A hierarchical collaborative program control system and method for a hot galvanizing full process

Abstract

The present application relates to the field of hot galvanizing production control, and discloses a layered collaborative program control system and method for the whole process of hot galvanizing, comprising a state synchronization module, a node deduction module, a space-time calculation module, a resource scheduling module and a closed-loop control module. The state synchronization module generates a time dimension, a linkage program segment and an environment transition state, the node deduction module calculates various indicators of candidate nodes, determines a composite stable node number, generates a commitment section and a collaborative request, the space-time calculation module processes a received time window, configures a boundary label, generates a commitment window set and performs conflict correction, the resource scheduling module completes resource reservation and linkage permission chain generation, and the closed-loop control module updates an available time window according to an action driving instruction, verifies a jointly completed state and advances a program execution pointer. The present application realizes resource reservation and closed-loop control of program execution for the whole process of hot galvanizing through composite stable nodes, time window directional correction and multi-region reservation permission collaboration.

Description

Technical Field

[0001] This invention relates to the field of hot-dip galvanizing production control, specifically a hierarchical collaborative program control system and method for the entire hot-dip galvanizing process. Background Technology

[0002] A hot-dip galvanizing production line includes processes such as pretreatment, workpiece transfer, hot-dip galvanizing, cooling, post-treatment, environmental protection, and resource recycling. When workpieces flow between these processes, they must simultaneously meet process dwell conditions, transfer equipment status, receiving position status, environmental protection status, and safety interlock status. Existing production lines typically employ programmable logic controllers (PLCs), zone control equipment, and a higher-level scheduling system for coordinated control. Each zone executes actions based on feedback from its own equipment and the receiving conditions of adjacent workstations.

[0003] The existing control method mainly arranges workpiece flow based on the completion status of the current workstation and the receiving status of the next workstation, without taking subsequent processes, environment, transfer, and safety conditions as continuous control boundaries. When the environmental preparation, transfer path, or receiving position status of the downstream area changes, the workpiece will stay in the intermediate area, and there is a lack of continuous constraints between process actions, environmental protection actions, and transfer actions.

[0004] During cross-regional scheduling, the receiving time windows of each region are mutually constrained. Existing methods typically involve recalculating the overall schedule or adjusting the timing of equipment actions. When time windows conflict, the system struggles to identify the source of the corresponding constraints and adjustable conditions based on the conflict boundaries. Unrelated regions may also participate in the window recalculation, affecting subsequent scheduling processes.

[0005] Existing resource locking and action permissions are handled separately by different regions. When there is a lack of unified verification of resource reservation status, device status version, action permissions, and on-site feedback, unused permissions will be retained after the device status changes, and the program execution pointer and resource release status will also be inconsistent. Summary of the Invention

[0006] To address the shortcomings of existing technologies, this invention provides a hierarchical collaborative program control system and method for the entire hot-dip galvanizing process, which solves the problems of existing hot-dip galvanizing process control lacking continuous commitment segment control, time window conflict directional correction, and collaborative closed-loop mechanism for resource reservation and action permission.

[0007] To achieve the above objectives, the present invention provides the following technical solution:

[0008] The first aspect of this invention provides a hierarchical collaborative program control system for the entire hot-dip galvanizing process, including a state synchronization module, a node deduction module, a spatiotemporal calculation module, a resource scheduling module, and a closed-loop control module.

[0009] The state synchronization module collects state data based on the time dimension, generates linkage program segments, and establishes environmental transition states.

[0010] The node deduction module acquires the actual state of the current node during environmental transitions, calculates various markers for candidate nodes, determines the composite stable node number based on the node search formula, and generates commitment segments and coordination requests from the linkage program segments based on the actual state of the current node. The commitment segment defines the process program segments, transfer program segments, and environmental program segments that are executed continuously during the period from the position corresponding to the actual state of the current node to the candidate node corresponding to the composite stable node number.

[0011] The spatiotemporal calculation module obtains the reception time window for the relevant region based on the collaboration request and configures boundary labels. The module then performs a reverse conversion of the reception time window and calculates its intersection with the process initiation window to obtain a commitment window set. When the commitment window set is empty, the module forms conflict boundary pairs based on the boundary labels and performs conflict correction, ensuring that the time window adjustment corresponds to the region constraints and boundary attributes that caused the conflict.

[0012] When a reservation request passes verification, the resource scheduling module generates a confirmed and effective reservation, and combines this with the committed segment to generate a linkage permission chain. When the permission output status of the linkage permission chain is satisfied, the resource scheduling module outputs an action-driven command.

[0013] The closed-loop control module generates an available time window based on the action-driven instructions. When the available time window is an empty set or the duration is less than the preset time requirement, it releases the confirmed effective reservations that have not been referenced by consumed licenses. The closed-loop control module verifies the actual bistable state. When the actual bistable state is satisfied, it verifies the joint completion state and advances the program execution pointer.

[0014] Furthermore, the state synchronization module includes a time synchronization unit and a program generation unit.

[0015] The time synchronization unit sends out a synchronization frame that includes a reference time, a request sequence number, and a status version number. It determines the reference time based on the clock synchronization record or the reference count value, the event count value, and the sampling period, and outputs the time dimension after the acquisition version number, request sequence number, and status version number have been verified.

[0016] The program generation unit generates a sequence of program segments based on the time dimension and process attributes, configuring the shortest execution time, longest execution time, environmental control events, action lead time, and action lag time, and generating linked program segments and environmental transition states. Process attributes include workpiece number, workpiece type, process route, process parameters, production sequence, and program version.

[0017] Furthermore, the node deduction module includes a state deduction unit and a stability determination unit.

[0018] The state inference unit obtains the actual state of the current node under the environmental transition state. Based on the process route in the process attributes and the actual state of the current node, it infers the expected workpiece holding state, expected environmental protection state and expected transfer availability state of the candidate node, and generates node prediction data.

[0019] The stability determination unit maps the process holding conditions, expected environmental protection status, and expected transfer availability status of candidate nodes, as well as the safety loop status and PLC local safety interlock status, to workpiece holding markers, environmental protection markers, transfer availability markers, and safety holding markers, respectively, and determines the composite stable node number based on the node search formula.

[0020] Furthermore, the node deduction module also includes a segment delineation unit.

[0021] The segment delineation unit uses the current program execution pointer and the composite stable node number as the interception boundary to extract the process program segment, transfer program segment and environmental program segment from the linkage program segment, and generate commitment segments and collaboration requests.

[0022] The collaborative request carries the program segment sequence corresponding to the committed segment, the resources used, the shortest execution time, the longest execution time, the environmental control event, the status version number, and the request sequence number, so that the relevant regions can generate a receiving time window.

[0023] Furthermore, the spatiotemporal calculation module includes a window projection unit.

[0024] The window projection unit processes the receiving time window generated by the regional terminal in the relevant area according to the coordination request into discrete receiving intervals, and configures boundary labels for the discrete receiving intervals.

[0025] Boundary labels include the constraint source region, adjustable attributes, and region state version. The window projection unit accumulates the shortest single-step time and longest single-step time of the intermediate program segment within the commitment section, generates an effective start time window based on the projection conversion formula, and removes inverted intervals where the start time is later than the end time.

[0026] Furthermore, the spatiotemporal computing module also includes an intersection computing unit and a conflict correction unit.

[0027] The intersection calculation unit performs intersection calculation on the process start-up window and the effective start-up time window according to the intersection calculation formula, and outputs the commitment window set.

[0028] When the commitment window set is empty, the conflict correction unit determines the latest start time and earliest end time based on the start and end times of the current interval in each round, traces the corresponding boundary labels to form conflict boundary pairs, and sends an early adjustment request or a delayed adjustment request accordingly. The regional terminal in the relevant area generates a projected adjusted time window. If the projected adjusted time window does not affect the confirmed and effective commitment segments and the regional state version is consistent with the current calculation task, the spatiotemporal calculation module regenerates the commitment window set. If the commitment window set is still empty and the actual state of the current node meets the preset composite stable state, the spatiotemporal calculation module outputs a dwell instruction.

[0029] Furthermore, the resource scheduling module includes a resource reservation unit.

[0030] The resource reservation unit sends reservation requests to relevant areas based on the committed window set and the occupied resources in the committed segment. The regional terminal of the relevant area verifies the resource occupancy status, reservation time interval, full process status version, and PLC local safety interlock status corresponding to the reservation request. When the verification is successful, a temporary lock status is established and a reservation feedback status is returned.

