, control parameter boundaries, and single correction limit values. The controller selects the corresponding production formula based on the buckle specification, material batch, or processing method, and writes the production formula into the parameter area of ​​each station.

[0081] The controller performs initial state verification for each workstation. Initial state verification includes execution state verification, detection state verification, and communication state verification. Execution state verification determines whether the workstation's actuator is in an operable state; detection state verification determines whether the sensor or detection unit is in a valid state; and communication state verification determines whether the data transmission between the controller and the corresponding workstation is normal. When all workstations meet the execution, detection, and communication state requirements, the controller allows the production line to enter automatic operation mode. If any workstation fails to meet the initial state requirements, the controller remains in an automatic operation prohibited state and outputs initial state abnormality information for the corresponding workstation. For actuator reset, temperature control status reading, sensor status detection, and communication diagnostics, those skilled in the art can use PLC input / output detection, driver status reading, temperature controller status reading, or industrial computer communication detection methods. These implementation methods are well-known technologies in the field and will not be elaborated upon here.

[0082] See attached document Figure 4 Step S200 is executed after the production line is initialized. It is used to establish a correspondence between the buckles entering the production line and the data collected at each workstation. The controller generates a virtual number based on the buckle entry signal and maintains a queue of workstation numbers during the buckle circulation process, so that the time data, positioning data, processing status data and abnormal data generated by the buckle at different workstations are classified into the same buckle record.

[0083] S201. After detecting the buckle entry signal at the loading position, the controller generates a virtual number. The buckle entry signal is triggered by the loading position detection signal, the fixture occupancy signal, the conveyor position arrival signal, or the material channel release completion signal. The controller only generates a new virtual number when the loading position is idle, downstream reception is allowed, and the buckle entry signal is valid, to avoid invalid numbers caused by empty material signals or repeated triggering signals.

[0084] When the production line uses a single-ring continuous flow method, the controller directly binds the new virtual number to the current ring. When the production line uses a fixture cyclic flow method, the controller binds the new virtual number to the current fixture position and uses this virtual number as the fixture passes through each station. When the production line uses a material queue flow method, the controller writes the new virtual number to the end of the loading station number queue and transfers it to each station according to the queue order with the rings.

[0085] When multiple buckles entering the same material channel within the same inspection cycle are brought to subsequent positions by the same feeding action, the controller establishes a numbering system based on the buckle group. The virtual numbering system for the buckle group is generated according to the entry order, and each buckle within the group is assigned a group number according to the material channel arrangement order. Stations with single-piece identification capabilities split the virtual numbering system of the buckle group into individual virtual numbers; stations without single-piece identification capabilities use the virtual numbering system of the buckle group to record station processing data and inspection results.

[0086] S202. The controller maintains a numbered queue according to the flow direction of the workstation. Each workstation has a corresponding numbered queue, which is used to store virtual numbers of the current workstation that are waiting to be processed, are being processed, or are waiting to be transferred out.

[0087] The numbered queues are arranged according to the order in which the buckles entered their corresponding workstations. The first buckle of the first workstation has been rotated out and has entered the second workstation. When the controller is at the first workstation, it will... The first virtual number in the workstation number queue is removed and written to the first virtual number. The tail of the workstation number queue. The number queue update is performed synchronously with the interlocking transfer signal. The interlocking transfer signal is jointly confirmed by the upstream workstation departure signal and the downstream workstation entry signal.

[0088] When the upstream station departure signal is valid but the downstream station entry signal is invalid, the controller maintains the virtual number in the upstream station number queue and outputs a transfer unconfirmed status. When the downstream station entry signal is valid but the upstream station has no transfer-out number, the controller outputs an abnormal status in the number queue and prohibits the loop from directly entering the normal production record.

[0089] When parallel workstations have merging points, the controller writes the merging workstation numbers into the queue according to the actual arrival order of the retainers at the merging points. When parallel workstations have splitting points, the controller writes the virtual numbers into the corresponding downstream workstation number queues according to the splitting execution signal. In rotary table production lines, the controller transfers the virtual numbers corresponding to the fixtures to the next workstation position based on the rotary table indexing completion signal. In linear conveyor production lines, the controller completes the number transfer based on the conveyor position arrival signal and the workstation arrival signal.

[0090] S203. The controller records station time data when the retainer enters and leaves each station, and synchronously collects station processing data. The retainer enters the... When the device reaches a workstation, the controller reads the current control clock and records the entry time; when the buckle leaves the workstation... When a workstation is reached, the controller reads the current control clock again and records the departure time.

[0091] No. The buckle is in the first The station dwell time and processing record for each workstation are represented as follows: ; ; in, For the first The buckle is in the first The time spent at each workstation; For the first The buckle leaves the first The time of departure from each workstation; For the first The first buckle enters the... The entry time of each workstation; For the first The buckle is in the first Workstation processing records; For the first The buckle is in the first Positioning status values ​​of each workstation; For the first The buckle is in the first The processing status value of each workstation; For the first The buckle is in the first The workstation exception code.

