Ceramic chain type automatic rolling line integrated control system and method

Abstract

This invention relates to the field of ceramic chain automatic rolling line technology, specifically disclosing an integrated control system and method for a ceramic chain automatic rolling line. This invention receives production requests, performs comprehensive self-inspection and fully automatic reset; generates an interactive control menu, receives production parameters, and performs corresponding automatic mechanical configuration; performs automatic operation control for continuous production; performs real-time fault monitoring and automatically handles and issues warnings for different fault conditions; performs stop-feed control and gradually clears and shuts down the line. It can perform comprehensive self-inspection, fully automatic reset, receive production parameters, perform automatic mechanical configuration and operation control, and simultaneously perform real-time fault monitoring and handling. This reduces labor costs, avoids the impact of personnel skill levels on production efficiency, effectively reduces changeover time, lowers scrap rates, and effectively adapts to multi-variety, small-batch production.

Description

Technical Field

[0001] This invention belongs to the technical field of ceramic chain automatic rolling line, and particularly relates to an integrated control system and method for ceramic chain automatic rolling line. Background Technology

[0002] Ceramic chain automatic rolling line is an automated production equipment and conveying system used for continuous forming, compaction and surface shaping of ceramic blanks. It is widely used in the production of building ceramics, ceramic slabs, refractory ceramics and industrial ceramics. Its core structure generally consists of a chain conveying mechanism, an automatic rolling mechanism, a pressure regulating mechanism, a guiding and positioning mechanism and an intelligent control system. Through chain conveying, it realizes the continuous and stable transmission of ceramic blanks between multiple workstations, and uses rolling rollers to continuously compact, control the thickness and level the ceramic material.

[0003] In existing technologies, multiple processes of ceramic chain automatic rolling lines often require multiple workers to operate or monitor them separately, resulting in high labor costs. Production efficiency is affected by the skill level of the workers, and changing molds, rolling heads, suction cups, edge washing sponges, etc., requires manual adjustment of parameters one by one, resulting in long changeover times. Incorrect parameter settings lead to high scrap rates, making it unsuitable for multi-variety, small-batch production. Summary of the Invention

[0004] The purpose of this invention is to provide an integrated control system and method for a ceramic chain automatic rolling line, which aims to solve the problems mentioned in the background art.

[0005] To achieve the above objectives, the embodiments of the present invention provide the following technical solutions: An integrated control method for a ceramic chain automatic rolling line, the method specifically includes the following steps: Upon receiving a production and processing request, the system performs a comprehensive self-inspection and a security area scan analysis. If both the comprehensive self-inspection and the security area scan are normal, the system performs a fully automatic reset. Generate an interactive control menu, receive production and processing parameters input by staff, and perform corresponding automatic machine configuration; Automatic operation control for continuous production is implemented according to the aforementioned production and processing parameters; During the production and processing process, real-time fault monitoring is carried out, and automatic handling and early warning notifications are provided for different fault scenarios; Upon receiving a processing stop request, the system will stop feeding, gradually clear and shut down the system, and record and back up production operation data.

[0006] The present invention also provides an integrated control system for a ceramic chain automatic rolling line, the system comprising: The integrated self-test processing unit is used to receive production and processing requests, perform integrated self-test processing, perform safety area scanning analysis, and perform fully automatic reset when the integrated self-test and area scanning are normal. The processing parameter processing unit is used to generate interactive control menus, receive production processing parameters input by staff, and perform corresponding automatic mechanical configurations. An automatic operation control unit is used to automatically control continuous production according to the aforementioned production and processing parameters; The fault monitoring and processing unit is used to monitor faults in real time during the production and processing process, and to automatically handle and issue early warnings for different fault conditions. The processing stop unit is used to receive processing stop requests, control the material feeding to stop, perform gradual emptying and shutdown control, and record production operation data for backup.

[0007] Compared with the prior art, the beneficial effects of the present invention are: 1. This invention uses the results of the safety zone scan analysis as the execution interlock condition for mechanical configuration. It operates under no-load conditions without adding mud and uses the pre-configuration state benchmark for differential calculation to offset the inherent error of the equipment. At the same time, after configuration, it triggers the re-execution of the safety zone scan analysis to update the scan analysis results, forming a closed-loop interlock mechanism of "safety permission - no-load verification - differential comparison - safety update". This breaks the technical prejudice that "no-load verification data is unreliable and the safety system and configuration system are independent of each other". It realizes accurate verification of the correctness of the configuration without the need for material feeding and trial production, and can actively trigger the adaptive update of the safety benchmark.

[0008] 2. This invention integrates real-time scanning data from the safety zone scan with real-time operating parameters of the equipment by aligning them with timestamps, and uses the pre-action state benchmark dynamically updated by the safety zone scan analysis as a reference for fault judgment. This allows fault monitoring to obtain a dual perspective of "external environment state" and "equipment internal state" simultaneously, enabling the differentiation between anomalies caused by external factors and equipment malfunctions. It breaks the technical bias that "safety data is only used for safety decisions and fault judgment should use fixed thresholds," and significantly improves the accuracy and adaptability of fault diagnosis.

[0009] 3. This invention identifies candidate fault types by matching the current fault feature pattern with a historical fault feature database, distinguishes between primary and secondary faults based on the propagation time sequence of deviations between upstream and downstream workstations to achieve root cause tracing, and cross-validates the tracing results using real-time scanning data from the safety area scan. It upgrades from "single-point anomaly detection" to a triple root cause tracing mechanism of "pattern recognition + propagation chain inference + safety data mutual verification", breaking multiple technical biases such as "fault diagnosis = threshold judgment, faults at each workstation are independent of each other, and fault diagnosis and safety monitoring are unrelated", and achieves accurate location of fault root causes and fundamental repair. Attached Figure Description

[0010] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention.

[0011] Figure 1 A flowchart of the method provided by an embodiment of the present invention is shown.

[0012] Figure 2 The diagram illustrates the integrated self-testing process and fully automatic reset in the method provided by the embodiments of the present invention.

[0013] Figure 3 The diagram illustrates the generation of an interactive control menu in the method provided by an embodiment of the present invention.

[0014] Figure 4 The diagram illustrates the stop feeding control, gradual emptying and shutdown control in the method provided by the embodiments of the present invention.

[0015] Figure 5 An application architecture diagram of the system provided in an embodiment of the present invention is shown. Detailed Implementation

[0016] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention.

[0017] Understandably, in existing technologies, multiple processes of ceramic chain automatic rolling lines often require multiple workers to operate or monitor them separately, resulting in high labor costs. Production efficiency is affected by the skill level of the workers, and changing molds, rolling heads, suction cups, edge washing sponges, etc., requires manual adjustment of parameters one by one, resulting in long changeover times. Incorrect parameter settings lead to high scrap rates, making it unsuitable for multi-variety, small-batch production.

