A control management system for visual dispensing software integrated valve assemblies

Abstract

The application relates to the technical field of production management, and particularly discloses a control management system for visual dispensing software integrated valve components, which comprises a parameter analysis module, a state coefficient evaluation module and a fault analysis module.The parameter analysis module obtains a relative change rate based on the change of operation parameters of a valve between two adjacent switching processes, and forms a change sequence according to the valve types between the two switching processes.The state coefficient evaluation module analyzes the change sequence to obtain a state coefficient.The fault analysis module performs fault analysis according to the state coefficient and outputs an analysis result, which comprises a first type of fault and a second type of fault.The application can distinguish the valve degradation and the control system abnormality to a certain extent under the integrated control scheme, and realizes early prediction of valve faults.

Description

Technical Field

[0001] This invention relates to the field of production management technology, specifically to a control and management system for integrating valve components with vision dispensing software. Background Technology

[0002] Existing vision-based dispensing software only offers motion mechanism control and visual correction functions, with limited control over valve bodies. When using different dispensing valves, corresponding valve controllers are required. For example, when using a screw valve, the vision software can control the motion mechanism to complete the dispensing trajectory, but it cannot directly control the screw valve's dispensing. This is because the screw valve is driven by a servo motor, but the vision-based dispensing control software can only output a valve opening signal and cannot directly drive the screw valve's servo motor. Therefore, a screw valve controller is needed to control the dispensing. The vision software triggers the start and stop of dispensing via the valve opening signal through an I / O interface. Screw valve parameter adjustment and calibration can only be set in the screw valve controller. When the dispensing valve is changed to a metering plunger valve, a specific plunger valve controller needs to be replaced. This increases costs and makes it difficult to directly adjust valve parameters through the vision-based dispensing software during debugging, making it very cumbersome. When multiple valves need to be configured on a single device, an equivalent controller is required, making parameter adjustments for each valve even more inconvenient.

[0003] With the development of software-integrated control technology, some manufacturers engaged in small-batch customized production have introduced integrated management methods due to the frequent need to adjust valves. This allows multiple valves to be managed and switched uniformly within the same visual dispensing software. The problem is that, in the traditional method, each valve is controlled independently, making fault diagnosis and repair convenient. However, in the integrated method, the control system may also experience faults such as parameter drift and bus communication abnormalities, which can lead to production problems such as poor dispensing. However, it is difficult to quickly determine whether the fault lies with the valve itself or the control system, resulting in long troubleshooting times and a high rate of misdiagnosis.

[0004] In view of this, the present invention proposes a control and management system for valve components integrated with visual dispensing software, which can effectively distinguish between valve degradation and control system abnormalities, and realize early prediction of valve failures. Summary of the Invention

[0005] The purpose of this invention is to provide a control and management system for integrating valve components into vision dispensing software, thereby solving the following technical problems: How to effectively distinguish between valve degradation and control system malfunctions under an integrated control scheme, and achieve early prediction of valve failures.

[0006] The objective of this invention can be achieved through the following technical solutions: A control and management system for integrating valve components into vision dispensing software includes: The parameter acquisition module is used to record the operating parameters of a valve before and after each switching process. The operating parameters include at least: valve type, valve opening response delay, valve closing response delay, unit pulse width dispensing volume, tailing time after valve closing, and back suction stroke efficiency coefficient. The parameter analysis module obtains the relative rate of change based on the change in operating parameters of a valve between two adjacent switching operations, and forms a change sequence according to the valve type between the two switching operations. An evaluation module that analyzes the change sequence to obtain state coefficients; The fault analysis module performs fault analysis based on state coefficients and outputs analysis results, which include first-type faults and second-type faults.