[0092] The controller collects corresponding processing data based on the workstation type. The feeding and sorting workstation collects the feeding waiting status, material channel arrival status, and release completion status; the positioning workstation collects the buckle arrival status, clamping status, and number of secondary positioning attempts; the processing workstation collects the action completion status, processing status signals, and execution abnormal status; the detection workstation collects the detection judgment results; and the sorting workstation collects the unloading path status and sorting completion status.

[0093] Location status value Used to characterize whether the buckle is in place, clamped, and whether repositioning has occurred. Machining status values. Used to characterize the current workstation's action completion status, pressure status, displacement status, temperature status, or detection status. Workstation exception codes. This is used to characterize situations such as material shortages, material jams, inadequate execution, invalid detection, or abnormal numbering queues at the current workstation. For workstations without corresponding data collection items, the controller will write a null value flag to the corresponding field; null value flags will not be used in the normal record validity judgment.

[0094] The controller verifies the validity of each workstation processing record. If the entry time is earlier than or equal to the exit time, and the workstation exception code is not a data missing exception code, the controller writes the corresponding workstation processing record into the valid record area. If the entry time is later than the exit time, or the workstation exception code is a data missing exception code, the controller writes the corresponding workstation processing record into the exception record area and decides whether to continue processing, wait for confirmation, or enter the exception handling process based on the exception type.

[0095] S204. After the buckle completes the inspection, the controller associates the virtual number, the processing records of each station, and the inspection results to generate a complete production record for the buckle. The complete production record uses the virtual number as the primary key and connects the records of the same buckle generated at different stations in the order of the process flow, so that the process data of a single buckle or a group of buckles in the production line can form a complete record.

[0096] No. The complete production record for each buckle is represented as follows: ; in, For the first Complete production records for each buckle; For the first The processing record of each buckle at the first workstation; For the first The processing record of the buckle at the second workstation; For the first The buckle is in the first Workstation processing records; For the first The defect code for each buckle.

[0097] When the controller generates a complete production record, it verifies the workstation record order, virtual number consistency, and inspection result binding relationship. The workstation record order is used to confirm that the buckle records are arranged according to the process flow; the virtual number consistency is used to confirm that the processing records of each workstation belong to the same virtual number; and the inspection result binding relationship is used to confirm that the inspection defect code is written into the complete production record of the corresponding buckle.

[0098] After a complete production record is generated, the controller saves the record to the data storage area. The data storage area is indexed according to a virtual number and saves the record generation time, workstation processing record, detection defect code, record validity marker, and abnormal record location.

[0099] If the buckle has already entered a rework path, manual confirmation path, or scrap path before entering the inspection station, the controller generates a phased production record based on the existing station processing records and writes the corresponding path status into the record. The phased production record is used to retain the process data of the buckle before it leaves the normal processing path. For virtual number generation, queue maintenance, timestamp recording, and field signal acquisition, those skilled in the art can use PLC data blocks, industrial control computer databases, or touch screen recipe recording methods. The relevant implementation methods are well-known technologies in this field and will not be described in detail here.

[0100] See attached document Figure 5 Step S300 is executed after the buckle forms a processing record at each station. It is used to control the process flow based on the actual processing status of the buckle at each station on the production line and to handle production cycle deviations. The controller reads the station dwell time, positioning status value, processing status value, and station exception code from the complete production record of the buckle, converts the processing status of the forming protection station into a release judgment criterion, and limits the cycle deviation to the adjustable waiting station for processing.

[0101] S301, Controller reads the... The complete production record of each buckle was obtained, and the processing record of the corresponding station for the forming and protection station was extracted from it. For the first... The first molding protection station, the controller reads the first... The time each buckle stays at this workstation Location status value Processing status values and workstation exception codes .

[0102] No. The set of positioning states for each workstation is allowed to be: , No. The processing status of each workstation can be set as follows: No exception code is The controller will With the Minimum allowable processing time for each workstation Compare, With the The positioning status of each workstation allows for the collection Compare, With the The processing status of each workstation allows for the collection of... Compare and judge Is it an exception-free code? .

[0103] Location State Allowed Set Written from the production formula, used to indicate the first The positioning status that allows release at each workstation. The processing status allows for a set of... Written from the production formula, used to indicate the first The processing status at each workstation is allowed to proceed. For workstations using pressure, displacement, or temperature sensors, the controller first compares the detected values ​​with the allowable ranges in the production formula, and then writes the comparison result into the processing status value. For workstations that use arrival or completion signals for determination, the controller directly writes the signal status into the positioning status value. or processing status value .

[0104] When the The buckle is in the first If the dwell time at a molding protection station is less than the minimum allowable processing time, or the positioning status value does not belong to the allowable set of positioning statuses, or the processing status value does not belong to the allowable set of processing statuses, or the station's exception code is not a no-exception code, the controller will... The buckle is in the first The status of each forming protection station is recorded as "release conditions not met". Situations lacking valid processing records at a station are treated as "release conditions not met".

[0105] S302, The controller calculates the number of steps based on the processing time, positioning status, processing status, and abnormal status of the molding protection station. The release judgment value for each retainer. The release judgment value is used to convert the processing status in multiple forming protection stations into the same program judgment result, so that the turnover of retainers does not only depend on a fixed delay.