[0018] To address the aforementioned issues, this invention receives production requests, performs comprehensive self-inspection, and conducts safety area scanning analysis. Upon successful completion of both the comprehensive self-inspection and the safety area scan, a fully automatic reset is initiated. An interactive control menu is generated to receive production parameters input by staff and corresponding automatic mechanical configuration is performed. Continuous automatic production control is implemented according to these parameters. Real-time fault monitoring is conducted during production, with automatic handling and early warning notifications for different fault scenarios. Upon receiving a processing stop request, material feeding is stopped, and gradual clearing and shutdown control are implemented, while production operation data is recorded and backed up. This system enables comprehensive self-inspection, fully automatic reset, receiving production parameters, automatic mechanical configuration and operation control, and real-time fault monitoring and handling. It reduces labor costs, avoids the impact of staff skill levels on production efficiency, effectively reduces changeover time, lowers scrap rates, and effectively adapts to multi-variety, small-batch production.

[0019] Figure 1 A flowchart of the method provided by an embodiment of the present invention is shown.

[0020] Specifically, an integrated control method for a ceramic chain automatic rolling line includes the following steps: Step S101: Receive the production and processing request, perform a comprehensive self-inspection, and perform a security area scan analysis. If the comprehensive self-inspection and the area scan are normal, perform a fully automatic reset.

[0021] In this embodiment of the invention, a production and processing request is received, and then, in response to the request, power-on control is performed. Specifically, automatic detection processing is performed for voltage detection, compressed air detection, gas pressure detection, and tap water detection. Communication detection is also performed on the PLC, touch screen, servo driver, frequency converter, and remote I / O module. A safety area scan analysis is conducted on the ceramic chain automatic rolling line to detect the presence of personnel or obstacles. Afterwards, if the overall self-test and area scan are normal, a full reset command is generated to reset the main chain, forming machine, pressing cylinder, demolding robot, blanking robot, and edge washing machine. Specifically, in the compressed air detection, the gas source pressure is read through a pressure transmitter, requiring 0.6~0.8MPa; in the gas pressure detection, the natural gas pressure requires 4~10kPa, and the liquefied petroleum gas pressure requires 3~5kPa; in the tap water detection, the water supply is confirmed to be normal through a flow switch. Figure 2 The diagram illustrates the integrated self-testing process and fully automatic reset in the method provided by the embodiments of the present invention.

[0022] Specifically, in the preferred embodiment provided by the present invention, the steps of receiving the production and processing request, performing a comprehensive self-inspection, conducting a security area scan analysis, and performing a fully automatic reset when the comprehensive self-inspection and the area scan are normal specifically include the following steps: Receive production and processing requests; Automatic detection and processing for voltage detection, compressed air detection, gas pressure detection, and tap water detection; Perform communication testing on PLCs, touch screens, servo drives, frequency converters, and remote I / O modules; Safety area scanning analysis of ceramic chain automatic rolling line; When the overall self-test and area scan are normal, a full reset command is generated to reset and control the main chain, forming machine, pressing cylinder, demolding robot, blanking robot and edge washing machine.

[0023] Furthermore, a safety area scanning analysis was performed on the ceramic chain automatic rolling line, specifically including the following steps: The current cycle phase of the main chain of the ceramic chain automatic rolling line is obtained, and the timing trigger window corresponding to each safety monitoring area is determined based on the current cycle phase of the main chain; wherein, the timing trigger window is the time interval during which the equipment in each safety monitoring area is in a non-operational gap; According to the corresponding time-series trigger window for each safety monitoring area, the safety scan of each safety monitoring area is triggered separately, and the scan start time of each safety monitoring area is staggered to obtain the staggered scan results of each safety monitoring area. Based on the staggered scanning results of each safety monitoring area, the pre-action status benchmark of each safety monitoring area is updated and generated before each corresponding device operation; wherein, the pre-action status benchmark is the standard scanning data of the safety monitoring area when there are no personnel or obstacles before the corresponding device is about to operate; During the operation of the equipment, real-time scanning data of each safety monitoring area is continuously acquired, and the real-time scanning data is compared with the corresponding pre-operation state benchmark. When the real-time scanning data deviates from the pre-operation state benchmark and exceeds a preset threshold, it is determined to be an abnormal intrusion event, and the identified abnormal intrusion event and the corresponding safety monitoring area are obtained. Based on the degree of deviation of the identified abnormal intrusion events, the corresponding security response level is determined; according to the corresponding security response level, a graded security response is executed for the security monitoring area corresponding to the abnormal intrusion event, and the graded security response execution results for each security monitoring area are obtained; Based on the hierarchical safety response execution results of each safety monitoring area, determine whether all safety monitoring areas meet the safety conditions; if all safety monitoring areas meet the safety conditions, output a normal and safe scanning analysis result; otherwise, output a scanning analysis result containing abnormal area location information.

[0024] In this embodiment of the invention, a safety area scanning analysis is performed on the ceramic chain automatic rolling line. Specifically, the current cycle phase of the main chain of the ceramic chain automatic rolling line is obtained. For example, the cycle period of one revolution of the main chain is 3.2s. The action time distribution of each station within the cycle period is as follows: the action time of the rolling station of the forming machine is 0~0.8s, the action time of the demolding robot is 0.6~1.4s, and the action time of the edge washing machine is 1.2~2.0s. Then, the timing trigger window of the rolling station of the forming machine is 0.8~3.2s (excluding action gaps), and the timing trigger window of the demolding robot is... The timing window for the edge washing machine is 1.4~3.2s, and the timing trigger window for the edge washing machine is 2.0~3.2s. The scanning start times for each safety monitoring area are set to 0.9s, 1.5s, and 2.1s respectively, staggered by 0.6s to avoid crosstalk when multiple laser scanners work simultaneously. Before each corresponding equipment operation, such as before starting the rolling station of the forming machine, a reference scan is performed using this timing trigger window to update the scan data when there are no personnel or obstacles to the pre-operation status reference of the station. This reference includes position reference data, speed reference data, and pressure reference data. During equipment operation, real-time scanning data of each safety monitoring area is continuously acquired at a frequency of 500Hz. The real-time scanning data is compared with the corresponding pre-operation state baseline. When the difference exceeds a preset threshold of 5%, it is determined as an abnormal intrusion event. The safety response level is determined according to the degree of deviation of the abnormal intrusion event. When the deviation is 5%~15%, a Level 1 response is executed (equipment decelerates and provides audible and visual warnings). When the deviation exceeds 15%, a Level 2 response is executed (equipment stops immediately). Each safety monitoring area is divided according to its hazard level. Level 1 hazard areas (forming machine rolling station, demolding machine) The scanning frequency for the robotic arm movement area and the billet unloading robotic arm movement area is 200Hz, and the scanning frequency for the secondary danger areas (main chain conveyor area, mud pressing cylinder movement area, and edge washing machine movement area) is 100Hz. Based on the graded safety response execution results of each safety monitoring area, it is determined whether all safety monitoring areas meet the safety conditions. If there are no abnormal intrusion events in all areas, a safe and normal scanning analysis result is output. Otherwise, a scanning analysis result containing abnormal area location information (such as "abnormal intrusion exists in the first-level danger area of ​​the rolling station of the forming machine, with a deviation of 18%)" is output.