[0007] The above technical solution provides a process for obtaining a change sequence based on the changes in operating parameters during valve switching and for analyzing the state coefficient based on the change sequence. When the dispensing quality is poor during production, the corresponding fault location can be determined based on the dispensing process. However, due to integrated control, it is impossible to determine whether the fault is a device-related fault of the valve or a software-level fault of the control software, thus causing difficulties in maintenance. This invention classifies fault types into a first type of fault and a second type of fault based on the state coefficient. Under the first type of fault, the valve's operating parameters are relatively stable, and it is recommended to prioritize fault investigation in the software direction. Under the second type of fault, the valve's operating parameters will fluctuate to some extent compared with historical data. By analyzing the historical data of the fluctuation, the efficiency of fault investigation in the maintenance process can be improved.

[0008] As a further technical solution of the present invention: the process of obtaining the relative rate of change based on the change of operating parameters of a valve between two adjacent switching includes: For valve P, in a total of N switching records, a certain operating parameter is during the k-th switching process. The baseline value corresponding to this operating parameter is ; The relative change rate after the k-th switch is: ; in, This represents the relative rate of change.

[0009] As a further technical solution of the present invention: the process of forming a variation sequence includes: Valve classification is performed, wherein the valves are initialized using several different natural numbers, and the initialization is based on the valve type. During the k-th switching process, the set of natural numbers corresponding to the valve division and the relative rate of change after the k-th switching are combined into a three-dimensional change vector; The set of several changing vectors is denoted as a changing sequence.

[0010] As a further technical solution of the present invention: the process of forming the change sequence also includes a secondary representation of the valve, wherein the secondary representation process includes: Based on the natural numbers used in the initialization, valves of the same type but with different specifications are represented a second time using similar constants; The approximate constant is the original natural number ± 0.a. The specifications include at least the nozzle diameter, the amount of adhesive sprayed, and the method of spraying adhesive, where a is a non-zero natural number.

[0011] The above technical solution provides a process for initializing and representing valves. During valve switching, the parameter changes vary between different types and even between the same type. Therefore, by initializing the valve based on its type before and after switching, and by representing the same type based on its specifications, parameters with similar changes can be grouped together for analysis, thereby improving the accuracy of data analysis. Based on type classification, this invention can represent valves of different specifications using numerical changes with similar constants, which is more suitable for the needs of some non-standard customized factories that frequently change valve specifications or types.

[0012] As a further technical solution of the present invention: the process of analyzing the changing sequence to obtain state coefficients includes: Organize the change sequence, and represent the vectors with the same constant representing the valve type in the three-dimensional vectors adjacently according to the acquisition order to obtain m sub-sequences; Through the formula: Obtaining state coefficients Where i is a non-zero natural number not greater than m, and j is a non-zero natural number not greater than m. nonzero natural numbers, This represents the weight value of the i-th subsequence. It is the number of vectors in the i-th subsequence. yes The relative rate of change of the j-th vector among a vector. and It represents the mean and standard deviation of the relative rate of change of the valve corresponding to the j-th vector under healthy conditions.

[0013] As a further technical solution of the present invention: the process of analyzing the changing sequence to obtain state coefficients includes: Organize the change sequence, and represent the vectors with the same constant representing the valve type in the three-dimensional vectors adjacently according to the acquisition order to obtain m sub-sequences; Through the formula: Obtaining state coefficients Where i is a non-zero natural number not greater than m, and j is a non-zero natural number not greater than m. nonzero natural numbers, This represents the weight value of the i-th subsequence. It is the number of vectors in the i-th subsequence. yes The relative rate of change of the j-th vector among a vector. and It represents the mean and standard deviation of the relative rate of change of the valve corresponding to the j-th vector under healthy conditions.

[0014] As a further technical solution of the present invention: the process of obtaining the weight values ​​of the subsequences includes: The subsequence includes an initial sequence and a secondary sequence. The initial sequence is the subsequence generated by the initialization representation, and the secondary sequence is the subsequence generated by the secondary representation. The weight value of the initial sequence is a preset value. The weight values ​​of the secondary sequence are allocated according to a preset rule based on the weight values ​​of the corresponding initial sequence.