[0106] No. The release determination quantity for each buckle is expressed as: ; in, For the first The release determination quantity for each buckle; Weights are determined based on processing time; Weights are determined based on the positioning status; Weights are assigned to determine the processing status; Deduct weights for abnormal states; The function evaluates to 1 if the condition is true, and 0 otherwise. This represents the set of numbers for the molding protection station. Workstation number Perform summation.

[0107] The controller will make the release decision. Compare with the release threshold and generate the first... Release permission mark for each buckle When the number of clearance requests reaches the clearance threshold, Set to 1; when the release determination quantity does not reach the release threshold, Take 0.

[0108] when At that time, the controller allows the first The buckle moves to the next workstation. When When the controller determines the flow path based on the type of unmet condition, if the station dwell time is insufficient, the retainer enters the waiting path or cooling hold path; if the positioning status does not meet the conditions, the retainer enters the repositioning path or manual confirmation path; if the processing status does not meet the conditions, the retainer enters the rework path or manual confirmation path; if a station abnormality code exists, the retainer enters the abnormality handling path. The path selection result is written to the first... Complete production record for each buckle.

[0109] S303, the controller according to the... The cycle time deviation is calculated by taking the dwell time of each buckle at each workstation and the standard processing time at each workstation. The cycle time deviation is used to represent the cycle time deviation of the first buckle. The cumulative deviation of each buckle from the standard processing time in the production formula.

[0110] No. The beat deviation of each buckle is expressed as: ; in, For the first The beat deviation of each buckle; Represents the set of workstation numbers Workstation number Perform summation.

[0111] when When the time lag exceeds the cycle time limit, the controller will... The production status corresponding to each buckle is recorded as cycle time lag. When When the time is less than the beat advance boundary, the controller will... The production status corresponding to each buckle is recorded as cycle time advance. When When the cycle time is between the advance and lag boundaries, the controller maintains the current cycle time processing parameters unchanged. The cycle time deviation is only used to determine the cycle time status of the production line and does not change the already formed cycle time. Processing records for each buckle station.

[0112] S304. The controller allocates the cycle time deviation to the adjustable waiting station according to the current waiting status of the adjustable waiting station, and limits the actual running processing time of the molding protection station to no less than the minimum allowable processing time.

[0113] No. The buckle is assigned to the first... The cycle time of an adjustable waiting station is expressed as: ; in, For the first The buckle is assigned to the first... The cycle time of each adjustable waiting station; The numbering is adjusted for the waiting workstations; For the first The buckle is in the first The time spent at each workstation; For the first The minimum allowable processing time for each workstation; To prevent constants with a denominator of 0; This indicates that the maximum value among the values ​​within the parentheses is selected. This represents the set of adjustable waiting workstation numbers. Adjustable waiting station summation number Perform summation.

[0114] Controller's clock cycle processing quantity Amplitude limiting is applied. Amplitude limiting is performed according to the following procedure: The single-wait adjustment limit value is executed for each adjustable waiting station. When the cycle processing volume is greater than the single-wait adjustment limit value, the actual written value is the single-wait adjustment limit value; when the cycle processing volume is less than the negative of the single-wait adjustment limit value, the actual written value is the negative of the single-wait adjustment limit value; in other cases, the actual written value is the cycle processing volume itself.

[0115] The controller determines the first value based on the actual written value after the limit. The waiting time for each adjustable waiting station can be adjusted. For the molding protection station, the controller maintains the first... The buckle is in the first The dwell time at each workstation after the update shall not be less than the [number]th workstation. Minimum allowable processing time for each workstation .

[0116] When the rhythm deviation When the delay exceeds the cycle time lag boundary, the controller prioritizes reducing the waiting time of adjustable waiting stations. When the cycle time deviation... When the time is less than the cycle time advance boundary, the controller allows for an increase in the waiting time of the adjustable waiting station. When the waiting adjustment margin of the adjustable waiting station is insufficient to handle the cycle time deviation, the controller maintains the processing time of the forming protection station unchanged and outputs a status indicating that the cycle time deviation has not been eliminated. For waiting time writing, conveyor pause control, and buffer position control, those skilled in the art can use PLC timers, conveyor drive control, or station buffer markers to implement these functions. These implementation methods are well-known technologies in the field and will not be elaborated upon here.

[0117] See attached document Figure 6 Step S400 is executed after the buckle inspection result is output at the inspection station. It is used to convert the inspection result into a defect code and read the complete production record of the corresponding buckle based on the defect code. The controller determines the preceding candidate station according to the pre-configured defect back-check relationship, calculates the back-check judgment result by combining the station dwell time, positioning status value, processing status value and station abnormal code of the candidate station, and performs amplitude limit correction on the control parameters of the corresponding station when the correction conditions are met.

[0118] S401. After the detection station completes the buckle status detection, the controller reads the detection output signal and converts the detection output signal into the first... Defect codes for each buckle The output signals include a pass signal and an fail signal. The fail signal is converted into a corresponding defect code based on the test item.