[0031] After receiving the reservation feedback status, the resource reservation unit verifies the status of the confirmed temporary reservation in each relevant area and the consistency of the device status version according to the reservation formula; if the verification is successful, an activation command is sent to change the temporary lock status of the relevant area terminal to the confirmed effective reservation and return the activation feedback status; if the verification fails, a rollback command and a window recalculation command are sent.

[0032] When all regional terminals in the relevant areas return an effective feedback status, a global resource lock is established for the workpiece number, committed segment number, and resource number in the reservation request.

[0033] Furthermore, the resource scheduling module also includes a license issuance unit.

[0034] The license issuance unit generates a linked license chain based on the confirmed effective reserved and committed segments. The linked license chain includes environmental preparation license, workpiece transfer license, process execution license, environmental maintenance license, and environmental release license. The local controller verifies the workpiece number, program version, program segment pointer, license validity range, confirmed effective reserved status, previous sub-license completion status, and PLC local safety interlock status corresponding to the sub-licenses in the linked license chain according to the license verification formula, and generates a license output status; when the license output status is a logical truth value of 1, the local controller outputs an action drive instruction.

[0035] Furthermore, the closed-loop control module includes a dynamic calculation unit and a state joint unit.

[0036] The dynamic rolling calculation unit receives feedback data associated with the action-driven instructions, calculates the expected arrival time interval based on the actual completion time, the current program execution pointer, and the flow time margin in the feedback data, compares the expected arrival time interval with the receiving time window corresponding to the unconsumed license, and generates an available time window.

[0037] The state coordinating unit verifies the actual workpiece holding state, the actual environmental protection state, the actual transfer availability state, and the actual safety holding state. If all four states are satisfied, the actual bistable state is determined to be satisfied. The state coordinating unit then verifies the physical arrival state, the process completion state, the equipment disengagement state, the action completion state, and the permission chain closure state, generating a coordinating completion state. When the coordinating completion state is satisfied, the closed-loop control module advances the program execution pointer and cancels the global resource lock.

[0038] A second aspect of this invention provides a layered collaborative program control method for the entire hot-dip galvanizing process, comprising the following processing steps:

[0039] The state synchronization module collects state data based on the time dimension, generates linkage program segments, and establishes environmental transition states.

[0040] The node inference module obtains the actual state of the current node during the environmental transition state, calculates various markers of the candidate node, determines the composite stable node number according to the node search formula, and generates the commitment segment and cooperation request from the linkage program segment in combination with the actual state of the current node.

[0041] The spatiotemporal calculation module obtains the receiving time window and configures the boundary label according to the collaboration request. It then performs reverse conversion of the receiving time window and performs intersection calculation with the preset process start window to obtain the commitment window set. When the commitment window set is empty, it forms conflict boundary pairs according to the boundary label and performs conflict correction.

[0042] When the reservation request is verified, the resource scheduling module generates a confirmed and effective reservation, generates a linkage permission chain in combination with the committed segment, and outputs action-driven instructions based on the permission output status of the linkage permission chain.

[0043] When the available time window is empty or the duration is less than the preset time requirement, the closed-loop control module releases the confirmed effective reservations that have not been referenced by consumed licenses, verifies the actual bistable state, and verifies the joint completion state when the actual bistable state is satisfied, and advances the program execution pointer.

[0044] This invention provides a layered collaborative process control system and method for the entire hot-dip galvanizing process. It has the following beneficial effects:

[0045] 1. This invention delineates the commitment segment based on the actual state of the current node and the composite stable node number, and incorporates the process program segment, transfer program segment and environmental program segment into the continuous control range. The system jointly deduces the process maintenance conditions, environmental protection conditions, transfer availability conditions and safety conditions of the candidate node, and determines the downstream composite stable node number accordingly, thereby reducing the situation where the workpiece stays in the transfer path or the area where the environmental protection conditions are not met.

[0046] 2. By processing the receiving time window into discrete receiving intervals and recording the constraint source region, adjustable attributes, and region status version in the boundary label, the system can form conflict boundary pairs based on the latest start time and the earliest end time when the commitment window set is empty, and send early adjustment requests or delayed adjustment requests to the corresponding regions, thereby reducing the participation of irrelevant regions in window recalculation.

[0047] 3. This invention completes the reservation of resources in multiple regions through temporary locking state, reserved feedback state, effective command and rollback command, and uses the confirmed effective reservation as the execution basis of the linkage permission chain. After the local controller completes the sub-permission verification, it outputs the action drive command. The closed-loop control module updates the available time window according to the feedback data, and combines the joint completion state to advance the program execution pointer and cancel the global resource lock, so that the resource release and program advancement correspond to the same field state. Attached Figure Description

[0048] Figure 1 This is a system architecture diagram of the present invention;

[0049] Figure 2 This is a flowchart of the method of the present invention;

[0050] Figure 3 This is a working logic diagram of the state synchronization module of the present invention;

[0051] Figure 4 This is a working logic diagram of the node deduction module of the present invention;

[0052] Figure 5 This is a working logic diagram of the spatiotemporal calculation module of the present invention;

[0053] Figure 6 This is a working logic diagram of the resource scheduling module of the present invention;

[0054] Figure 7 This is a working logic diagram of the closed-loop control module of the present invention;

[0055] Figure 8 This is a timing diagram of the execution of the commitment section of the workpiece in an application embodiment of the present invention;

[0056] Figure 9 This is a Gantt chart showing the effective startup time windows for each region in an application embodiment of the present invention;

[0057] Figure 10 This is a Gantt chart showing the effective start-up time window of the cooling area before and after conflict correction in an application embodiment of the present invention.

[0058] Figure 11 This is a box plot showing the total time from workpiece completion to cooling and receiving position in an application embodiment of the present invention. Detailed Implementation

[0059] 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.

[0060] Please see the appendix Figure 1 This invention provides a hierarchical collaborative program control system for the entire hot-dip galvanizing process, comprising:

[0061] The status synchronization module is used to send a synchronization frame, including reference time, request sequence number and status version number, through the master clock. It determines the reference time based on the clock synchronization record or reference count value, event count value and preset sampling period, removes the collected data with inconsistent version numbers, outputs the time dimension, and generates linkage program segments and environmental transition states.

[0062] The node simulation module is used to obtain the actual status of the current node, and combine it with the preset flow rate, preset reservation plan, program execution progress, preset available equipment status, preset environmental action completion status and preset effective reservation status to simulate the expected workpiece holding status, expected environmental protection status, expected transfer availability status and safety holding mark of the candidate node; the node simulation module determines the composite stable node number through the node search formula, and generates the commitment segment accordingly.

[0063] The spatiotemporal calculation module is used to receive the receiving time windows generated in the relevant area, process the receiving time windows into discrete receiving intervals and configure boundary labels; the spatiotemporal calculation module generates an effective start time window based on the cumulative shortest time and cumulative longest time through the projection conversion formula, and generates a commitment window set through the intersection calculation formula; when the commitment window set is an empty set, the spatiotemporal calculation module generates adjustment time boundaries or dwell instructions based on the conflict boundary pairs.

[0064] The resource scheduling module is used to send reservation requests to relevant areas based on the commitment window set, and generate confirmed effective reservation or window recalculation instructions according to the reservation feedback status, device status version and current decision version. The resource scheduling module generates a linkage permission chain based on the confirmed effective reservation and commitment segment, and the local controller outputs action driving instructions according to the permission verification formula.

[0065] The closed-loop control module is used to update the available time window based on feedback data and flow time margin, revoke unconsumed licenses and release confirmed effective reservations that are not referenced by consumed licenses; the closed-loop control module verifies the actual bistable state and joint completion state, advances the program execution pointer and cancels the global resource lock; the closed-loop control module completes the switching between the old version program flow and the new version program flow according to the version switching formula.

[0066] See appendix Figure 2 This invention also provides a hierarchical collaborative program control method for the entire hot-dip galvanizing process, comprising the following steps:

[0067] S1, the status synchronization module sends out a synchronization frame and determines the reference time based on the clock synchronization record or reference count value, event count value, and sampling period. The status synchronization module verifies the status version number and acquisition version number and outputs the time dimension; the status synchronization module generates linkage program segments and environmental transition states based on process attributes, status data, and process routes.

[0068] S2, the node deduction module obtains the actual state of the current node and deduces the state of candidate nodes, generating the expected workpiece holding state, expected environmental protection state, expected transfer availability state, and safety holding marker. The node deduction module determines the composite stable node number through the node search formula and generates the commitment segment based on the actual state of the current node and the composite stable node number.