[0025] In existing technologies, safety scanning in ceramic chain automatic rolling lines typically employs a continuous, uninterrupted fixed scanning method. Each safety monitoring area is scanned simultaneously, and a fixed safety threshold (such as triggering an emergency stop when the grating is blocked) is used for judgment. This "all or nothing" scanning method not only suffers from signal crosstalk when multiple sensors are working simultaneously, but also leads to sensor baseline drift due to dust adhesion, temperature changes, and mechanical vibrations in the ceramic production environment. Fixed thresholds are difficult to adapt to dynamically changing working environments, easily resulting in false alarms or missed alarms.

[0026] This invention determines the timing trigger window for each safety monitoring area by obtaining the current cycle phase of the main chain, deeply binding safety scanning with the inherent action cycle of the production line. It utilizes the action gaps between each workstation to perform scanning, and avoids signal crosstalk from simultaneous scanning of multiple areas by staggering the scanning start times of each safety monitoring area. Furthermore, this invention updates and generates a pre-action state benchmark before each equipment action, comparing real-time scanning data with this dynamic benchmark instead of using a fixed threshold. This allows the safety judgment standard to adapt to factors such as equipment wear, changes in ambient light, and dust accumulation, significantly reducing false alarm and false negative rates. At the same time, the graded safety response mechanism avoids the impact on production efficiency caused by a "one-size-fits-all" emergency stop for first-level and second-level hazardous areas.

[0027] Furthermore, the integrated control method for the ceramic chain automatic rolling line also includes the following steps: Step S102: Generate an interactive control menu, receive production and processing parameters input by staff, and perform corresponding automatic mechanical configuration.

[0028] In this embodiment of the invention, the ceramic product model is determined according to the production and processing request, and then a corresponding interactive control menu is generated based on the ceramic product model, such as... Figure 3The diagram illustrates the generation of an interactive control menu in the method provided by this embodiment of the invention. Then, through the interactive control menu, production and processing parameters input by the staff are received. Based on the ceramic product model, mechanical specification data is matched, and corresponding automatic mechanical configuration is performed according to the mechanical specification data. The production and processing parameters include forming parameters, clay refining parameters, clay pressing parameters, edge washing parameters, demolding parameters, blanking parameters, and drying parameters. Specifically, the forming parameters include the four positions and speeds of the roller head descent, the spindle speed, the holding pressure time, the shifting execution distance, and the slow speed of the roller head rising away from the module, etc. The parameters for preparing clay include clay feeding delay, cutting blade delay, clay removal extension time, vacuum breaking time, and clay release descent time; the parameters for pressing clay include pressing times, pressing time, and pressing intervals; the parameters for edge washing include edge washing delay, centering time, edge washing time, air blowing time, and retraction time; the parameters for demolding clay include blank removal position, blank release position, blank removal descent time, vacuum suction time, and blank turning delay; the parameters for blank extrusion clay include blank removal position, blank release position, number of stacking clay pieces, and time reduction for each descent; and the parameters for drying clay include front / rear section set temperature, fan frequency, hysteresis temperature, and alarm temperature.

[0029] Specifically, in the preferred embodiment provided by the present invention, the step of generating an interactive control menu, receiving production and processing parameters input by the staff, and performing corresponding automatic mechanical configuration includes the following steps: Based on the aforementioned production and processing request, determine the ceramic product model; Generate a corresponding interactive control menu according to the ceramic product model; The interactive control menu receives production and processing parameters input by the staff, including molding parameters, clay refining parameters, clay pressing parameters, edge washing parameters, demolding parameters, blanking parameters, and drying parameters. Match the mechanical specifications according to the ceramic product model; According to the stated mechanical specifications, perform the corresponding automatic mechanical configuration.

[0030] Furthermore, according to the aforementioned mechanical specifications, the corresponding automatic mechanical configuration is performed, specifically including the following steps: Determine whether the configuration execution conditions are met. If the scan analysis result is a safe and normal scan analysis result, confirm that the execution conditions for automatic mechanical configuration are met. If the scan analysis result contains abnormal area location information, terminate the automatic mechanical configuration and output an abnormal area prompt message. After confirming that the configuration execution conditions are met, the mechanical specification data is parsed, the target configuration parameters corresponding to each actuator are extracted, and a virtual configuration parameter set is generated; wherein, the virtual configuration parameter set includes the target position parameters, target speed parameters, and target pressure parameters of each actuator; The ceramic chain automatic rolling line is controlled to run each station in sequence without adding mud, and the actual motion data of each actuator is collected during the no-load operation to obtain no-load operation data. The no-load operation data includes the actual position data, actual speed data and actual pressure data of each actuator under no mud load. The pre-action state baseline of each safety monitoring area before automatic mechanical configuration is obtained from the output of the safety area scanning analysis. The difference between the no-load operation data and the pre-action state baseline is calculated to obtain the measured configuration change of each actuator. The difference calculation is to subtract the corresponding position baseline data, speed baseline data and pressure baseline data in the pre-action state baseline from the actual position data, actual speed data and actual pressure data in the no-load operation data, respectively. The measured configuration changes of each actuator are compared one by one with the target configuration parameters corresponding to the virtual configuration parameter set. If the deviations between the measured configuration changes and the target configuration parameters are within the preset allowable range, a qualified configuration judgment result is generated; otherwise, an unqualified configuration judgment result is generated, which includes the positioning information of the actuators with excessive deviations. If the mechanical configuration qualification judgment result is qualified, a mechanical automatic configuration completion signal is output; if the mechanical configuration qualification judgment result is unqualified, a configuration anomaly signal containing actuator positioning information with excessive deviation is output, and the mechanical automatic configuration is completed; wherein, the mechanical automatic configuration completion signal simultaneously triggers the re-execution of the safety area scan analysis.