[0119] When the inspection station outputs a qualified signal, the controller will... Defect codes for each buckle Write defect-free code When an abnormal signal is output from the inspection station, the controller writes the abnormal signal into the corresponding inspection defect code according to the inspection item. The correspondence between inspection items and inspection defect codes is configured in the production formula. The inspection items include engagement status inspection, ring status inspection, positioning status inspection, processing status inspection, and feeding status inspection.

[0120] The raw detection signal output from the detection station does not directly participate in parameter correction; the controller converts it into a detection defect code and writes it into the first... The complete production record for each buckle. During the writing process, the controller verifies the consistency of the virtual number. When the current virtual number at the inspection station matches the virtual number in the complete production record, the controller allows the writing of the inspection defect code; when the current virtual number at the inspection station does not match the virtual number in the complete production record, the controller outputs the inspection result, binds it to the abnormal status, and writes the inspection result to the abnormal record area.

[0121] S402, the controller according to the... Defect codes for each buckle Read the defect lookup relationship and determine the corresponding defect code. Related candidate workstations. Candidate workstations for back-checking are not determined by the inspection workstations on an ad-hoc basis, but by the defect back-checking relationships configured in the production formula.

[0122] The controller will invoke the defect back-lookup relationship configured in step S100 to the currently detected defect code. The controller starts from the first... Defect codes are read and detected from the complete production record of each buckle. Relevant candidate workstation processing records. The content to be read includes the... The buckle is in the first Workstation dwell time Location status value Processing status values and workstation exception codes .

[0123] When the processing record corresponding to a candidate backtracking station is missing, the controller marks the candidate backtracking station as having a missing record. The missing record status does not directly generate control parameter correction values; instead, the controller writes it to the exception record area to indicate that the currently detected defect code lacks corresponding preceding station data support.

[0124] S403: The controller calculates the back-check judgment value based on the processing records of the candidate back-check stations. The back-check judgment value is used to represent the detected defect code. The degree of correspondence between the candidate workstation's processing status and the status of the back-check station. The back-check judgment value is jointly determined by the deviation of the workstation dwell time, the deviation of the positioning status, the deviation of the processing status, and the abnormal status.

[0125] No. The buckle is in the first The callback judgment value for each candidate callback station is represented as follows: ; in, For the first The buckle is in the first The return judgment value of each candidate return workstation; The deviation of the workstation dwell time from the weight; The weight is the deviation of the positioning state; The weight is determined by the deviation of the processing state. Weights for abnormal states; This indicates taking the absolute value.

[0126] The controller will check the judgment value. Compare with the callback judgment threshold. When the callback judgment value reaches the callback judgment threshold, the first... The candidate workstation for review is included in the range of workstations to be corrected. If the review judgment value does not reach the review judgment threshold, the first... Candidate back-check stations are not included in the range of stations to be corrected. When there are multiple stations to be corrected, the controller processes each station sequentially according to the back-check order configured in the production formula, avoiding unrestricted simultaneous changes in parameters of multiple stations corresponding to the same detection defect code within the same processing cycle.

[0127] S404, The controller detects defect codes. The parameter correction amount is determined by the station to be corrected, the control parameter boundaries, and the single correction limit value. For the first... At each workstation, the controller only processes control parameters that are registered as permissible for modification in the production recipe. Control parameters not registered as permissible for modification remain unchanged.

[0128] No. The first workstation The parameter correction amount and update value of each control parameter are expressed as follows: ; ; in, For the first The first workstation The parameter correction amount for each control parameter; For the first Correction coefficients for each control parameter; For the first The first workstation Updated values ​​for each control parameter; This indicates taking the minimum value among the values ​​within the parentheses; This indicates that the maximum value among the values ​​within the parentheses is selected.

[0129] when At that time, the controller increases the parameter correction amount by the first step. The first workstation One control parameter. When At that time, the controller reduces the first parameter according to the parameter correction amount. The first workstation One control parameter. When At that time, the first The first workstation The first control parameter remains unchanged. The controller synchronously applies parameter boundary constraints when generating updated values, ensuring that the updated control parameter is greater than or equal to the first parameter. The first workstation The lower limit of the first control parameter, and less than or equal to the first... The first workstation The upper limit of each control parameter.

[0130] S405. The controller writes the updated control parameters into the corresponding workstation parameter area. Before writing, the controller confirms that the workstation to be written belongs to the range of workstations to be corrected, that the control parameters to be written belong to the allowed correction control parameters registered in the production formula, and that the value to be written is greater than or equal to the lower limit of the corresponding parameter boundary and less than or equal to the upper limit of the corresponding parameter boundary.

[0131] After the parameters are written, the controller generates a parameter correction record. The parameter correction record includes a virtual number, detected defect code, station number to be corrected, control parameter sequence number, lookup judgment value, parameter correction direction, parameter correction amount, updated control parameters, writing time, and writing result. The parameter correction record is related to the... The complete production record of each buckle is saved together.