[0069] S3, the spatiotemporal calculation module acquires the receiving time windows generated in the relevant region and forms discrete receiving intervals with boundary labels. Based on the cumulative shortest and longest times of intermediate program segments within the commitment segment, the spatiotemporal calculation module generates an effective start-up time window according to the projection conversion formula; the module also generates a commitment window set based on the intersection calculation formula. When the commitment window set is empty, the spatiotemporal calculation module generates adjusted time boundaries based on conflict boundary pairs and recalculates the commitment window set.

[0070] S4, the resource scheduling module sends reservation requests to relevant areas based on the commitment window set. The resource scheduling module generates confirmed and effective reservations or generates window recalculation instructions based on the reservation feedback status, device status version, and current decision version. The resource scheduling module generates a linkage permission chain based on the confirmed and effective reservations and the committed segments, and the local controller outputs action-driven instructions according to the permission verification formula.

[0071] S5, the closed-loop control module receives feedback data, updates the available time window based on the remaining flow time, and revokes unconsumed licenses and releases confirmed effective reservations not referenced by consumed licenses. The closed-loop control module verifies the actual bistable state and joint completion state, advances the program execution pointer, and cancels the global resource lock. Based on the version switching formula, the closed-loop control module enables the new version of the program flow when the old version meets the switching conditions.

[0072] To make the technical solutions in the embodiments of the present invention clearer and more complete, the technical solutions are further explained below in conjunction with each specific processing flow.

[0073] See appendix Figure 3 In this embodiment, step S1 is executed by the state synchronization module. The state synchronization module includes a time synchronization unit and a program generation unit, which are used to establish the time dimension, verify the field state data, and generate linkage program segments and environmental transition states.

[0074] S11, the time synchronization unit sends out a synchronization frame, determines the reference time, and outputs the time dimension that has passed the verification.

[0075] The time synchronization unit uses the master clock to send synchronization frames to each area. The synchronization frame contains a reference time, a request sequence number, and a status version number. The reference time is the starting timescale of the current calculation cycle; the request sequence number is used to associate the same round of status acquisition; and the status version number identifies the field status version used in the current calculation cycle. The status version number is updated when the workpiece position, equipment occupancy status, interlock and fault status, confirmed effective reservations, or program execution pointer changes.

[0076] In areas with a synchronization protocol, the regional terminal calibrates its local clock based on a reference time and generates a clock synchronization record. The clock synchronization record includes the region number, request sequence number, status version number, synchronization completion time, and clock deviation value; the time synchronization unit determines the base time based on the clock synchronization record and the reference time.

[0077] In areas lacking network time synchronization capabilities, the underlying controller latches its local counter and generates a reference count value when receiving a synchronization frame. When the area terminal acquires information such as sensor status changes, actuator completion, workpiece arrival / departure, environmental equipment status switching, or safety loop status changes, it latches its local counter and generates an event count value. The time synchronization unit subtracts the reference count value from the event count value and multiplies it by the sampling period to obtain the time offset. This time offset is then added to a reference time to obtain the reference time corresponding to the field event.

[0078] The sampling period is set based on the counter resolution and scan period of the underlying controller. For example, if the scan period of the underlying controller is 10ms to 50ms, the sampling period is set to 10ms to 50ms. When the counter uses a cyclic counting method, if the event count value is less than the reference count value and the count difference is within one counting period, the time synchronization unit adds the event count value to the counting range and calculates the count difference. If the count difference exceeds one counting period, the corresponding acquired data is marked as invalid data.

[0079] The acquisition version number is written by the regional terminal when collecting data on-site. The time synchronization unit compares the acquisition version number, request sequence number, and status version number, and checks whether the acquisition response time is within the preset range. The acquisition response time is set based on the calculation cycle and communication cycle. For example, when the calculation cycle is 1 second to 5 seconds, the acquisition response time is no more than one calculation cycle. When the acquired data from all relevant regions passes verification, the time synchronization unit associates the base time, region number, request sequence number, and status version number, and outputs the time dimension. If any relevant region fails verification, the time dimension of the current calculation cycle is not output, no new linkage program segment is generated, and the synchronization frame is resent in the next calculation cycle.

[0080] Among them, the status version number is the full-process status version, the regional status version is the version formed by the regional terminal based on the status of devices in the region, and the device status version is the status identifier of the corresponding device under the regional status version.

[0081] S12, the program generation unit collects state data based on the time dimension and generates timing program segments, linkage program segments and environmental transition states.

[0082] The program generation unit reads process attributes and parameters including workpiece number, workpiece type, process route, production sequence, and program version, and collects physicochemical status, transfer status, actuator status, environmental protection status, and resource regeneration status based on the time dimension. Physicochemical status includes process tank level, concentration, pH value, temperature, and treatment status; transfer status includes the location, occupancy status, and runnable path of the rack, crane, or RGV (Rail Guided Vehicle); environmental protection status includes closed status, negative pressure status, fan operation status, acid mist collection status, and zinc fume collection status.

[0083] The program generation unit compares analog quantities with the allowable range of process parameters and compares digital quantities with equipment feedback status to generate status data. The allowable range of process parameters is set according to the galvanizing process specifications, equipment rated parameters, and safe operation requirements. For example, the allowable range of zinc pot temperature is 430℃ to 470℃. When the position sensor continuously outputs an arrival signal for a preset duration, the workpiece position is written into the transfer status. The preset duration is set according to the sensor response time and the scanning cycle of the underlying controller, for example, 100ms to 500ms.

[0084] The program generation unit decomposes process attributes and status data into a sequence of program segments based on the process route. Each program segment includes a program segment number, entry conditions, execution actions, completion conditions, minimum execution time, maximum execution time, resource usage, input workpiece status, output workpiece status, environmental control events, normal completion path, and abnormal recovery path.

[0085] The program generation unit configures the minimum and maximum execution times for each program segment, generating timing program segments. The minimum execution time is set based on the minimum processing time, the minimum running time of the transfer equipment, and the minimum preparation time of the environmental equipment; the maximum execution time is set based on the maximum allowable dwell time, the maximum running time of the transfer path, and the maximum recovery time of the environmental equipment. For example, the minimum execution time for the fluxing program segment is 60s to 180s, and the maximum execution time is 300s to 900s.

[0086] The program generation unit associates timing program segments with environmental control events and configures action lead and lag amounts to generate linked program segments. Environmental control events include closed-room door control, fan status switching, acid mist collection, zinc fume collection, environmental maintenance, and environmental release. The action lead amount is set based on the time required for the environmental equipment to reach the specified negative pressure or collection state, and the action lag amount is set based on the collection time of residual acid mist or zinc fume after the workpiece leaves the corresponding area; for example, the action lead amount is 20s to 120s, and the action lag amount is 15s to 90s.

[0087] The program generation unit sends operating instructions to the environmental protection equipment based on the linkage program segment, establishing an environmental transition state. The environmental transition state includes a closed state, a negative pressure state, a fan operating state, and a treatment equipment availability state. The regional terminal writes the execution feedback from the environmental protection equipment into the status data; when the environmental transition state meets the completion conditions of an environmental control event, the corresponding linkage program segment enters the subsequent node deduction process; otherwise, the entry condition for the corresponding program segment remains unmet.

[0088] See appendix Figure 4In this embodiment, step S2 is executed by the node deduction module. The node deduction module includes a state deduction unit, a stability determination unit, and a segment delineation unit, which are used to determine the composite stable node number and generate a commitment segment with the current actual node state and the candidate node corresponding to the composite stable node number as the boundary.

[0089] S21, the state inference unit obtains the actual state of the current node under the environmental transition state and generates the node prediction data corresponding to the candidate node.

[0090] The state deduction unit determines the current node number based on the actual workpiece position, program execution pointer, hanger number, crane number, or RGV number. When the workpiece position feedback matches the process position pointed to by the program execution pointer, the actual state of the current node is generated; when they do not match, the current position is marked as pending confirmation, and the current program execution pointer remains stationary.

[0091] The current node's actual status includes the actual workpiece holding status, the actual environmental protection status, the actual transfer availability status, and the actual safety holding status, which are determined based on the workpiece position and dwell conditions, the closed state and negative pressure state, the path release and receiving position status, the safety loop status, and the PLC (Programmable Logic Controller) local safety interlock status, respectively.

[0092] The state deduction unit extracts candidate nodes after the current node from the process route. Candidate nodes include process tank receiving position, rack waiting position, crane or RGV handover position, zinc pot feeding position, cooling zone receiving position, passivation zone receiving position, and unloading position, and are associated with node number, area number, allowed input workpiece state, allowed output workpiece state, receiving position state, and process holding conditions.