[0031] In this embodiment of the invention, the corresponding automatic mechanical configuration is performed according to the mechanical specification data. For example, if the ceramic product model corresponding to the current production and processing request is a type A bowl blank, the matched mechanical specification data is as follows: the roller head specification is a φ120mm dome roller head, the mold specification is a φ125mm concave mold, the suction cup specification is a φ60mm sponge suction cup, and the edge washing sponge specification is 40mm×30mm×20mm. Specifically, firstly, the scanning analysis results output by the safety area scanning analysis are obtained. If the scanning analysis result is safe and normal, the configuration execution conditions are confirmed to be met. If the scanning analysis result contains abnormal area positioning information (such as "abnormal intrusion exists in the demolding robot's action area"), the automatic mechanical configuration is terminated, and the prompt message "abnormal demolding robot's action area, configuration paused" is output. After confirming that the configuration execution conditions are met, the mechanical specification data is parsed to generate a virtual configuration parameter set. For example, the target descent position of the forming machine roller head is 150mm, the target spindle speed is 800rpm, and the target holding pressure is 0.6MPa. The control equipment runs unloaded without adding mud, sequentially operating each station at 50% of its rated speed. During the unloaded operation, the actual motion data is collected through the absolute encoders and pressure sensors built into each actuator. For example, the actual descent position of the roller head is collected as 152.3mm, and the actual spindle speed is 700rpm. The actual holding pressure was 0.58 MPa, and the actual operating speed was 96 rpm. The pre-operation state reference recorded by the equipment in the safe area before automatic mechanical configuration was obtained (e.g., the reference value of the roller head descent position before configuration was 148.5 mm, the reference value of the spindle speed was 802 rpm, and the reference value of the holding pressure was 0.59 MPa). The difference between the no-load running data and the pre-operation state reference was calculated to obtain the measured configuration change (the change in roller head descent position was +3.8 mm, the change in spindle speed was -6 rpm, and the change in holding pressure was -0.01 MPa). The measured configuration changes are compared one by one with the target configuration parameters in the virtual configuration parameter set. In this embodiment, the allowable range for position deviation is ±2.0mm, the allowable range for speed deviation is ±10rpm, and the allowable range for pressure deviation is ±0.02MPa. After comparison, the roller head descent position deviation of 3.8mm exceeds the allowable range of ±2.0mm, and the mechanical configuration of the actuator is determined to be unqualified. A configuration unqualified judgment result containing "forming machine roller head descent position deviation exceeds the standard" is generated. A configuration anomaly signal containing the positioning information of the actuator with excessive deviation is output, and the automatic mechanical configuration is completed. The operator readjusts the roller head installation position according to the anomaly signal and executes the configuration process again. If the measured configuration changes of all actuators are within the allowable range, a mechanical automatic configuration completion signal is output. This signal also triggers the re-execution of the safety area scan analysis, and updates the no-load state based on the new configuration to the new pre-action state benchmark.

[0032] In existing technologies, when changing molds, rollers, suction cups, edge-washing sponges, etc., in ceramic chain automatic rolling lines, workers typically adjust the mechanical parameters of each station manually based on their experience. After adjustment, the equipment is directly fed into the line for trial production verification. If defective products are found, adjustments are repeated until the product is qualified. This not only results in long changeover times and high scrap rates, but also poses serious safety hazards because the safety system is usually bypassed or shut down during the changeover debugging period. Some solutions attempt to use sensors to detect the configuration position, but the detection values ​​include inherent factors such as the mechanical clearance of the equipment itself, transmission errors, and sensor drift, leading to unreliable detection results. In contrast, this invention uses the scanning analysis results of the safety area as the execution interlock condition for automatic mechanical configuration. Mechanical configuration is only allowed when the scanning analysis result is safe and normal, extending the boundary of safety protection from the production operation stage to the changeover configuration stage, completely eliminating the safety blind spot during the changeover debugging period. Meanwhile, this invention operates each workstation under no-load conditions without adding mud, and uses the pre-configuration state benchmark for differential calculation. By subtracting the pre-configuration benchmark from the no-load operation data, it offsets inherent factors such as mechanical clearance, transmission error, and sensor drift of the equipment itself, accurately extracting the real change brought about by the configuration change. The correctness of the configuration can be accurately verified without material feeding and trial production. Furthermore, after the configuration is completed, it automatically triggers the re-execution of the safety area scan analysis to update the pre-configuration state benchmark of each safety monitoring area, ensuring that the safety judgment benchmark is accurately matched with the new mechanical configuration state. This forms a complete closed loop of "safety permission - no-load verification - differential comparison - safety update", avoiding the cumbersome operation and human error risk of manually resetting safety parameters after production change in traditional solutions.

[0033] Furthermore, the integrated control method for the ceramic chain automatic rolling line also includes the following steps: Step S103: Perform automatic operation control for continuous production according to the production and processing parameters.

[0034] In this embodiment of the invention, continuous production is automatically controlled according to production and processing parameters. Specifically, continuous production includes clay preparation and supply control, such as clay preparation start-up, clay rack stepping, clay discharge, clay cutting, clay taking, flipping, and retrying; continuous production includes clay pressing control; continuous production includes roll forming control, such as positioning, spindle and roller head rotation, multi-stage descent, synchronous action, pressure holding, rising and demolding, vacuum breaking, displacement and return, and main chain rotation; demolding and blank turning control, such as servo blank taking, auxiliary air blowing, blank turning, and dust blowing after demolding; edge washing control, such as turntable positioning, centering, edge washing, air blowing cleaning, and retraction; blank output and stacking control, such as blank taking, blank placement, blank stacking, and finished product conveying; and drying adjustment control synchronized with the production cycle. Each rotation of the main chain increases the output count and records the total production. The timing of all workstation actions is triggered by the stepping signal of the main chain to ensure synchronization.

[0035] Specifically, in the preferred embodiment provided by the present invention, the automatic operation control for continuous production includes the following steps: The control of continuous production of mud preparation and supply includes mud preparation start-up, mud loading step-by-step, mud discharge, mud cutting, mud taking, turning and retesting; Sludge pressing control for continuous production; The control of continuous production roll forming includes positioning, spindle and roller rotation, multi-stage descent, synchronous action, pressure holding, rising and demolding, vacuum breaking, displacement and return, and main chain rotation by one step; Demolding and blank turning control, including servo blank picking, auxiliary air blowing, blank turning and dust blowing after demolding; Edge washing control includes turntable positioning, centering, edge washing, air blowing cleaning, and retraction; Control of billet output and stacking, including billet taking, billet placement, billet stacking and finished product conveying; Drying adjustment and control are synchronized with the production cycle.

[0036] Furthermore, the integrated control method for the ceramic chain automatic rolling line also includes the following steps: Step S104: During the production and processing process, real-time fault monitoring is performed, and automatic handling and early warning notifications are issued for different fault conditions.

[0037] In this embodiment of the invention, during the production and processing process, real-time fault monitoring is performed to acquire fault monitoring data, and the fault monitoring data is analyzed to determine the fault type. The fault type includes recoverable faults and unrecoverable faults. Specifically, for recoverable faults, automatic reset attempts are performed; for unrecoverable faults, the machine is immediately stopped and an early warning notification is issued, thereby realizing automatic fault identification, automatic reset attempts, and automatic isolation, reducing manual intervention and increasing continuous operation time.

[0038] Specifically, in the preferred embodiment provided by the present invention, the real-time fault monitoring during the production and processing process, and the automatic handling and early warning notification of different fault conditions, specifically include the following steps: During the production and processing process, real-time fault monitoring is carried out to obtain fault monitoring data; The fault monitoring data is analyzed to determine the type of fault. For recoverable faults, an automatic reset attempt will be performed; For unrecoverable faults, the system will be shut down immediately and a warning notification will be issued.