[0132] The controller confirms the parameter writing results. If the writing result is valid, the updated control parameters are saved in the corresponding workstation parameter area; if the writing result is invalid, the controller retains the original control parameters and outputs a parameter writing error status. For reading detection signals, writing to the parameter area, and saving data records, those skilled in the art can use PLC data registers, industrial control computer databases, or touch screen recipe data. The relevant implementation methods are well-known technologies in this field and will not be described in detail here.

[0133] See attached document Figure 7 The S500 step is executed after the buckle has completed inspection, release judgment, or anomaly judgment. It is used to determine the buckle feeding path and to perform shutdown, material discharge, reset, and resumption control when an abnormal state occurs on the production line. The controller writes the sorting results, anomaly handling results, and production data to the corresponding storage area, making the buckle processing process, inspection results, sorting status, and parameter correction results a queryable record.

[0134] S501, the controller according to the... Defect codes for each buckle Release permission mark and the exception codes for each workstation Determine the sorting path. The sorting path includes the path for qualified products, the path for reworked products, the path for defective products, and the path for manual verification.

[0135] No. When the defect code for the first buckle is "no defect code", the release permission mark is 1, and all workstation exception codes are "no exception code", the controller will control the sorting mechanism to... Each buckle is fed into the qualified product path. If the defect code of the first buckle is a rework defect code registered in the production formula, and there are no abnormal codes at any workstation that would affect the rework judgment, the controller will control the sorting mechanism to... Each retainer is fed into the rework path, and the corresponding retainer's workstation processing record and inspection defect code are retained. When the defect code of the first buckle matches the scrap defect code registered in the production formula, the controller controls the sorting mechanism to... The first loop is fed into the scrap path. When there is an inconsistency between the detection defect code, the release permission mark, or the workstation exception code, the controller controls the first... Each buckle enters the manual verification path and is prohibited from being processed as a qualified product.

[0136] Before the sorting operation is executed, the controller reads the occupancy status of the sorting position and the status of the sorting execution mechanism. If the sorting position is not in an acceptable state, the controller pauses the entry of the buckle into the sorting position. After the sorting operation is executed, the controller reads the sorting completion signal and writes the sorting path and sorting completion status into the first... Production records for each buckle.

[0137] S502: During production operation, the controller continuously reads the status of each workstation and identifies production line abnormalities based on workstation error codes, execution status, detection status, temperature status, positioning status, and number queue status. Abnormal statuses include material blockage, actuator misalignment, abnormal detection status, abnormal temperature status, positioning failure, and number queue abnormality.

[0138] When the execution status is invalid, the detection status is invalid, the temperature status exceeds the allowable range, the positioning status is invalid, or the numbering queue status is invalid, the controller will record the corresponding workstation as an abnormal workstation. The controller records the abnormal workstation number and the abnormality type, and stops the upstream material feeding. When stopping the upstream material feeding, the controller closes the material release signal and suspends the delivery of new buckles to the abnormal workstation and its upstream adjacent workstations.

[0139] Rings already in the forming protection station are not directly discharged. The controller maintains the current processing action at that station until the minimum allowable processing time is met, and then controls the rings to enter the discharge path, manual confirmation path, or scrap path based on the station status. When a numbering queue anomaly occurs, the controller stops the queue transfer corresponding to the anomaly position. Numbering queue anomalies include downstream arrival signals present but no transfer number upstream, upstream departure signals present but no number received downstream, duplicate virtual numbers in the same station's numbering queue, and virtual numbers inconsistent with the detection position. When a numbering queue anomaly occurs, the controller writes the relevant ring record to the anomaly record area and prohibits it from entering the qualified product path.

[0140] S503. The controller performs material discharge and reset control before the abnormal state is eliminated. Material discharge control is performed according to the position of the buckle in the production line. Buckles located at adjustable waiting stations are discharged by the controller in queue order; buckles located at forming protection stations are discharged after the minimum allowable processing time of the corresponding station is met; buckles located at inspection or sorting stations enter the corresponding path according to the current inspection and sorting status.

[0141] For workstations whose virtual numbers cannot be confirmed, the controller clears the workstation's number queue. Before clearing the number queue, the controller writes the workstation's current status, exception type, original number queue, and clearing time into the exception record area. After clearing, the workstation must not immediately enter automatic operation; it must first complete actuator reset, detection status confirmation, and no-load action confirmation.

[0142] The controller performs a reset operation on the workstations involved in the anomaly. The reset operation includes returning the actuator to its reference position, restoring the detection status to validity, ensuring the temperature status returns to the allowable range, re-establishing the numbering queue, and clearing the workstation occupancy status. After reading the reset completion signal, the controller confirms the production line's recovery status. If all workstations involved in the anomaly have completed the reset and the operational anomaly has been resolved, the controller allows the resumption of material feeding and automatic operation. If any workstation involved in the anomaly has not completed the reset or the operational anomaly still exists, the controller maintains the stopped upstream material feeding state and outputs the workstation number and status information for the unreset workstation.

[0143] S504. The controller saves production data after sorting, exception handling, or parameter correction is completed. The saved data includes complete production records of the buckles, inspection records, sorting records, exception records, and parameter correction records.