[0015] The above technical solution provides a rule for adjusting the weight values ​​of the sequence. In the production process of manufacturers that produce small batches of customized products, in order to adapt to various customer needs, it is necessary to frequently add new valves to meet different widths and types of adhesive spraying processes. If the weight value of each new valve is determined through long-term testing, it will obviously delay the production rhythm. The allocation scheme provided by this invention allocates the weight value based on the initial weight value, which can quickly adapt to the production methods of manufacturers that produce small batches of customized products.

[0016] As a further technical solution of the present invention: the process of allocating according to preset rules includes: Obtain the magnitude of the vector difference between the initial vector of the quadratic sequence and each vector in the corresponding initial sequence, and obtain the average value. The initial vector is the first vector of the sequence generated by the quadratic representation. Based on valve type, set standard values ​​and obtain judgment values. , The initial weight values ​​of the initial sequence are calculated based on the judgment values.

[0017] As a further technical solution of the present invention: the process of calculating the weight value corresponding to the initial sequence includes: For an initial sequence and several quadratic sequences The initial weight value is The corresponding weight value is ; If u takes the value of (0.9, 1.1), then , The values ​​are all ,in This is the preset correction function.

[0018] If the value of u does not belong to the interval (0.9, 1.1), then The values ​​are all And a pop-up notification will be displayed.

[0019] The above technical solution provides a basis for... The weight correction process of the present invention The accuracy of calculating the state coefficient can be increased by offsetting errors. In this way, the newly added valve can be directly applied to the present invention without long-term testing, which saves costs and is more suitable for the production process of manufacturers producing small batches of customized products.

[0020] As a further technical solution of the present invention: the management system further includes a fault prediction module, which uses a preset prediction model to extrapolate the state coefficients and calculate the time to reach the preset failure threshold. The preset prediction model includes at least linear regression, exponential smoothing or grey prediction model.

[0021] The beneficial effects of this invention are: (1) This invention provides a process for initializing and secondary representing valves. During the switching process, the parameters of different types of valves, and even the same type, change in different ranges. Therefore, by initializing the valve based on the type before and after the valve switching, and by secondary representing the same type based on the specification parameters, parameters with similar change ranges can be placed in the same group for analysis, thereby improving the accuracy of data analysis. Based on the type division, this invention can perform secondary representation of valves with different specifications by numerical changes with similar constants, which can better meet the needs of some non-standard customized factories that need to frequently change valve specifications or types.

[0022] (2) This invention provides a rule for the allocation and adjustment of the weight values ​​of the sequence. In the production process of manufacturers that make small-batch customized production, in order to adapt to the various needs of customers, it is necessary to frequently add new valves to meet the different widths and types of glue spraying processes. If the weight value of each new valve is determined by long-term testing, it will obviously delay the production rhythm. The allocation scheme provided by this invention is to allocate based on the initial weight value, which can quickly adapt to the production mode of manufacturers that make small-batch customized production.

[0023] (3) The present invention increases the accuracy of calculating the state coefficient by means of error cancellation, and realizes the technical solution that the newly added valve can be directly applied to the present invention without long-term testing, which saves more costs and is suitable for the production process of manufacturers with small-batch customized production. Attached Figure Description

[0024] The invention will now be further described with reference to the accompanying drawings.

[0025] Figure 1 This is a schematic diagram of the module composition of the management system of the present invention. Detailed Implementation

[0026] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0027] Please see Figure 1 As shown, in one embodiment, a control and management system for integrating valve components with vision dispensing software is provided, including: The parameter acquisition module is used to record the operating parameters of a valve before and after each switching process. The operating parameters include at least: valve type, valve opening response delay, valve closing response delay, dispensing volume per unit pulse width, tailing time after valve closing, and back suction stroke efficiency coefficient. The parameter analysis module obtains the relative rate of change based on the changes in operating parameters of a valve between two adjacent switching operations, and forms a change sequence according to the valve type between the two switching operations. The evaluation module analyzes the change sequence to obtain state coefficients; The fault analysis module performs fault analysis based on state coefficients and outputs the analysis results, which include Class I faults and Class II faults.