[0039] During the production and processing process, real-time fault monitoring is conducted to acquire fault monitoring data, specifically including: Real-time operating parameters of each actuator are collected under the current production cycle; the real-time scan data and the real-time operating parameters are aligned and fused according to a unified timestamp to generate multi-source fusion fault monitoring data; wherein, the real-time operating parameters include the drive current value, actual position value, actual speed value and actual pressure value of each actuator; From the multi-source fusion fault monitoring data, the drive current value, actual position value, actual speed value and actual pressure value of each actuator under the current production cycle are extracted and used as the current characteristic value, position characteristic value, speed characteristic value and pressure characteristic value of each actuator, respectively, to obtain the operating characteristic value of each actuator; The operating characteristic values ​​of each actuator are compared one by one with the corresponding reference current value, reference position value, reference speed value and reference pressure value in the pre-action state reference of each safety monitoring area. The current deviation, position deviation, speed deviation and pressure deviation are calculated respectively. The calculated deviations are summarized to generate the characteristic deviation data of each actuator. Each deviation in the characteristic deviation data of each actuator is compared with the corresponding preset fault threshold. If all deviations do not exceed the corresponding preset fault threshold, it is determined to be a normal operating state. If any deviation exceeds the corresponding preset fault threshold but does not exceed the preset emergency stop threshold, it is determined to be a recoverable fault. If any deviation exceeds the corresponding preset emergency stop threshold, it is determined to be an unrecoverable fault, thus obtaining the identified fault type and the corresponding severity level. If the fault type is a recoverable fault, the corresponding actuator will be automatically reset; if the fault type is an unrecoverable fault, a full-line emergency stop will be triggered and a warning notification will be output, and the graded fault response execution result will be obtained. Record the multi-source fusion fault monitoring data, operating characteristic values, characteristic deviation data, identified fault types and severity, and graded fault response execution results generated during this fault monitoring process. Summarize and generate fault monitoring records, and use the data in the fault monitoring records as fault monitoring data.

[0040] In this embodiment of the invention, real-time operating parameters of each actuator under the current production cycle are collected. For example, during continuous production, the driving current value of the rolling station of the molding machine is 12.3A, the actual position is 148.7mm, the actual speed is 320mm / s, and the actual pressure is 0.58MPa, collected at a sampling frequency of 500Hz. At the same time, real-time scanning data of each safety monitoring area output by the safety area scanning analysis are obtained. For example, the real-time scanning data of the safety area of ​​the rolling station of the molding machine is in an unobstructed state. The real-time scanning data and real-time operating parameters are aligned and fused according to a unified timestamp. For example, the scanning data at t=10.25s is fused with the operating parameters at the same time into a single data record to generate multi-source fused fault monitoring data. The drive current, actual position, actual speed, and actual pressure values ​​of each actuator are extracted from the multi-source fusion fault monitoring data as operating characteristic values. Each actuator's operating characteristic value is then compared one by one with the corresponding reference current value (e.g., 11.8A), reference position value (e.g., 150.0mm), reference speed value (e.g., 315mm / s), and reference pressure value (e.g., 0.60MPa) in the pre-action state reference. For example, the current deviation of the rolling station on the molding machine is +0.5A (+4.2%), the position deviation is -1.3mm (-0.87%), the speed deviation is +5mm / s (+1.6%), and the pressure deviation is -0.02MPa (-3.3%). These deviations are then summarized to generate the characteristic deviations of each actuator. Data; Each deviation is compared with a preset fault threshold. In this embodiment, the preset fault thresholds are: a current deviation exceeding ±15%, a position deviation exceeding ±5mm, a speed deviation exceeding ±10%, and a pressure deviation exceeding ±10% are considered recoverable faults; a current deviation exceeding ±30%, a position deviation exceeding ±15mm, a speed deviation exceeding ±25%, and a pressure deviation exceeding ±25% are considered unrecoverable faults. After comparison, all deviations of the rolling station of the molding machine do not exceed the preset fault thresholds, and it is determined to be in normal operation. If the current deviation of a certain actuator reaches +22% (exceeding 15% but not exceeding 30%), it is determined to be a recoverable fault, and an automatic reset attempt is performed on the actuator (such as automatically powering off and restarting the servo drive). If the current deviation of a certain actuator reaches +35% (exceeding 30%), it is determined to be an unrecoverable fault, triggering an emergency stop for the entire line and outputting a warning notification of "Abnormal excessive drive current at the rolling station of the molding machine, emergency shutdown". Various data generated during this fault monitoring process are recorded and summarized to form a fault monitoring record. For example, a record might be created such as "Station: Rolling station of the molding machine; Time: 2026-07-27 10:25:03; Fault type: Recoverable fault; Current deviation +22%; Response measure: Automatic reset; Reset result: Success". The data in this fault monitoring record will be used as the fault monitoring data.

[0041] In existing technologies, fault monitoring of ceramic chain automatic rolling lines typically only collects the equipment's own operating parameters (such as drive current, position, speed, pressure, etc.) and uses fixed factory-calibrated thresholds for fault judgment. This single-data-source monitoring method has two fundamental drawbacks: First, the equipment's operating parameters can only reflect the equipment's "internal" state and cannot perceive the equipment's "external" environmental state (such as abnormalities caused by external factors such as personnel accidentally entering, tools left behind, or billet accumulation). When external factors cause abnormal operating parameters, traditional systems cannot distinguish whether it is a fault in the equipment itself or external interference. Second, fixed factory-calibrated thresholds cannot adapt to wear, aging, and environmental changes during long-term operation of the equipment, easily leading to false alarms (thresholds too strict) or missed alarms (thresholds too wide).

[0042] This invention integrates real-time scanning data (reflecting the external environment) from each safety monitoring area output by the safety area scanning analysis with real-time operating parameters of the equipment (reflecting the internal state) by timestamp alignment. This allows the fault monitoring system to simultaneously obtain a dual perspective of "external environment" and "internal state." For example, when the current of a certain actuator rises abnormally, if the synchronous scanning data detects an obstacle in that area, it can be determined as a recoverable fault caused by external obstruction. If the scanning data is normal but the current is still abnormal, it can be determined as an unrecoverable fault inside the equipment, effectively solving the problem of accurately distinguishing the root cause of the fault. At the same time, this invention uses the dynamically updated pre-action state benchmark (which includes the benchmark current value, benchmark position value, benchmark speed value, and benchmark pressure value of each actuator in a healthy state) as a dynamic reference for fault judgment, enabling the fault judgment standard to adapt to equipment wear and environmental changes, fundamentally solving the problem of false alarms and missed alarms caused by fixed thresholds.