[0093] The preset node search range is set based on the number of continuous process areas, transfer path length, and sustainable positions, covering at least all candidate nodes between the current node and the next sustainable position; for example, including 2 to 8 candidate nodes after the current node. If no composite stable node number is obtained within the current range, the state simulation unit expands the node search range in the next calculation cycle until it covers the next sustainable position of the current process route. The state simulation unit performs spatiotemporal calculations on candidate nodes based on preset flow rates, preset reservation plans, program execution progress, preset available equipment status, preset environmental action completion status, and preset effective reservation status.

[0094] The preset flow rate is set based on the rated operating speed, acceleration time, deceleration time, and path length of the rack, crane, or RGV, for example, from 0.1m / s to 1.5m / s. The preset reservation plan includes confirmed and effective reservations, prepared but not yet effective temporary reservations, and resource allocation plans for uncommitted tasks; the program execution progress includes the current program execution pointer, completed program segments, currently executing program segments, unconsumed licenses, and the remaining execution time of the current equipment action.

[0095] The state deduction unit calculates the estimated arrival time of candidate nodes according to the normal completion path of the program segment sequence, and excludes candidate nodes whose resources are occupied, whose equipment is in a fault or maintenance state, whose environmental actions are not completed, or whose PLC local safety interlock status is not met within the estimated arrival time.

[0096] The state simulation unit generates the expected workpiece holding state based on the process holding conditions, the expected environmental protection state based on the closed state, negative pressure state, fan operation state and processing equipment availability state, and the expected transfer availability state based on the runable path, path occupancy state, collision avoidance state, laser ranging state and receiving position state.

[0097] The process holding conditions are set based on the allowable residence time, the state of the process bath, the operating conditions of the zinc pot, and the input state of the workpiece. For example, the allowable residence time from fluxing to hot-dip galvanizing is 300s to 900s. The threshold for negative pressure is set based on the design airflow of the enclosed area, contaminant collection requirements, and the range of the pressure detection device, for example, -5Pa to -30Pa; it is considered satisfied when the fan operates at 80% to 100% of its rated speed. The anti-collision status is determined based on the anti-collision detection results between the transfer equipment; the laser ranging status is determined based on the detection distance between the transfer equipment and the workpiece, the process bath, and the receiving position. When the anti-collision detection results and detection distances meet the PLC local safety interlock status, the expected transfer availability status is satisfied.

[0098] The state simulation unit associates the expected workpiece status, expected environmental support status, expected transfer availability status, candidate node number, expected arrival time, status version number, and effective reserved status to generate node prediction data. When the status version number changes during the simulation, the state simulation unit discards the current node prediction data and re-simulates based on the new time dimension.

[0099] S22, the stability determination unit determines the composite stable node number based on the node prediction data, and generates a standby instruction or an escape transfer instruction when the stability conditions are not met.

[0100] The stability determination unit maps the node prediction data to various markers (including workpiece holding markers, environmental assurance markers, transfer availability markers, and safety holding markers). The specific mapping process is as follows:

[0101] The stability determination unit maps process holding conditions to workpiece holding markers, closed state, negative pressure state, fan operating state, and processing equipment availability state to environmental protection markers, collision avoidance state, laser ranging state, and receiver position state to transfer availability markers, and safety loop state and PLC local safety interlock state to safety holding markers. When the corresponding condition is met, the marker is 1; when it is not met, the marker is 0. The stability determination unit uses a node search formula to determine the smallest composite stable node number after the current node:

[0102] ;

[0103] In the formula, Number the composite stable nodes; This is an operation to find the minimum value; Number the candidate nodes; Number the current node; This is a condition separator; Candidate nodes The corresponding workpiece retains the markings; Candidate nodes Corresponding environmental protection markings; Candidate nodes The corresponding transshipment markers are available; Candidate nodes Corresponding safety holding markers; For logical AND operation; The result of the logical combination is equal to the logical truth value 1.

[0104] When the current node's actual state meets the preset composite stability state and the composite stable node number is not empty, the stability determination unit outputs the composite stable node number. The preset composite stability state is a state in which the actual workpiece holding state, the actual environmental protection state, the actual transfer usable state, and the actual safety holding state are all satisfied.

[0105] When the composite stable node number is empty and the actual state of the current node meets the preset composite stable state, the stability determination unit generates a standby instruction. The regional terminal maintains the current position of the workpiece and the corresponding environmental protection state, and re-executes the candidate node simulation when the equipment status version changes, inactive reserved releases occur, environmental actions are completed, or the preset standby review period expires. When the actual state of the current node does not meet the preset composite stable state, the stability determination unit does not generate a new commitment segment and generates an escape transfer instruction.

[0106] The escape transfer instruction includes the workpiece number, current node number, program version, target safe location, permitted transfer path, environmental maintenance requirements, and valid status version. The target safe location is determined based on the nodes that have been confirmed as acceptable in the current linkage permission chain; if there are no acceptable nodes in the current linkage permission chain, the target safe location is the location within the area where safe dwell is permitted. The area terminal executes safety actions based on the PLC's local safety interlock status and anomaly recovery path, and maintains the corresponding environmental protection status until the workpiece position is reconfirmed.

[0107] S23, the segment delineation unit generates a committed segment based on the current node's actual state and the composite stable node number, and sends a coordination request to the relevant region.

[0108] When the current node's actual state meets the preset composite stable state and the composite stable node number is not empty, the segment delineation unit reads the linkage program segment between the current program execution pointer and the composite stable node number, extracts the process program segment, transfer program segment, and environmental program segment, and encapsulates them according to the normal completion path, actual execution order, action lead time, and action lag time to generate the commitment segment.

[0109] The commitment section includes the commitment section number, workpiece number, program version, starting node number, composite stable node number, program segment sequence, resources used, input workpiece status, output workpiece status, shortest execution time, longest execution time, environmental control events, normal completion path, and abnormal recovery path.

[0110] The segment delineation unit determines the relevant areas based on resource usage and environmental control events, and packages the committed segments into a coordination request, sending it to the regional terminals in the relevant areas. The coordination request includes the workpiece number, program version, committed segment number, starting node number, composite stable node number, program segment sequence, resource usage, shortest execution time, longest execution time, environmental control events, status version number, and request sequence number. The composite stable node number is used for committed segment planning and is not used as the basis for program execution pointer advancement or resource release.

[0111] See appendix Figure 5 In this embodiment, step S3 is executed by the spatiotemporal calculation module. The spatiotemporal calculation module includes a window projection unit, an intersection calculation unit, and a conflict correction unit, which are used to generate a set of valid start-up time windows and commitment windows, and to correct conflict boundary pairs when the commitment window set is empty.

[0112] S31, the window projection unit acquires the receiving time window and generates a discrete receiving interval and an effective start time window.

[0113] After receiving the coordination request, the regional terminals in the relevant areas generate a receiving time window based on the workpiece number, committed section number, program segment sequence, occupied resources, environmental control events, and status version number. The pre-processing area generates a process receiving time window based on the state of the process bath and process holding conditions; the transfer area generates a transfer receiving time window based on the location of the transfer equipment, path occupancy status, and action interlocks; the hot-dip galvanizing area, post-processing area, environmental protection area, and resource regeneration area generate receiving time windows based on the corresponding equipment occupancy status, environmental control events, and processing program running status, respectively.

[0114] The regional terminal excludes time periods where resources are reserved and confirmed to be in effect, equipment is in a fault or maintenance state, PLC local safety interlock status is not met, or environmental control events cannot be completed on time, forming non-overlapping discrete receiving intervals. The window projection unit configures boundary labels for the start and end boundaries of each discrete receiving interval. The boundary labels include the constraint source region, corresponding device or program segment, boundary type, adjustable attributes, control actions that can change the boundary, and region status version.

[0115] Process hold conditions and PLC local safety interlocks form non-adjustable boundaries; inactive tasks, switchable equipment, environmental preparation procedures that can be executed in advance, and uncommitted tasks that can be postponed form adjustable boundaries. The window projection unit accumulates the shortest and longest single-step times of intermediate program segments between the current program segment and the constraint object according to the actual execution order, obtaining the cumulative shortest and longest cumulative times. The cumulative time includes process execution time, transfer time, and environmental preparation time; when the cumulative shortest time is greater than the cumulative longest time, the corresponding program segment sequence is invalid, the window projection unit does not generate a valid start time window, and sends a program segment sequence review request to the program generation unit.