[0028] This embodiment provides a process for obtaining a change sequence based on the changes in operating parameters during valve switching and for analyzing the state coefficient based on the change sequence. When the dispensing quality is poor during production, the corresponding fault location can be determined based on the dispensing process. However, due to integrated control, it is impossible to determine whether the fault is an equipment-related fault of the valve or a software-related fault of the control software, thus causing difficulties in maintenance. This invention classifies fault types into a first type of fault and a second type of fault based on the state coefficient. Under the first type of fault, the valve's operating parameters are relatively stable, and it is recommended to prioritize fault investigation in the software direction. Under the second type of fault, the valve's operating parameters will have certain fluctuations compared to historical data. At this time, the fluctuation status of the historical data in which the fluctuation occurs is observed. The preferred observation method is to output the parameter fluctuation image. If the fluctuation is relatively uniform and has a certain regularity compared to the normal state, it is recommended to prioritize fault investigation in the equipment direction. If the fluctuation is less regular than the normal state, it is recommended to prioritize fault investigation in the software direction, thereby improving the efficiency of fault investigation in the maintenance process. It should be noted that in the analysis of the second type of fault, software fluctuations may also bring about uniform and somewhat regular parameter fluctuation images, while equipment faults may also have exceptions with irregular fluctuations. The state coefficient judgment provides a recommended direction for fault diagnosis rather than an absolutely correct direction.

[0029] The process of obtaining the relative rate of change based on the change in operating parameters of a valve between two adjacent switching operations includes: For valve P, in a total of N switching records, a certain operating parameter is during the k-th switching process. The baseline value corresponding to this operating parameter is ; The relative change rate after the k-th switch is: ; in, This represents the relative rate of change.

[0030] The process of forming a change sequence includes: Valve classification is performed, and each valve is initialized using several different natural numbers, with the initialization based on the valve type. During the k-th switching process, the set of natural numbers corresponding to the valve division and the relative rate of change after the k-th switching are combined into a three-dimensional change vector; The set of several changing vectors is denoted as a changing sequence.

[0031] The process of forming a change sequence also includes the quadratic representation of the valve, and the process of quadratic representation includes: Based on the natural numbers used in the initialization, valves of the same type but with different specifications are represented a second time using similar constants; The approximate constant is the original natural number ± 0.a. The specifications include at least the nozzle diameter, the amount of adhesive applied, and the method of applying adhesive, where a is a non-zero natural number.

[0032] This embodiment provides a process for initializing and re-representing the valve. During valve switching, the parameter changes vary between different types and even between the same type. Therefore, by initializing the valve based on its type before and after switching, and by re-representing the same type based on its specifications, parameters with similar changes can be grouped together for analysis, thereby improving the accuracy of data analysis. Based on type classification, this invention can re-represent valves of different specifications by using numerical changes with similar constants, which is more suitable for the needs of some non-standard customized factories that frequently change valve specifications or types.

[0033] The process of analyzing a changing sequence to obtain state coefficients includes: Organize the change sequence, and represent the vectors with the same constant representing the valve type in the three-dimensional vectors adjacently according to the acquisition order to obtain m sub-sequences; Through the formula: Obtaining state coefficients Where i is a non-zero natural number not greater than m, and j is a non-zero natural number not greater than m. nonzero natural numbers, This represents the weight value of the i-th subsequence. It is the number of vectors in the i-th subsequence. yes The relative rate of change of the j-th vector among a vector. and It represents the mean and standard deviation of the relative rate of change of the valve corresponding to the j-th vector under healthy conditions.

[0034] The process of analyzing a changing sequence to obtain state coefficients includes: Organize the change sequence, and represent the vectors with the same constant representing the valve type in the three-dimensional vectors adjacently according to the acquisition order to obtain m sub-sequences; Through the formula: Obtaining state coefficients Where i is a non-zero natural number not greater than m, and j is a non-zero natural number not greater than m. nonzero natural numbers, This represents the weight value of the i-th subsequence. It is the number of vectors in the i-th subsequence. yes The relative rate of change of the j-th vector among a vector. and It represents the mean and standard deviation of the relative rate of change of the valve corresponding to the j-th vector under healthy conditions.