[0144] The controller establishes a data index based on virtual numbers and saves the record generation time, workstation processing record, detection defect code, sorting path, workstation exception code, exception record location, and parameter correction record location. Sorting records include the virtual number, sorting path, sorting execution signal, sorting completion signal, and sorting time. Exception records include the exception workstation number, exception type, trigger time, handling action, reset status, and recovery time. Parameter correction records include the detection defect code, workstation number to be corrected, control parameter sequence number, correction direction, parameter correction amount, updated control parameters, and write result.

[0145] The controller verifies the integrity of the saved data. If a complete production record for the buckle exists, a defect code is present, a sorting path exists, and the data index is established, the data is saved as valid. If any necessary data is missing, the data is saved as invalid, and an abnormal data saving status is output. Invalid data is not written into the production formula.

[0146] When the parameter correction result meets the saving conditions, the controller writes the corresponding control parameters into the production formula. The saving conditions include: the parameter writing result is valid; the updated control parameters are within the parameter boundaries; no operational abnormality is triggered at the corresponding workstation; and the data saving status is valid. When the parameter correction result does not meet the saving conditions, the controller only saves the parameter correction record and does not update the production formula. For sorting execution, material discharge reset, on-site alarms, and data storage, those skilled in the art can use PLC output control, driver status reading, touchscreen alarm recording, and industrial computer database storage methods. These implementation methods are well-known technologies in the field and will not be elaborated upon here.

[0147] Specific application examples: To better understand the technical solution of this invention, the invention will be further described in detail below with reference to specific application scenarios and accompanying drawings. This specific application embodiment is built into the program control system of an automated shower curtain fastener processing production line. This system runs in a continuous shower curtain fastener processing production line, responsible for acquiring fastener processing data across workstations and executing process release, cycle time allocation, and defect review and correction control.

[0148] During the cycle time processing stage, the cycle time deviation calculation unit extracts the dwell time of the 216th buckle at each station to calculate the cycle time deviation. The parameters are set as follows: the production line has 7 stations, and the standard processing times for stations 1 to 7 are 0.35 seconds, 0.60 seconds, 1.20 seconds, 1.00 seconds, 0.55 seconds, 0.30 seconds, and 0.40 seconds, respectively; the controller obtains the dwell times of the 216th buckle at stations 1 to 7 as 0.38 seconds, 0.82 seconds, 1.28 seconds, 1.05 seconds, 0.74 seconds, 0.30 seconds, and 0.42 seconds, respectively. The cycle time deviation calculation unit substitutes these values ​​into the formula to calculate the cycle time deviation. ; Substitute the values ​​into the calculation: ; The results show that the system obtained a beat deviation of 0.59 seconds. The preset beat lag boundary is 0.40 seconds. Since the calculated beat deviation is greater than the beat lag boundary, the beat lag judgment condition is met. The beat deviation calculation unit determines that the 216th buckle is in a beat lag state, and the system activates the beat allocation module.

[0149] During the cycle time allocation phase, the deviation allocation unit calculates the cycle time processing capacity based on the adjustable waiting station data. The parameters are set as follows: stations 2 and 5 are adjustable waiting stations; the minimum allowable processing time for station 2 is 0.30 seconds, and for station 5 it is 0.25 seconds. A constant of 0.01 is used to prevent the denominator from being zero. The deviation allocation unit then substitutes these values ​​into the formula to calculate the cycle time processing capacity: ; Substitute the values ​​from the second workstation into the calculation: ; Substitute the values ​​from the 5th workstation into the calculation: ; The results show that the cycle time for the second station is 0.30 seconds, and the cycle time for the fifth station is 0.28 seconds. The preset single-wait adjustment limit is 0.35 seconds. Since the calculated cycle time is within the single-wait adjustment limit, the deviation allocation unit determines that both adjustable waiting stations meet the cycle time conditions. The system reduces the waiting time for the second and fifth stations while maintaining the actual operating time of the molding protection station at no less than the minimum allowable processing time.

[0150] During the defect review and correction phase, the parameter limiting correction unit calculates the parameter correction amount by combining the detected defect code and candidate review station data. The parameters are set as follows: After the detection station outputs the detected defect code corresponding to the abnormal engagement state, the controller determines the 4th station as a candidate review station, with a review judgment value of 0.46 and a review judgment threshold of 0.40. Since the review judgment value reaches the review judgment threshold, the controller includes the 4th station in the range of stations to be corrected. The second control parameter of the 4th station is the pressing and holding time, currently 1.80 seconds, with a lower limit of 1.50 seconds and an upper limit of 2.30 seconds. The correction direction is increasing, the correction coefficient is 0.60, and the single correction limit is 0.20 seconds. The parameter limiting correction unit substitutes the values ​​into the formula to calculate the parameter correction amount and update value: ; ; Substitute the values ​​into the calculation: ; ; The results show that the parameter correction amount obtained by the system is 0.20 seconds, and the updated control parameter is 2.00 seconds. Since the updated control parameter is within the range of 1.50 seconds to 2.30 seconds, it meets the parameter boundary conditions. The parameter limiting correction unit determines that the parameter writing is valid, and the system writes the updated control parameter into the corresponding station parameter area and generates a parameter correction record.