[0043] The fault monitoring data is analyzed to determine the type of fault, specifically including the following steps: Characteristic deviation data of each actuator is obtained from fault monitoring data, and classified according to actuator type and deviation type to generate current fault characteristic mode; wherein, the current fault characteristic mode includes current deviation mode, position deviation mode, speed deviation mode and pressure deviation mode of each actuator; The similarity between the current fault feature pattern and each historical fault feature pattern in the historical fault feature library is calculated one by one. All historical fault feature patterns with similarity exceeding the preset matching threshold are selected. The fault types corresponding to each selected historical fault feature pattern are used as candidate fault types, and the matching similarity of each candidate fault type is recorded. The propagation time sequence of deviations between upstream and downstream stations in a ceramic chain automatic rolling line is obtained. Based on the propagation time sequence of deviations and the matching similarity corresponding to candidate fault types, primary fault types and secondary fault types are identified from the candidate fault types according to a preset propagation chain inference rule, and the root cause tracing results are obtained. Among them, the primary fault type is the fault type in which the deviation occurs first and is unrelated to the deviation of the upstream station, and the secondary fault type is the fault type of the downstream station caused by the propagation of the primary fault type. The system acquires real-time scanning data of each safety monitoring area from the output of the safety area scanning analysis. It then correlates and verifies the location of the actuator corresponding to the primary fault type located in the root cause tracing results with the real-time status of the corresponding actuator location in the real-time scanning data. If there is abnormal intrusion or abnormal equipment status at the actuator location in the real-time scanning data, the root cause tracing results are confirmed as valid. Otherwise, the root cause tracing results are marked as pending confirmation, and the fault status verification results are obtained. If the fault status verification result is valid, the primary fault type in the fault root cause tracing result will be output as the final determined fault type; if the fault status verification result is pending confirmation, the fault type with the highest matching similarity among the candidate fault types will be output as the final determined fault type, thus obtaining the fault type determined after fault monitoring data analysis.

[0044] In this embodiment of the invention, fault monitoring data is analyzed to determine the type of fault. For example, the characteristic deviation data of the rolling station of the molding machine are: current deviation +22%, position deviation -0.5mm, speed deviation +2%, and pressure deviation -1%. The characteristic deviation data of the demolding robot are: current deviation +8%, position deviation -4.2mm, speed deviation -3%, and pressure deviation +5%. The current fault feature pattern is generated by classifying the actuator type and deviation type. The similarity of the current fault feature pattern with the historical fault feature library is calculated one by one. For example, the similarity of "roller head wear fault pattern" (current deviation +18%~25%, position deviation -5%~-1mm, pressure deviation -2%~+1%) stored in the historical fault feature library is 92%, and the similarity of "mold offset fault pattern" (current deviation +5%~10%, position deviation -6%~-3mm, speed deviation -5%~-1%) is 68%. Historical fault feature patterns with similarity exceeding the preset matching threshold of 80% are selected, and the candidate fault type is "roller head wear fault" with a matching similarity of 92%. The propagation time sequence of deviations between upstream and downstream stations is obtained. For example, based on the process sequence, the upstream station is the roll forming station, and the downstream station is the demolding station. The deviation propagation time difference is approximately 1.2 seconds. The current deviation of +22% at the roll forming station first appears at t=10.25 seconds, and the position deviation of -4.2mm at the demolding robot appears later at t=11.48 seconds. According to the propagation chain inference rule, the primary fault type is identified as "roller head wear" (the deviation first appears at the roll forming station and is unrelated to the upstream station), and the secondary fault type is identified as "demolding position deviation" (caused by roller head wear leading to blank size deviation, which in turn leads to abnormal demolding position). The safety area scan analysis output is obtained. Real-time scanning data across the entire monitoring area, such as if the real-time scanning data shows no abnormal intrusion into the safe area of ​​the rolling station of the molding machine and the equipment status is normal, confirms the validity of the root cause tracing results. Finally, the primary fault type "roller head wear" is output as the final determined fault type, prompting the operator to replace the roller head rather than simply adjust the position of the demolding robot, thus achieving a fundamental solution to the fault. If the real-time scanning data shows abnormal conditions such as tools left behind at this location, the root cause tracing results are marked as pending confirmation. At this time, the candidate fault type with the highest similarity, "roller head wear" (92% similarity), is output as the final determined fault type, and the operator is prompted to check and confirm on-site.

[0045] In existing technologies, fault type determination in ceramic chain automatic rolling lines typically employs a simple single-point fault detection method based on whether a parameter exceeds the limit. This means that if a parameter at a certain station exceeds a preset threshold, it is considered a fault of that type at that station. This method has three major drawbacks: First, single-point fault detection can only answer "whether there is a fault" and "how severe the fault is," but cannot answer "what kind of fault it is"—for example, high current could be caused by increased load due to roller wear, increased resistance due to bearing jamming, or voltage fluctuations, which single-point fault detection cannot differentiate. Second, faults at each station are treated as independent events for independent diagnosis, completely ignoring the fault propagation characteristics of ceramic chain automatic rolling lines as serial production lines—minor faults in upstream stations (such as rolling forming) can propagate to downstream stations (such as demolding, edge washing, and blanking) and manifest as different abnormal symptoms downstream. Traditional independent diagnostic methods often only address the superficial symptoms downstream while ignoring the true root cause upstream, resulting in a "treating the symptoms but not the root cause" approach. Third, fault diagnosis and safety monitoring are treated as two completely independent functional modules, and the fault diagnosis results lack independent external verification. This invention performs multi-dimensional pattern matching between the current fault feature pattern and the historical fault feature database. It identifies the specific fault type by comprehensively considering the deviation patterns of four dimensions: current, position, speed, and pressure (e.g., the deviation pattern of "roller head wear" is current deviation +18%~25%, position deviation -5%~-1mm, and pressure deviation -2%~+1%), thus achieving an upgrade from "single-point anomaly detection" to "pattern recognition". Meanwhile, this invention obtains the propagation sequence relationship of deviations between upstream and downstream workstations. Based on the order of occurrence and direction of propagation of deviations, it distinguishes between primary and secondary faults. For example, when the current deviation of the rolling forming station occurs first and the position deviation of the demolding station occurs later, the primary fault is identified as "roller head wear" and the secondary fault as "demolding position offset" according to the propagation chain inference rule. This prompts the operator to replace the roller head instead of simply adjusting the position of the demolding robot, thus achieving precise location and fundamental repair of the fault root cause. Furthermore, this invention correlates and verifies the fault root cause tracing results with real-time scanning data of the safety area scan. It uses safety perception data to independently verify the fault diagnosis results. If the fault location located by the tracing does indeed show an anomaly in the real-time scanning data, the tracing is confirmed to be effective; otherwise, it is marked as pending confirmation. This greatly improves the reliability of root cause tracing and forms a triple root cause tracing mechanism of "pattern recognition + propagation chain inference + safety data mutual verification".

[0046] Furthermore, the integrated control method for the ceramic chain automatic rolling line also includes the following steps: Step S105: Receive processing stop request, perform stop feeding control, perform gradual emptying and shutdown control, and record production operation data for backup.