[0035] The process of fault analysis based on state coefficients includes: Set critical threshold ,when If the fault analysis result is displayed correctly, it is classified as a second type of fault; otherwise, it is classified as a first type of fault. The Through the formula: ; in, and It represents the mean and standard deviation of the valve's state coefficients over several tests under healthy conditions. It is a selection function that makes numerical selections based on the expected false alarm rate x.

[0036] Based on empirical data, as an example, The selection chart is as follows: Table 1 The process of obtaining the weight values ​​of the subsequence includes: The subsequence includes an initial sequence and a secondary sequence. The initial sequence is the subsequence generated by the initialization representation, and the secondary sequence is the subsequence generated by the secondary representation. The weight value of the initial sequence is a preset value. The weights of the secondary sequence are allocated according to a preset rule based on the weights of the corresponding initial sequence.

[0037] This embodiment provides a rule for adjusting the weight values ​​of the sequence. In the production process of manufacturers that produce small batches of customized products, in order to adapt to various customer needs, it is necessary to frequently add new valves to meet different widths and types of adhesive spraying processes. If the weight value of each new valve is determined through long-term testing, it will obviously delay the production rhythm. The allocation scheme provided by this invention allocates the weight value based on the initial weight value, which can quickly adapt to the production mode of manufacturers that produce small batches of customized products.

[0038] The process of allocating resources according to preset rules includes: Obtain the magnitude of the vector difference between the initial vector of the quadratic sequence and each vector in the corresponding initial sequence, and obtain the average value. The initial vector is the first vector of the sequence generated by the quadratic representation. Based on valve type, set standard values ​​and obtain judgment values. , The initial weight values ​​of the initial sequence are calculated based on the judgment values.

[0039] The process of calculating the weights corresponding to the initial sequence includes: For an initial sequence and several quadratic sequences The initial weight value is The corresponding weight value is ; If u takes the value of (0.9, 1.1), then , The values ​​are all ,in This is a preset correction function, used as an example. When u equals 1, the new valve has very similar characteristics to the old valve. Set it to 0, thus directly using the weight of the old valve.

[0040] If the value of u does not belong to the interval (0.9, 1.1), then The values ​​are all A pop-up notification will be displayed stating that if the value of u does not fall within the interval (0.9, 1.1), the weight value will not be applicable. Therefore, the correction was made to distribute the costs equally and a pop-up notification was sent to the control software.

[0041] Through the above technical solution, this embodiment provides a basis... The weight correction process of the present invention The accuracy of calculating the state coefficient can be increased by offsetting errors. This allows newly added valves to be directly applied to the invention without long-term testing, which is more cost-effective and adaptable to the production process of manufacturers producing small batches of customized products.

[0042] The management system also includes a fault prediction module. The fault prediction module uses a preset prediction model to extrapolate the state coefficients and calculates the time to reach the preset failure threshold. The preset prediction model includes at least linear regression, exponential smoothing, or grey prediction model.

[0043] The foregoing has provided a detailed description of one embodiment of the present invention, but this description is merely a preferred embodiment and should not be construed as limiting the scope of the invention. All equivalent variations and modifications made within the scope of the claims of this invention should still fall within the patent coverage of this invention.

Claims

1. A control and management system for integrating valve components into vision dispensing software, characterized in that, include: The parameter acquisition module is used to record the operating parameters of a valve before and after each switching process. The operating parameters include at least: valve type, valve opening response delay, valve closing response delay, unit pulse width dispensing volume, tailing time after valve closing, and back suction stroke efficiency coefficient. The parameter analysis module obtains the relative rate of change based on the change in operating parameters of a valve between two adjacent switching operations, and forms a change sequence according to the valve type between the two switching operations. An evaluation module that analyzes the change sequence to obtain state coefficients; The fault analysis module performs fault analysis based on state coefficients and outputs analysis results, which include first-type faults and second-type faults.