[0151] To verify the accuracy and stability of the control strategy, which includes constraints on the molding protection station, adjustable waiting station cycle time allocation, and defect backtracking limit correction, during system operation, the system compared and output production process data of the comparative control method and the control method of this application embodiment under the same experimental environment. For each test group, process data for 4096 buckles were continuously collected, with the sampling order determined by the ascending order of virtual numbers.

[0152] See attached document Figure 8 , Figure 8 The horizontal axis represents the normalized frequency, which is the ratio of the actual frequency to the sampling frequency and is a dimensionless quantity. The vertical axis represents the relative power spectral density of the beat deviation sequence. In the comparative control method shown in the figure, due to the use of a fixed waiting time, the beat deviation distribution exhibits a high main spectral peak around 0.02, a secondary spectral peak around 0.05, and maintains a high spectral density in the range of 0.06 to 0.20. In contrast, the control method in this application embodiment, which uses an adjustable waiting position to allocate the beat deviation, shows a significantly reduced peak height and maintains a low power spectral density in the mid-to-high frequency range. This result verifies the ability of this invention to reduce the periodic fluctuations of the beat deviation.

[0153] Based on the completion of cycle deviation verification, in order to further verify the effectiveness of parameter updating under defect back-check and correction conditions, the system compared the key control parameter correction sequences under different control methods.

[0154] See attached document Figure 9 , Figure 9 The horizontal axis represents the normalized frequency, and the vertical axis represents the logarithmic amplitude, in dB. The comparative control method in the figure, lacking defect backtracking and single-step amplitude limiting correction mechanisms, exhibits a significant spectral peak near 0.03 and a secondary peak near 0.085 in its key control parameter correction sequence, resulting in concentrated periodic components in the parameter adjustment process. The control method in this application embodiment, by introducing defect backtracking and parameter amplitude limiting correction, shows a significant reduction in the spectral peaks near 0.03 and 0.085, with most curves in the 0.10 to 0.20 range maintaining a low amplitude. This result verifies the ability of this invention to reduce parameter correction amplitude and maintain parameter update stability.

[0155] Furthermore, the system statistically analyzed the production status under two sets of tests. Under the comparative control method, the average absolute value of the cycle time deviation was 0.46 seconds, the maximum cycle time deviation was 1.24 seconds, and the percentage of buckles entering the manual confirmation path and rework path was 8.6%. Under the control method of this application embodiment, the average absolute value of the cycle time deviation was 0.18 seconds, the maximum cycle time deviation was 0.52 seconds, and the percentage of buckles entering the manual confirmation path and rework path was 3.1%. These results demonstrate that, without compressing the minimum allowable processing time of the forming protection station, this invention can address cycle time deviations through adjustable waiting stations and perform limited corrections to the corresponding station control parameters through defect backtracking, thereby ensuring the continuity of the buckle processing process and the stability of control parameter updates.

[0156] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A program control method for an automated production line for shower curtain fasteners, characterized in that, Includes the following steps: Before production starts, establish a processing technology table, workstation type table, control parameter table, and defect review table, and confirm the initial status of each workstation. After the buckle enters the production line, a virtual number is assigned, and the workstation processing record formed by the buckle passing through each workstation is recorded according to the virtual number. Based on the processing record of the workstation, the release judgment is made on the status of the buckle in the forming protection workstation to generate a release permission mark, and the cycle deviation is calculated based on the workstation dwell time and then allocated to an adjustable waiting workstation. After the detection station outputs the detection defect code, a complete production record is generated. Based on the defect back-check table, candidate back-check stations are determined and back-check judgment values ​​are calculated. When the back-check judgment value meets the correction conditions, the control parameters of the candidate back-check stations are limited and corrected, and a parameter correction record is generated. The sorting path is determined based on the detected defect code, the release permission mark, and the workstation exception code, and the production data is saved.

2. The program control method for the automated production line of shower curtain fasteners according to claim 1, characterized in that, The processing schedule includes the standard processing time, minimum allowable processing time, maximum allowable waiting time, allowable range of process status, and release conditions for each station. The workstation type table divides the workstations in the production line into material loading and sorting workstations, forming protection workstations, adjustable waiting workstations, inspection workstations, and sorting workstations. The control parameter table includes the adjustable control parameters and corresponding parameter boundaries for each workstation. The defect lookup table includes the correspondence between the detected defect code and the previous workstation, the data type to be read for processing, and the control parameters that allow for correction.

3. The program control method for the automated production line of shower curtain fasteners according to claim 1, characterized in that, The steps for confirming the initial state of each workstation are as follows: Perform legality checks on processing time parameters and control parameters; Perform execution status confirmation, detection status confirmation, and communication status confirmation for each workstation; When all workstations meet the initial state requirements, the production line is allowed to enter automatic operation mode; if any workstation fails to meet the initial state requirements, automatic operation is prohibited and the corresponding workstation's initial state abnormality information is output.