[0116] The window projection unit uses the projection conversion formula to inversely convert the receiving time window of the constraint object into the effective start time window of the current program segment:

[0117] ;

[0118] In the formula, For constraint objects Reverse conversion to the current program segment The effective startup time window; The number of the constraint object; This is the number of the current program segment; This is a multi-interval union operation; It is a delimiter for closed intervals; For discrete receiving intervals, use the index number. For constraint objects The total number of corresponding discrete receiving intervals; For the first Each reception start time; For the first Each reception end time; The current program segment Start-up to reaching the constraint object The shortest cumulative time; The current program segment Start-up to reaching the constraint object The longest cumulative time.

[0119] When the start time of the effective start time window is later than the end time, the window projection unit will discard the corresponding interval as an inverted interval. When the regional status version is inconsistent with the status version number in the coordination request, the window projection unit will not use the corresponding discrete receiving interval, but will send a status acquisition request to the status synchronization module, and will resend the coordination request after obtaining the new time dimension and the new committed segment.

[0120] S32, the intersection calculation unit generates a commitment window set based on the process start window and the effective start time window.

[0121] The intersection calculation unit reads the process start window of the current program segment. The process start window is a set of closed intervals that meet the entry conditions, process holding conditions, and PLC local safety interlock status. Its starting boundary is determined based on the startable time of the current workpiece, and its ending boundary is determined based on the allowable range of process parameters, the maximum allowable dwell time, or the release time of the preceding resources.

[0122] The intersection calculation unit sorts the closed intervals in the effective start time windows corresponding to the process start window and each constraint object by their start time, and sets a current interval pointer for each time window set. The intersection calculation unit reads the start and end times of each current interval, determines the maximum value among all start times as the candidate start time, and determines the minimum value among all end times as the candidate end time.

[0123] When the candidate start time is not later than the candidate end time, the intersection calculation unit constructs a commitment interval using the candidate start time and candidate end time, and writes it into the commitment window set. When the candidate start time is later than the candidate end time, it is not written into the commitment interval in this round. After each round of calculation, the intersection calculation unit advances the pointers of all current intervals with the earliest end time; the intersection calculation ends when no subsequent closed interval exists in any time window set.

[0124] When the commitment window set contains a commitment interval, the spatiotemporal calculation module sends the commitment window set to the resource scheduling module; when the commitment window set is empty, the spatiotemporal calculation module generates a conflict correction instruction.

[0125] S33, the conflict correction unit generates an adjustment time boundary based on the conflict boundary and recalculates the commitment window set.

[0126] The conflict correction unit reads the start and end times of the activity in the current interval of each round, determines the maximum value of the start time as the latest start time, determines the minimum value of the end time as the earliest end time, and traces the corresponding boundary labels to form conflict boundary pairs.

[0127] When the latest start time corresponds to an adjustable start boundary, the conflict correction unit sends an early adjustment request. This request may include advancing environment preparation, releasing inactive reservations, selecting other available transfer equipment, or adjusting uncommitted tasks. When the earliest end time corresponds to an adjustable end boundary, the conflict correction unit sends a delayed adjustment request. This request may include extending inactive reservations or delaying other uncommitted tasks.

[0128] Unadjustable boundaries, confirmed effective reservations, licenses already consumed by the PLC, and workpieces already in continuous commitment segments are not subject to adjustment. The relevant area's regional terminal generates an estimated post-adjustment time window based on the current equipment status, program execution progress, and resource occupancy status. The estimated post-adjustment time window does not affect confirmed effective commitment segments. If the regional status version is consistent with the current calculation task and the same adjustment action is not repeated, the conflict correction unit re-executes the intersection calculation.

[0129] When none of the adjustable boundaries can form a commitment window set, and the actual state of the current node satisfies the preset composite stable state, the conflict correction unit generates a dwell instruction, and the regional terminal controls the workpiece to remain in the actual state of the current node and maintain the corresponding environmental protection state; when the actual state of the current node does not satisfy the preset composite stable state, the spatiotemporal calculation module sends a state update request to the node inference module.

[0130] See appendix Figure 6 In this embodiment, step S4 is executed by the resource scheduling module. The resource scheduling module includes a resource reservation unit and a license issuance unit, which are used to convert the commitment window set into confirmed effective reservations and generate a linkage license chain based on the confirmed effective reservations.

[0131] S41, the resource reservation unit performs temporary reservation, verification, activation or rollback based on the commitment window set.

[0132] The resource reservation unit selects a commitment interval from the commitment window set that does not conflict with already confirmed and effective reservations. If multiple commitment intervals exist, the one with the earliest start time is selected; if the start times are the same, the commitment interval with the longer duration is selected. If a commitment interval cannot cover the cumulative shortest to the cumulative longest duration of the commitment segment, the resource reservation unit sends a window recalculation instruction to the spatiotemporal calculation module.

[0133] The resource reservation unit determines the current decision version based on the full-process status version corresponding to the commitment window set and sends reservation requests to relevant areas according to the occupied resources. The reservation request includes information such as the workpiece number, program version, commitment segment number, resource number, reservation time interval, full-process status version, and reservation expiration conditions. Reservation expiration conditions include failure to receive an activation instruction within the validity period, a change in the full-process status version, the end of the reservation time interval, or resource failure.

[0134] Each reservation request has a unique reservation number. The validity period of a reservation request is set based on the communication cycle, the regional terminal response time, and the current calculation cycle. For example, if the regional terminal response time is 0.5s to 3s, the validity period of the reservation request is 1s to 10s. When a regional terminal receives a duplicate reservation request with the same reservation number, it returns the already generated reservation feedback status and does not lock the resource again.

[0135] The regional terminal in the relevant area verifies the resource occupancy status, reserved time interval, full-process status version, and PLC local safety interlock status. If the reserved time interval overlaps with a confirmed effective reservation or other temporary reservation, or if the resource is in a fault state, maintenance state, or the PLC local safety interlock status is not met, a rejection status is returned. If the verification passes, the corresponding resource is marked as temporarily locked and a reservation feedback status is generated. The temporary locked status does not trigger equipment actions and does not constitute a confirmed effective reservation. When a rollback command is received, the validity period expires, the full-process status version changes, or the resource status changes, the regional terminal releases the temporary locked status.

[0136] The resource reservation unit receives the reservation feedback status and compares the device status version with the corresponding device status version recorded in the reservation request. The current decision version is the full-process status version used when generating the commitment window set. When the device status version changes, the regional terminal rejects the corresponding reservation request and returns the new device status version. The resource reservation confirmation status is determined by the reservation formula:

[0137] ;

[0138] In the formula, For the commitment section The resource reservation confirmation status, when set to a logical truth value of 1, indicates that all relevant areas have passed confirmation; the superscript... This indicates that resources are reserved in multiple regions; For multi-condition continuous logical AND operation; Numbering of the relevant area; This represents the total number of relevant regions; For the region The status of the temporary reservation has been confirmed. For the region The device status version is consistent with the corresponding device status version recorded in the reservation request.

[0139] When the resource reservation confirmation status is logically true (1), the reservation request verification is successful, and the resource reservation unit sends an activation instruction to each relevant region. The regional terminal re-verifies the temporary lock status, resource status, and full-process status version. If the verification is successful, the temporary lock status is changed to confirmed effective reservation, and an activation feedback status is returned.

[0140] If any region rejects temporary reservation, has inconsistent device status versions, fails to return a reservation feedback status within the validity period, or fails to return an effective feedback status, the resource reservation unit sends a rollback command to the regions that have been temporarily locked or have confirmed effective reservations, and sends a window recalculation command to the spatiotemporal calculation module. When all relevant regions return an effective feedback status, the resource reservation unit sends the confirmed effective reservation to the license issuance unit and establishes a global resource lock for the workpiece number, committed section number, and resource number; if the effective feedback status is incomplete, the license issuance unit does not generate a linkage license chain.

[0141] S42, the license issuance unit generates a linkage license chain based on the confirmed effective reserved and committed segments, and outputs action drive instructions after verification by the local controller.

[0142] The permit issuance unit configures the action flow based on the process procedure segment, transfer procedure segment, environmental procedure segment, environmental control events, normal completion path, and abnormal recovery path to generate a linked permit chain. The sub-permits of the linked permit chain include environmental preparation permit, workpiece transfer permit, process execution permit, environmental maintenance permit, and environmental release permit, which correspond to environmental preparation action, transfer action, process action, environmental maintenance action, and environmental recovery action, respectively.

[0143] Each sub-license has the same license chain number and includes the artifact number, program version, program segment pointer, resource reservation number, license validity period, preceding sub-license number, entry condition, completion condition, and exception recovery path. The license validity period is determined based on the commitment period, action lead time, action lag time, shortest execution time, and longest execution time.