2. The control and management system for integrated valve components in vision dispensing software according to claim 1, characterized in that, The process of obtaining the relative rate of change based on the change in operating parameters of a valve between two adjacent switching operations includes: For valve P, in a total of N switching records, a certain operating parameter is during the k-th switching process. The baseline value corresponding to this operating parameter is ; The relative change rate after the k-th switch is: ； in, This represents the relative rate of change.

3. The control and management system for integrated valve components in vision dispensing software according to claim 2, characterized in that, The process of forming a change sequence includes: Valve classification is performed, wherein the valves are initialized using several different natural numbers, and the initialization is based on the valve type. During the k-th switching process, the set of natural numbers corresponding to the valve division and the relative rate of change after the k-th switching are combined into a three-dimensional change vector; The set of several changing vectors is denoted as a changing sequence.

4. The control and management system for integrated valve components in vision dispensing software according to claim 3, characterized in that, The process of forming the change sequence also includes a secondary representation of the valve, the secondary representation process including: Based on the natural numbers used in the initialization, valves of the same type but with different specifications are represented a second time using similar constants; The approximate constant is the original natural number ± 0.a. The specifications include at least the nozzle diameter, the amount of adhesive sprayed, and the method of spraying adhesive, where a is a non-zero natural number.

5. The control and management system for integrated valve components in vision dispensing software according to claim 3, characterized in that, The process of analyzing a changing sequence to obtain state coefficients includes: Organize the change sequence, and represent the vectors with the same constant representing the valve type in the three-dimensional vectors adjacently according to the acquisition order to obtain m sub-sequences; Through the formula: Obtaining state coefficients Where i is a non-zero natural number not greater than m, and j is a non-zero natural number not greater than m. nonzero natural numbers, This represents the weight value of the i-th subsequence. It is the number of vectors in the i-th subsequence. yes The relative rate of change of the j-th vector among a vector. and It represents the mean and standard deviation of the relative rate of change of the valve corresponding to the j-th vector under healthy conditions.

6. The control and management system for integrated valve components in vision dispensing software according to claim 5, characterized in that, The process of fault analysis based on state coefficients includes: Set critical threshold ,when If the fault analysis result is displayed correctly, it is classified as a second type of fault; otherwise, it is classified as a first type of fault. The Through the formula: ； in, and It represents the mean and standard deviation of the valve's state coefficients over several tests under healthy conditions. It is a selection function that makes numerical selections based on the expected false alarm rate x.

7. The control and management system for integrated valve components in vision dispensing software according to claim 5, characterized in that, The process of obtaining the weight values ​​of the subsequence includes: The subsequence includes an initial sequence and a secondary sequence. The initial sequence is the subsequence generated by the initialization representation, and the secondary sequence is the subsequence generated by the secondary representation. The weight value of the initial sequence is a preset value. The weight values ​​of the secondary sequence are allocated according to a preset rule based on the weight values ​​of the corresponding initial sequence.

8. The control and management system for integrated valve components in vision dispensing software according to claim 7, characterized in that, The process of allocating resources according to preset rules includes: Obtain the magnitude of the vector difference between the initial vector of the quadratic sequence and each vector in the corresponding initial sequence, and obtain the average value. The initial vector is the first vector of the sequence generated by the quadratic representation. Based on valve type, set standard values ​​and obtain judgment values. , The initial weight values ​​of the initial sequence are calculated based on the judgment values.

9. The control and management system for a vision dispensing software integrated with valve components according to claim 8, characterized in that, The process of calculating the weights corresponding to the initial sequence includes: For an initial sequence and several quadratic sequences The initial weight value is The corresponding weight value is ; If u takes the value of (0.9, 1.1), then , The values ​​are all ,in This is a preset correction function; If the value of u does not belong to the interval (0.9, 1.1), then The values ​​are all And a pop-up notification will be displayed.

10. The control and management system for integrated valve components in vision dispensing software according to claim 1, characterized in that, The management system also includes a fault prediction module. The fault prediction module uses a preset prediction model to extrapolate the state coefficients and calculates the time to reach the preset failure threshold. The preset prediction model includes at least linear regression, exponential smoothing, or grey prediction model.

Images