4. The program control method for the automated production line of shower curtain buckles according to claim 1, characterized in that, The step of assigning a virtual number to the buckle after it enters the production line, and recording the station processing records formed by the buckle through each station based on the virtual number, is as follows: The virtual number is generated after the buckle entry signal is detected; Maintain a numbered queue for each workstation according to the workstation flow direction, and update the numbered queue synchronously after the buckle transfer signal is confirmed; The entry and exit times of the buckle are recorded when it enters and leaves each workstation. The dwell time at the workstation is calculated. The positioning status value, processing status value and the workstation error code are collected simultaneously to form the processing record of the workstation.

5. The program control method for the automated production line of shower curtain fasteners according to claim 4, characterized in that, The process of generating the workstation processing record and the complete production record is as follows: When the entry time is earlier than or equal to the exit time, and the workstation exception code is not a data missing exception code, the corresponding workstation processing record is written into the valid record area. When the entry time is later than the exit time, or when the workstation exception code is a data missing exception code, the corresponding workstation processing record will be written into the exception record area. After the buckle is inspected, the virtual number, the processing records of each workstation, and the inspection defect code are associated to generate the complete production record.

6. The program control method for the automated production line of shower curtain fasteners according to claim 1, characterized in that, The step of determining the release status of the buckle at the forming protection station based on the processing record of the workstation and generating a release permission mark is as follows: The station dwell time is compared with the shortest allowable processing time, the positioning status value is compared with the allowable positioning status set, the processing status value is compared with the allowable processing status set, and it is determined whether the station abnormality code is an abnormality code. Based on the comparison results, a release decision quantity is generated, and the release decision quantity is compared with the release threshold to generate the release permission mark; When the release determination quantity reaches the release threshold, the buckle is allowed to enter the next station; When the release determination quantity does not reach the release threshold, the transfer path is determined according to the type of condition not met.

7. The program control method for the automated production line of shower curtain fasteners according to claim 1, characterized in that, The step of calculating the cycle time deviation based on the station dwell time and then allocating it to an adjustable waiting station is as follows: The cycle time deviation is calculated based on the dwell time and standard processing time of the buckle at each workstation. Select the currently adjustable waiting workstation from the adjustable waiting workstations as the cycle processing object; Based on the current waiting state of each of the aforementioned beat processing objects, the beat deviation is allocated to the corresponding beat processing object to obtain the beat processing amount; The beat processing volume is limited according to the single wait adjustment limit value, and the waiting time of the corresponding beat processing object is adjusted according to the actual write value after the limit. During the cycle time allocation process, the actual operating time of the forming protection station is limited to be no less than the minimum allowable processing time.

8. The program control method for the automated production line of shower curtain fasteners according to claim 1, characterized in that, The steps for determining candidate review stations and calculating review judgment values ​​based on the defect review table are as follows: Read the preceding workstation associated with the detected defect code from the defect lookup table as the candidate lookup workstation; Read the station dwell time, positioning status value, processing status value, and station exception code of the candidate retrospective station from the complete production record; The back-check judgment value is determined based on the deviation of workstation dwell time, deviation of positioning status, deviation of processing status, and abnormal status. When the back-check judgment value reaches the back-check judgment threshold, the corresponding candidate back-check workstation is determined as the workstation to be corrected.

9. The program control method for the automated production line of shower curtain fasteners according to claim 8, characterized in that, The steps for performing amplitude limiting correction and generating parameter correction records are as follows: The parameter correction amount is determined based on the detected defect code, the station to be corrected, the control parameter boundary, and the single correction limit value. Based on the parameter correction amount and parameter correction direction, the control parameters that can be corrected in the station to be corrected are increased or decreased to obtain updated values. Apply parameter boundary constraints to the updated value so that the updated control parameter is greater than or equal to the lower limit of the control parameter boundary and less than or equal to the upper limit of the control parameter boundary. Write the updated control parameters into the corresponding workstation parameter area, and record the detected defect code, the workstation number to be corrected, the back-check judgment value, the parameter correction amount, and the updated control parameters to generate the parameter correction record.

10. The program control method for the automated production line of shower curtain fasteners according to claim 1, characterized in that, The step of determining the sorting path based on the detected defect code, the release permission mark, and the workstation exception code, and saving the production data, is as follows: When the detected defect code is a defect-free code, the release permission mark is 1, and the station abnormality codes of each station are all defect-free codes, the sorting path is determined as a qualified product path. When the detected defect code belongs to the rework defect code registered in the production formula, and there is no abnormal code at each workstation that affects the rework judgment, the sorting path is determined as the rework path. When the detected defect code belongs to the scrap defect code registered in the production formula, the sorting path is determined as the scrap path; When there is an inconsistency between the detected defect code, the release permission mark, or the workstation abnormality code, the sorting path will be determined as a manual confirmation path; When an abnormality occurs on the production line, the abnormal workstation number and abnormality type are recorded, material discharge and reset control are executed, and the production data is saved after sorting is completed, abnormality handling is completed, or parameter correction is completed.

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