[0144] The local controller reads the workpiece number, program version, program segment pointer, current time, confirmed effective reserved status, previous sub-license completion status, and PLC local safety interlock status corresponding to the sub-license, and generates the license output status using the license verification formula:

[0145] ;

[0146] In the formula, For the child permission The output state of the permission, when the logical truth value is 1, indicates a sub-permission. Executable; This refers to the sub-license number in the linked license chain; The workpiece numbers are consistent. The program version is consistent. The program segment pointer is matched. The current time is within the permitted valid range; The resource reservation number is in a confirmed and effective reservation status; The preceding sub-permission has been completed; This is the local safety interlock status for the PLC.

[0147] When a sub-permit is the first sub-permit in a linked permit chain, the local controller sets the completion status of the preceding sub-permit to satisfied. When the permit output status is a logical true value of 1, the local controller sends an action drive instruction to the corresponding local function block; the local function block is a PLC control program pre-configured in the local controller to execute the corresponding device action. After the local function block returns the action reception status, the local controller writes the consumed permit record; if the local function block does not return the action reception status, the local controller does not write the consumed permit record and re-verifies the permit output status within the permit validity period. When the permit validity period expires, a confirmed effective reservation becomes invalid, or the resource scheduling module revokes an unconsumed permit, the local controller refuses to execute the corresponding sub-permit and reports the permit invalidation status to the closed-loop control module.

[0148] When the PLC local safety interlock status is not met or the safety loop is triggered, the PLC safety program executes first, regardless of the interlock permission chain. The local controller marks unused permissions as non-executable and feeds back the permission chain number, program segment pointer, resource reservation number, and interlock status to the closed-loop control module.

[0149] See appendix Figure 7 In this embodiment, step S5 is executed by the closed-loop control module. The closed-loop control module includes a dynamic rolling calculation unit, a state joint unit, and a version switching unit, which are used to update the subsequent reception time window, confirm the joint completion status of the committed segment, and enable the new version of the program flow when the switching conditions are met.

[0150] S51, the dynamic rolling calculation unit updates the available time window based on feedback data, and revokes unused licenses and performs local recovery in abnormal situations.

[0151] The regional terminal associates action-driven commands with program execution progress, generates feedback data, and uploads it. The feedback data includes license chain number, sub-license number, workpiece number, program version, program segment pointer, actual start time, actual completion time, actual workpiece position, equipment action completion status, key process parameters, environmental equipment status, resource occupancy status, resource release status, interlock status, and fault status.

[0152] The dynamic rollover unit calculates the estimated arrival time interval of subsequent program segments based on the actual completion time, the current program execution pointer, and the preset transfer time margin. The preset transfer time margin is determined based on the shortest execution time, longest execution time, transfer time, and environment preparation time of the unexecuted program segments. The dynamic rollover unit compares the estimated arrival time interval with the receiving time window corresponding to the unconsumed license to form an available time window; the start time of the available time window is the later of the two start times, and the end time is the earlier of the two end times.

[0153] The preset time requirements are set based on the minimum duration of the action corresponding to the unconsumed permit, the environmental holding time, and subsequent receiving conditions. For example, the preset time requirement for a workpiece transfer permit is the minimum execution time of the transfer procedure segment plus a 10-30 second equipment response margin; the preset time requirement for an environmental holding permit is the minimum execution time of the environmental holding procedure segment. When the available time window is an empty set or its duration is less than the preset time requirement, the dynamic rollover unit cancels the unconsumed permit and releases confirmed effective reservations that are not referenced by consumed permits.

[0154] After the underlying device completes its hardware action, it enters the region recovery state. The finite state machine generates a self-healing strategy based on the device action completion state, the actual position of the workpiece, the environmental device state, the interlock state, and the fault state. If environment preparation fails, the workpiece transfer permit is not allowed to enter the executable state, unconsumed permits are revoked, and confirmed effective reservations not referenced by consumed permits are released, and the workpiece remains in the actual state of the current node; if a fault occurs before the transfer has started, unconsumed permits are revoked, and the transfer and subsequent resources are released.

[0155] If a fault occurs after the transfer has begun, the PLC maintains the environmental collection state and, according to the fault recovery path, sends the workpiece to a confirmed acceptable node in the current linkage permission chain, or keeps it at a safe position within the area. If a communication interruption occurs after the start of a process action, the PLC independently completes the local uninterrupted process action and does not enter a new program segment after completion. If position feedback is lost during environmental holding, the environmental equipment continues to maintain the collection state and does not execute the environmental release permission; if the workpiece position cannot be reconfirmed, it enters the manual handling state. When a safety loop is triggered, the PLC safety program is executed first, the closed-loop control module sets the permission chain to an abnormally closed state, and revokes any unused permissions.

[0156] S52, the state union unit verifies the actual bistable state, generates the union completion state, and advances the program execution pointer.

[0157] The status coordination unit verifies the actual workpiece holding status, actual environmental protection status, actual transfer availability status, and actual safety holding status through hardware sensors and PLC feedback. The actual workpiece holding status is satisfied when the workpiece is in place, the allowable dwell conditions at nodes, and the allowable range of process parameters are met; the actual environmental protection status is satisfied when the closed state, negative pressure state, fan operation status, and processing equipment availability status are met; the actual transfer availability status is satisfied when the transfer equipment release feedback, path release feedback, and receiving position status are met; and the actual safety holding status is satisfied when the safety loop status and PLC local safety interlock status are met.

[0158] When all four conditions are met, the joint state unit determines the actual bistable state as satisfied. The predicted composite stable node number is only used for the commitment segment planning and does not replace the actual bistable state.

[0159] When the actual bistable state is met, the state joint unit sequentially verifies the physical arrival state, process completion state, equipment disengagement state, action completion state, and permission chain closure state. A joint completion state is generated when the workpiece reaches the actual bistable node, the process program within the committed section is completed, the transfer equipment is released from exclusive occupation, the environment maintenance and environment release programs are completed, and the current linkage permission chain is closed normally.

[0160] When the joint completion state is satisfied, the state joint unit advances the program execution pointer of the workpiece control flow, cancels the global resource lock corresponding to the current commitment segment, and the global resource lock is a resource occupancy record established by the resource reservation unit for the workpiece number, commitment segment number and resource number, and releases the confirmed effective reservations that are not referenced by subsequent commitment segments; when the joint completion state is not satisfied, the program execution pointer remains not advanced.

[0161] S53, the version switching unit retains the old program flow and the new program flow, and performs an atomic replacement operation when the version switching formula is satisfied.

[0162] After receiving the recipe update instruction, the version switching unit retains the currently running old program flow and loads the new program flow. The new program flow includes the process route, process parameters, program segment sequence, environmental control events, minimum execution time, maximum execution time, and exception recovery path. Each regional coordination module verifies the program version, program segment number, resource number, and environmental control events in the new program flow. If the verification passes, a version-ready status is generated.

[0163] The version switching unit generates a trigger state when the workpiece reaches the actual bistable node, the current committed segment generates a joint completion state, the current linkage license chain is closed, the old license clearing state and the old reservation clearing state are both logically true (1), the first committed segment of the new program flow meets the time window and resource executability judgment, and all regional coordination modules are in the version ready state.

[0164] ;

[0165] In the formula, To trigger a state switch; Numbering composite stable nodes The corresponding actual bistable state; For the commitment section The joint completion status; This is the current committed segment number; For the commitment section The corresponding permissioned chain is closed; Clears the old license status; a logical truth value of 1 indicates that there is no old, unused license. Clear the old reservation status. A logical truth value of 1 indicates that there are no old version reservations that have been confirmed to be effective. This indicates that the first committed segment of the new program flow meets the time window and resource executability criteria. For the region It is in a version ready state.

[0166] When the trigger switch state is logically true (1), the version switch unit stops issuing new linkage permission chains for the old program flow and updates the program version and program execution pointer of the workpiece control flow with the same control transaction, outputting the global control switch result. After receiving the global control switch result, each regional coordination module enables the new program flow; the status synchronization module re-collects the field status and generates a new full-process status version based on the updated workpiece program version and field feedback.

[0167] To further aid in understanding the technical solutions of the embodiments of the present invention, a specific application example is given below.

[0168] This application example uses a batch-type rack-type hot-dip galvanizing production line. The production line includes a fluxing tank, a post-flushing waiting area, an overhead crane, a zinc pot, a cooling zone, a zinc fume collection hood, a negative pressure fan, a zone terminal, and a local controller. The workpiece to be processed is a steel structure support, workpiece number W-021, rack number H-05. The zinc pot temperature is 450℃, the negative pressure control range of the enclosed area is -5Pa to -30Pa, and the environmental protection status meets the environmental control requirements when the negative pressure fan reaches 80% of its rated speed. The allowable dwell time from the completion of fluxing to entering the zinc pot is set to 600s.