[0047] In this embodiment of the invention, upon receiving a processing stop request, the system responds by controlling the material feeding to stop, including stopping the clay rack and the cutter, clearing the chain and workstations, and performing direct shutdown control, including shutting down the molding machine, the clay mixing machine, the edge washing machine, the demolding / bulk ejection robot, the clay pressing cylinder, and the air blowing valve. Following this, a drying delay shutdown control is implemented. Simultaneously, production operation data is recorded and backed up to a historical database to achieve a safe and orderly production stoppage, protecting equipment and work-in-process. Figure 4 The diagram illustrates the stop feeding control, gradual emptying and shutdown control in the method provided by the embodiments of the present invention.

[0048] Specifically, in the preferred embodiment provided by the present invention, the steps of receiving a processing stop request, performing stop feeding control, performing gradual emptying and shutdown control, and recording production operation data for backup include the following steps: Receive processing stop request; Implement stop feeding control, including stopping the rotation of the mud rack and stopping the cutting blade; Perform chain clearing and workstation control; Direct shutdown control includes shutting down the molding machine, the ply mill, the edge washing machine, the demolding / bulk ejection robot, the pressing cylinder, and the blowing valve; Implement drying delay shutdown control; Record production operation data and save backups to the historical database.

[0049] Furthermore, Figure 5 An application architecture diagram of the system provided in an embodiment of the present invention is shown.

[0050] In another preferred embodiment of the present invention, an integrated control system for a ceramic chain automatic rolling line includes: The integrated self-test processing unit 101 is used to receive production and processing requests, perform integrated self-test processing, perform security area scanning analysis, and perform fully automatic reset when the integrated self-test and area scanning are normal.

[0051] In this embodiment of the invention, the integrated self-test processing unit 101 receives a production and processing request, and then responds to the request by performing power-on control. Specifically, it performs automatic detection processing for voltage detection, compressed air detection, gas pressure detection, and tap water detection, and performs communication detection for PLC, touch screen, servo driver, frequency converter, and remote IO module. It also performs a safety area scan analysis on the ceramic chain automatic rolling line to detect whether there are personnel or obstacles. Afterwards, if the integrated self-test and area scan are normal, a full reset command is generated to reset the main chain, forming machine, clay pressing cylinder, demolding robot, blanking robot, and edge washing machine. In the compressed air detection, the gas source pressure is read through a pressure transmitter, requiring 0.6~0.8MPa; in the gas pressure detection, the natural gas pressure is required to be 4~10kPa, and the liquefied gas pressure is required to be 3~5kPa; in the tap water detection, the water supply is confirmed to be normal through a flow switch.

[0052] Specifically, in the preferred embodiment provided by the present invention, the integrated self-test processing unit 101 specifically includes: The production request receiving module is used to receive production and processing requests; The electrical energy detection module is used for automatic detection and processing of voltage, compressed air, gas pressure and tap water. The communication detection module is used to detect the communication of PLCs, touch screens, servo drives, frequency converters, and remote I / O modules. The safety scanning module is used to perform safety area scanning analysis on the ceramic chain automatic rolling line; The reset control module is used to generate a full reset command when the comprehensive self-test and area scan are normal, and to reset the main chain, molding machine, pressing cylinder, demolding robot, blanking robot and edge washing machine.

[0053] Furthermore, the integrated control system for the ceramic chain automatic rolling line also includes: The processing parameter processing unit 102 is used to generate an interactive control menu, receive production processing parameters input by the staff, and perform corresponding automatic mechanical configuration.

[0054] In this embodiment of the invention, the processing parameter processing unit 102 determines the ceramic product model according to the production processing request, and then generates a corresponding interactive control menu based on the ceramic product model. Afterwards, it receives the production processing parameters input by the staff through the interactive control menu, matches the mechanical specification data according to the ceramic product model, and performs corresponding automatic mechanical configuration according to the mechanical specification data. The production processing parameters include forming parameters, clay preparation parameters, clay pressing parameters, edge washing parameters, demolding parameters, blanking parameters, and drying parameters. Specifically, the forming parameters include the four positions and speeds of the roller head descent, the spindle speed, the holding pressure time, and the shifting action. The parameters include: line distance, roller head rising speed from the module, etc.; clay mixing parameters, including clay feeding delay, cutter delay, clay removal extension time, vacuum breaking time, and clay release descent time, etc.; clay pressing parameters, including the number of pressing times, pressing time, and pressing interval, etc.; edge washing parameters, including edge washing delay, centering time, edge washing time, air blowing time, and retraction time, etc.; demolding parameters, including blank removal position, blank release position, blank removal descent time, vacuum suction time, and blank turning delay, etc.; blank extrusion parameters, including blank removal position, blank release position, number of stacking times, and time reduction for each descent, etc.; and drying parameters, including front / rear section set temperature, fan frequency, hysteresis temperature, and alarm temperature, etc.

[0055] Specifically, in the preferred embodiment provided by the present invention, the processing parameter processing unit 102 specifically includes: The model determination module is used to determine the model of the ceramic product based on the production and processing request. The menu generation module is used to generate a corresponding interactive control menu according to the model of the ceramic product; The parameter receiving module is used to receive production and processing parameters input by the staff through the interactive control menu. The production and processing parameters include molding parameters, clay refining parameters, clay pressing parameters, edge washing parameters, demolding parameters, blanking parameters, and drying parameters. The specification data matching module is used to match mechanical specification data according to the model of the ceramic product; The automatic mechanical configuration module is used to perform corresponding automatic mechanical configuration according to the mechanical specification data.

[0056] Furthermore, the integrated control system for the ceramic chain automatic rolling line also includes: The automatic operation control unit 103 is used to automatically control continuous production according to the production and processing parameters.

[0057] In this embodiment of the invention, the automatic operation control unit 103 performs automatic operation control for continuous production according to the production and processing parameters. Specifically, it performs continuous production clay preparation and supply control, including clay preparation start-up, clay rack stepping, clay discharge, clay cutting, clay picking, flipping, and retry; continuous production clay pressing control; continuous production roll forming control, including positioning, spindle and roller head rotation, multi-stage descent, synchronous action, pressure holding, rising and demolding, vacuum breaking, displacement and return, and main chain rotation; demolding and blank turning control, including servo blank picking, auxiliary air blowing, blank turning, and dust blowing after demolding; edge washing control, including turntable positioning, centering, edge washing, air blowing cleaning, and retraction; blank output and blank stacking control, including blank picking, blank placement, blank stacking, and finished product conveying; and drying adjustment control synchronized with the production cycle. Each rotation of the main chain increases the output count and records the total production. The timing of all workstation actions is triggered by the stepping signal of the main chain to ensure synchronization.

[0058] Specifically, in the preferred embodiment provided by the present invention, the automatic operation control unit 103 specifically includes: The mud refining and mud supply control module is used for continuous production mud refining and mud supply control, including mud refining start-up, mud loading frame stepping, mud discharge, mud cutting, mud picking, turning and retrying; The sludge pressing control module is used for sludge pressing control in continuous production. The roll forming control module is used for continuous production roll forming control, including positioning, spindle and roller rotation, multi-stage descent, synchronous action, pressure holding, rising and demolding, vacuum breaking, displacement and return, and main chain rotation by one step; The demolding and blank turning control module is used for demolding and blank turning control, including servo blank picking, auxiliary air blowing, blank turning and dust blowing after demolding; The edge washing control module is used for edge washing control, including turntable positioning, centering, edge washing, air blowing cleaning, and retraction. The billet output and stacking control module is used to control billet output and stacking, including billet picking, billet placement, billet stacking and finished product conveying; The adjustment and synchronization control module is used to adjust and control the drying process and synchronize it with the production cycle.