[0169] The moment when the workpiece completes the fluxing and remains in the post-flushing waiting position is taken as the zero point of the current calculation cycle. The current node number is 6, and the actual state of the current node satisfies the preset composite stable state. After the current node, the crane handover position 7, the zinc pot feeding position 8, and the cooling area receiving position 9 are set sequentially.

[0170] The state simulation unit generates node prediction data based on the program execution progress, transfer status, zinc pot status, cooling zone status, and environmental protection status. The workpiece holding marker, environmental protection marker, transfer availability marker, and safety holding marker for candidate node 7 are 0, 1, 0, and 1, respectively; the corresponding markers for candidate node 8 are 0, 1, 0, and 1, respectively; and the corresponding markers for candidate node 9 are all 1.

[0171] The stability determination unit calculates the composite stable node number according to the node search formula:

[0172] ;

[0173] Based on this, the segment delineation unit combines the environmental preparation program segment, process program segment, transfer program segment, environmental holding program segment, and environmental release program segment between nodes 6 and 9 into a commitment segment. Before the workpiece leaves node 6, it is necessary to confirm that the transfer area, hot-dip galvanizing area, cooling area, and environmental protection area can continuously receive the workpiece and perform the corresponding control tasks.

[0174] The current program segment's process start window is ;

[0175] The transfer area generates a receiving time window [190, 250]. The shortest cumulative time from the start of the current program segment to the corresponding constraint object in the transfer area is 50s, and the longest cumulative time is 75s. The window projection unit calculates the effective start time window of the transfer area according to the projection conversion formula: ;

[0176] The hot-dip galvanized zone generates a receiving time window [250, 310], with a minimum cumulative time of 110s and a maximum cumulative time of 145s. ;

[0177] The cooling zone generates a receiving time window [480, 560], with a minimum cumulative time of 320s and a maximum cumulative time of 360s. ;

[0178] The environmental protection zone generates a receiving time window [180, 220], with a minimum cumulative time of 20s and a maximum cumulative time of 30s. ;

[0179] The intersection calculation unit performs intersection calculations on the process start-up window, the effective start-up time window of the transfer area, the effective start-up time window of the hot-dip galvanizing area, the effective start-up time window of the cooling area, and the effective start-up time window of the environmental protection area.

[0180] ;

[0181] ;

[0182] like Figure 9 As shown, Figure 9 The effective start-up time windows for the process start-up, transfer area, hot-dip galvanizing area, cooling area, and environmental protection area are given respectively. The overlapping part of each time window corresponds to the commitment window set [160, 165], and its calculation result is determined by the intersection calculation process.

[0183] To verify the conflict correction process, it was assumed that there were uncommitted tasks in the cooling zone, and the initial reception time window for the cooling zone was [430, 500]. The window projection unit calculated the effective start-up time window before the cooling zone adjustment: ;

[0184] At this point, the effective start-up time window for the environmental protection zone is [160, 190]. The latest start time is 160s, and the earliest end time is 140s. Since these two times do not meet the intersection condition, the commitment window set is empty. Based on this, the conflict correction unit determines that the end boundary corresponding to the cooling zone is an adjustable boundary and sends a delay adjustment request to the cooling zone.

[0185] After the cooling zone delays uncommitted tasks by 40 seconds, the new reception time window is [470, 560]. The effective start time window after the cooling zone adjustment is: ;

[0186] After recalculation, the effective start-up time window of the cooling zone overlaps with the effective start-up time window of the environmental protection zone, and the commitment window set is restored: ;

[0187] like Figure 10 As shown, the effective start-up time window for the environmental protection zone is [160, 190], and the effective start-up time window for the cooling zone before adjustment is [110, 140], with no overlap between the two; the effective start-up time window for the cooling zone after adjustment is [150, 200], which overlaps with the effective start-up time window for the environmental protection zone.

[0188] The resource reservation unit selects the commitment interval [160, 165] from the commitment window set and sends reservation requests to the transfer area, hot-dip galvanizing area, cooling area, and environmental protection area. Each area returns a reservation feedback status, and the equipment status version matches the corresponding equipment status version recorded in the reservation request. The resource reservation confirmation status is: ;

[0189] When the resource reservation confirmation status is 1, the resource reservation unit establishes a confirmed and effective reservation and creates a global resource lock for the workpiece number, the committed segment number, and the resource number. The resource reservation unit sends the confirmed and effective reservation to the license issuance unit, which then generates a linked license chain.

[0190] like Figure 8 As shown, the resource reservation unit sends the confirmed and effective reservation to the license issuance unit, which then sends the linked license chain to the local controller. The local controller sequentially sends an environmental preparation license to the environmental protection area and receives the pre-process completion status; sends a workpiece transfer license to the transfer area and receives the equipment operation completion status; and sends a process execution license to the hot-dip galvanizing area and receives the process completion status.

[0191] The environmental assurance zone remains operational after environmental preparation permission is granted, and receives environmental maintenance permission upon returning to the process completion state, maintaining this environmental assurance status until the cooling zone returns to its physical position. The local controller continues to send workpiece transfer permission to the transfer area and receives equipment action completion status; it then sends workpiece transfer permission to the cooling area and receives physical position status. Finally, the local controller sends environmental release permission to the environmental assurance zone and receives action completion status.

[0192] The local controller sends feedback data, consisting of the license chain number, workpiece number, program version, program segment pointer, equipment action completion status, process end status, physical arrival status, environmental equipment status, and resource release status, to the status fusion unit. The status fusion unit generates a fusion completion status and feeds it back to the resource reservation unit.

[0193] Taking the sub-permit corresponding to the workpiece transfer permit as an example, the local controller calculates the permit output status according to the permit verification formula:

[0194] ;

[0195] After the workpiece arrives at node 9, the status co-location unit verifies the actual workpiece holding status, the actual environmental protection status, the actual transfer availability status, and the actual safety holding status:

[0196] ;

[0197] When the workpiece reaches the actual bistable node, the process procedure within the committed section is completed, the transfer equipment is released from exclusive occupancy, the environmental maintenance and release procedures are completed, and the current linkage permission chain is normally closed, the joint completion status is:

[0198] ;

[0199] When the state union unit is in state 1, it advances the program execution pointer, cancels the global resource lock, and releases the confirmed and effective reservations that are not referenced by subsequent committed sections.

[0200] To verify the control effect, 30 steel structure supports with the same process route were selected from the same production line for comparative operation. The control method adopted sequential control logic that was activated only based on the immediate idle state of the next piece of equipment and the local safety interlock status of the PLC; the test method adopted control logic based on commitment window set, confirmed effective reservation, and linkage permission chain.

[0201] During each operation, three types of disturbances are set: a 20-60 second delay in the time it takes for the negative pressure fan to reach its rated speed, a 30-90 second occupation of the cooling area, and a 20-50 second occupation of the travel path. Each type of disturbance corresponds to 10 workpieces. The total time from workpiece completion to the cooling receiving position, the number of unplanned waiting times within the committed section, and the number of interceptions due to insufficient environmental protection status are recorded.

[0202] Of the 30 workpieces tested in the control method, 9 experienced unplanned waiting between the completion of the plating process and receipt in the cooling zone. Six of these waiting occurred before receipt in the cooling zone, and 3 occurred during the waiting period for release along the vehicle path. Four instances of insufficient environmental assurance status resulted in interception. In the test method, conflict corrections or detention handling were completed before issuing workpiece transfer permits, and no unplanned waiting occurred within the designated section, nor were there any instances of insufficient environmental assurance status after transfer had commenced.

[0203] like Figure 11 As shown, the average completion time for the control method was 755s, and the average completion time for the experimental method was 728s. Figure 11 The two hollow circles represent outliers in the control and experimental methods, respectively. Outliers are records of total time for a single workpiece that are higher than the upper quartile plus 1.5 times the interquartile range. The outlier for the control method is 799s, and the outlier for the experimental method is 771s. The median line, upper and lower quartiles, and whisker lines of the two sets of boxes indicate that the total time from workpiece completion to cooling and receiving position is generally lower in the experimental method than in the control method.

[0204] This application embodiment restricts the start time of the workpiece by using a commitment window set, adjusts uncommitted tasks by using a conflict correction unit, and completes the device action control by using confirmed effective reservations and linkage permission chains, so that the workpiece completes the executability confirmation of subsequent continuous segments before leaving the actual state of the current node.

[0205] While specific embodiments of the present invention have been described above, those skilled in the art should understand that these specific embodiments are merely illustrative. Those skilled in the art can omit, substitute, and change the details of the above methods and systems in various ways without departing from the principles and essence of the present invention. For example, merging the above method steps to perform substantially the same function in substantially the same way to achieve substantially the same result falls within the scope of the present invention.

Claims

1. A hierarchical collaborative program control system for the entire hot-dip galvanizing process, characterized in that, include: The state synchronization module is used to collect state data based on the time dimension, generate linkage program segments, and establish environmental transition states. The node inference module is used to obtain the actual state of the current node under the environmental transition state, infer the various markers of the candidate node, output the composite stable node number using the node search formula, and generate the commitment segment and cooperation request from the linkage program segment in combination with the actual state of the current node. The spatiotemporal calculation module is used to obtain the receiving time window and configure the boundary label according to the cooperation request, reverse the receiving time window and intersect it with the preset process start window to obtain the commitment window set. When the commitment window set is empty, it forms a conflict boundary pair according to the boundary label and performs conflict correction. The resource scheduling module is used to generate a confirmed and effective reservation when the reservation request issued according to the commitment window set is verified, generate a linkage permission chain in combination with the commitment segment, and respond to the permission output status of the linkage permission chain to output action driving instructions. The closed-loop control module is used to release the confirmed effective reservation that has not been referenced by the consumed license when the available time window generated according to the action driving instruction is an empty set or the duration is less than the preset time requirement, verify the actual bistable state, verify the joint completion state when the actual bistable state is satisfied, and advance the program execution pointer.

2. The hierarchical collaborative program control system for the entire hot-dip galvanizing process according to claim 1, characterized in that, The state synchronization module includes: The time synchronization unit is used to send out synchronization frames, determine the reference time based on the generated clock synchronization record or reference count value, event count value and sampling period, and output the time dimension after verifying the acquisition version number, request sequence number and status version number. The program generation unit is used to generate a sequence of program segments based on the time dimension and the read process attributes, configure the shortest execution time, the longest execution time, environmental control events, action lead time and action lag time, and generate the linkage program segments and the environmental transition state.

3. The hierarchical collaborative program control system for the entire hot-dip galvanizing process according to claim 2, characterized in that, The node deduction module includes: The state deduction unit is used to obtain the actual state of the current node and the program execution progress of the linkage program segment under the environmental transition state, read the program execution pointer corresponding to the actual state of the current node from the program execution progress, use it as the current program execution pointer, and calculate the expected workpiece holding state, expected environmental protection state and expected transfer availability state of the candidate node according to the process route in the process attributes and the actual state of the current node, and generate node prediction data. The stability determination unit is used to map the process hold conditions, expected environmental protection status, expected transfer availability status, safety loop status, and PLC local safety interlock status of the candidate nodes to workpiece hold markers, environmental protection markers, transfer availability markers, and safety hold markers, respectively, and output the composite stable node number using the node search formula.

4. The hierarchical collaborative program control system for the entire hot-dip galvanizing process according to claim 3, characterized in that, The node deduction module also includes: The segment delineation unit is used to determine the program segment pointed to by the current program execution pointer as the starting end of the interception boundary, determine the program segment associated with the candidate node corresponding to the composite stable node number as the ending end of the interception boundary, extract the process program segment, transfer program segment and environmental program segment defined by the interception boundary from the linked program segment, and generate the commitment segment and the collaboration request.

5. The hierarchical collaborative program control system for the entire hot-dip galvanizing process according to claim 1, characterized in that, The spatiotemporal calculation module: The window projection unit is used to process the receiving time window generated by the regional terminal in the relevant area according to the cooperation request into discrete receiving intervals, configure the boundary label of the discrete receiving interval including the constraint source area, adjustable attributes and regional status version, accumulate the shortest single step time and longest single step time of the intermediate program segment in the committed segment, generate an effective start time window using the projection conversion formula, and remove the inverted interval.

6. The hierarchical collaborative program control system for the entire hot-dip galvanizing process according to claim 5, characterized in that, The spatiotemporal calculation module also includes: An intersection calculation unit is used to perform an intersection calculation on the process start-up window and the effective start-up time window using an intersection calculation formula, and output the commitment window set. The conflict correction unit is used to determine the latest start time and the earliest end time based on the activity start time and activity end time of the current interval of each round when the commitment window set is empty, trace the corresponding boundary labels to form the conflict boundary pair, and send an early adjustment request or a delayed adjustment request based on the conflict boundary pair. The regional terminal in the relevant area generates an expected adjusted time window. When the expected adjusted time window does not affect the confirmed effective commitment segment and the regional status version is consistent with the current computing task, the commitment window set is regenerated. When the commitment window set is still empty and the actual state of the current node satisfies the preset composite stable state, a dwell instruction is output.

7. The hierarchical collaborative program control system for the entire hot-dip galvanizing process according to claim 1, characterized in that, The resource scheduling module includes: A resource reservation unit is used to send the reservation request to the relevant area based on the commitment window set and the occupied resources in the commitment segment; The regional terminal in the relevant area verifies the resource occupancy status, reservation time interval, full process status version and PLC local safety interlock status corresponding to the reservation request. When the verification is successful, a temporary lock status is established and the reservation feedback status is returned. The resource reservation unit is also used to verify, when receiving the reservation feedback status, the status of the temporary reservation confirmed by each relevant area and the status of the equipment version are consistent using the reservation formula. When the verification is successful, an activation command is sent so that the regional terminal of the relevant area converts the temporary lock status to the confirmed effective reservation and returns the activation feedback status. If the verification fails, a rollback command and a window recalculation command will be sent. When all regional terminals in the relevant areas return the effective feedback status, a global resource lock is established for the workpiece number, committed segment number, and resource number in the reservation request.

8. The hierarchical collaborative program control system for the entire hot-dip galvanizing process according to claim 7, characterized in that, The resource scheduling module also includes: A license issuance unit, which is used to generate the linked license chain based on the confirmed effective reservation and the committed segment; The local controller verifies the workpiece number, program version, program segment pointer, valid license range, confirmed effective reserved status, previous sub-license completion status, and PLC local safety interlock status corresponding to the sub-license of the linkage license chain according to the license verification formula, and generates the license output status.

9. The hierarchical collaborative program control system for the entire hot-dip galvanizing process according to claim 7, characterized in that, The closed-loop control module includes: The dynamic rolling calculation unit is used to receive feedback data associated with the action driving instruction, calculate the expected arrival time interval based on the actual completion time in the feedback data, the read current program execution pointer and the preset flow time margin, and compare the expected arrival time interval with the receiving time window corresponding to the unconsumed license to generate the available time window. When the available time window is an empty set or the duration is less than the preset time requirement, release the confirmed effective reservation that has not been referenced by the consumed license. The state joint unit is used to verify the actual workpiece holding state, the actual environmental protection state, the actual transfer usable state, and the actual safety holding state. When all four states are satisfied, the actual bistable state is determined to be satisfied. It also verifies the physical position state, the process end state, the equipment detachment state, the action completion state, and the permission chain closure state, and generates the joint completion state. When the joint completion state is satisfied, the program execution pointer is advanced and the global resource lock is unregistered.

10. A hierarchical collaborative program control method for the entire hot-dip galvanizing process, characterized in that, A hierarchical collaborative process control system for the entire hot-dip galvanizing process, as described in any one of claims 1-9, comprising: The state synchronization module collects state data based on the time dimension, generates linkage program segments, and establishes environmental transition states. The node inference module obtains the actual state of the current node under the environmental transition state, infers various markers of candidate nodes, outputs the composite stable node number using the node search formula, and generates the commitment segment and cooperation request from the linkage program segment in combination with the actual state of the current node. The spatiotemporal calculation module obtains the receiving time window and configures the boundary label according to the collaborative request. It reverses the receiving time window and intersects it with the preset process start window to obtain the commitment window set. When the commitment window set is empty, it forms a conflict boundary pair according to the boundary label and performs conflict correction. When the reservation request issued based on the commitment window set is verified, the resource scheduling module generates a confirmed and effective reservation, generates a linkage permission chain in combination with the commitment segment, responds to the permission output status of the linkage permission chain, and outputs an action driving command. When the available time window generated according to the action-driven instruction is an empty set or the duration is less than the preset time requirement, the closed-loop control module releases the confirmed effective reservation that has not been referenced by the consumed license, verifies the actual bistable state, and verifies the joint completion state when the actual bistable state is satisfied, and advances the program execution pointer.

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