[0059] Furthermore, the integrated control system for the ceramic chain automatic rolling line also includes: The fault monitoring and processing unit 104 is used to perform real-time fault monitoring during the production and processing process, and to automatically handle and issue early warnings for different fault conditions.

[0060] In this embodiment of the invention, during the production and processing process, the fault monitoring and processing unit 104 performs real-time fault monitoring, acquires fault monitoring data, analyzes the fault monitoring data, and determines the fault type. The fault type includes recoverable faults and unrecoverable faults. Specifically, for recoverable faults, an automatic reset attempt is performed; for unrecoverable faults, the machine is immediately stopped and an early warning notification is issued, thereby realizing automatic fault identification, automatic reset attempt, and automatic isolation, reducing manual intervention, and improving continuous operation time.

[0061] The processing stop processing unit 105 is used to receive processing stop requests, perform stop feeding control, perform gradual emptying and shutdown control, and record production operation data for backup.

[0062] In this embodiment of the invention, the processing stop processing unit 105 receives a processing stop request, and then responds to the processing stop request by performing a stop feeding control, including stopping the rotation of the clay rack and the cutting knife, and performing a chain clearing and station control, and performing a direct shutdown control, including shutting down the molding machine, shutting down the clay mixing machine, shutting down the edge washing machine, shutting down the demolding / blanking robot, shutting down the clay pressing cylinder and shutting down the blowing valve. After that, a drying delay shutdown control is performed. At the same time, production operation data is recorded and backed up to the historical database to achieve safe and orderly production stoppage and protect equipment and work-in-process.

[0063] It should be understood that although the steps in the flowcharts of the various embodiments of the present invention are shown sequentially according to the arrows, these steps are not necessarily executed in the order indicated by the arrows. Unless explicitly stated herein, there is no strict order restriction on the execution of these steps, and they can be executed in other orders. Moreover, at least some steps in the various embodiments may include multiple sub-steps or multiple stages. These sub-steps or stages are not necessarily completed at the same time, but can be executed at different times. The execution order of these sub-steps or stages is not necessarily sequential, but can be performed alternately or in turn with other steps or at least a portion of the sub-steps or stages of other steps.

[0064] Those skilled in the art will understand that all or part of the processes in the methods of the above embodiments can be implemented by a computer program instructing related hardware. The program can be stored in a non-volatile computer-readable storage medium, and when executed, it can include the processes of the embodiments of the above methods. Any references to memory, storage, databases, or other media used in the embodiments provided in this application can include non-volatile and / or volatile memory. Non-volatile memory can include read-only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), or flash memory. Volatile memory can include random access memory (RAM) or external cache memory. By way of illustration and not limitation, RAM is available in various forms, such as static RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), dual data rate SDRAM (DDRSDRAM), enhanced SDRAM (ESDRAM), synchronous link DRAM (SLDRAM), Rambus direct RAM (RDRAM), direct memory bus dynamic RAM (DRDRAM), and memory bus dynamic RAM (RDRAM), etc.

[0065] The technical features of the above embodiments can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as there is no contradiction in the combination of these technical features, they should be considered to be within the scope of this specification.

[0066] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of this patent should be determined by the appended claims.

[0067] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. An integrated control method for a ceramic chain automatic rolling line, characterized in that, The method specifically includes the following steps: Upon receiving a production and processing request, the system performs a comprehensive self-inspection and a security area scan analysis. If both the comprehensive self-inspection and the security area scan are normal, the system performs a fully automatic reset. Generate an interactive control menu, receive production and processing parameters input by staff, and perform corresponding automatic machine configuration; Automatic operation control for continuous production is implemented according to the aforementioned production and processing parameters; During the production and processing process, real-time fault monitoring is carried out, and automatic handling and early warning notifications are provided for different fault scenarios; Upon receiving a processing stop request, the system will stop feeding, gradually clear and shut down the system, and record and back up production operation data.

2. The integrated control method for a ceramic chain automatic rolling line according to claim 1, characterized in that, The process of receiving a production and processing request, performing a comprehensive self-check, and conducting a security area scan analysis, followed by a fully automatic reset when both the comprehensive self-check and the security area scan are normal, specifically includes the following steps: Receive production and processing requests; Automatic detection and processing for voltage detection, compressed air detection, gas pressure detection, and tap water detection; Perform communication testing on PLCs, touch screens, servo drives, frequency converters, and remote I / O modules; Safety area scanning analysis of ceramic chain automatic rolling line; When the overall self-test and area scan are normal, a full reset command is generated to reset and control the main chain, forming machine, pressing cylinder, demolding robot, blanking robot and edge washing machine.

3. The integrated control method for a ceramic chain automatic rolling line according to claim 2, characterized in that, The safety area scanning analysis of the ceramic chain automatic rolling line includes the following steps: Obtain the current cycle phase of the main chain of the ceramic chain automatic rolling line, and determine the timing trigger window corresponding to each safety monitoring area based on the current cycle phase of the main chain; According to the corresponding time-series trigger window for each safety monitoring area, the safety scan of each safety monitoring area is triggered separately, and the scan start time of each safety monitoring area is staggered to obtain the staggered scan results of each safety monitoring area. Based on the staggered scanning results of each safety monitoring area, the pre-action status baseline of each safety monitoring area is updated and generated before each corresponding equipment action; During the operation of the equipment, real-time scanning data of each safety monitoring area is continuously acquired, and the real-time scanning data is compared with the corresponding pre-operation state benchmark. When the real-time scanning data deviates from the pre-operation state benchmark and exceeds a preset threshold, it is determined to be an abnormal intrusion event, and the identified abnormal intrusion event and the corresponding safety monitoring area are obtained. Based on the degree of deviation of the identified abnormal intrusion events, the corresponding security response level is determined; according to the corresponding security response level, a graded security response is executed for the security monitoring area corresponding to the abnormal intrusion event, and the graded security response execution results for each security monitoring area are obtained; Based on the hierarchical safety response execution results of each safety monitoring area, determine whether all safety monitoring areas meet the safety conditions; if all safety monitoring areas meet the safety conditions, output a normal and safe scanning analysis result; otherwise, output a scanning analysis result containing abnormal area location information.

4. The integrated control method for a ceramic chain automatic rolling line according to claim 3, characterized in that, Generating an interactive control menu, receiving production and processing parameters input by staff, and performing corresponding automatic machine configurations specifically includes the following steps: Based on the aforementioned production and processing request, determine the ceramic product model; Generate a corresponding interactive control menu according to the ceramic product model; The interactive control menu receives production and processing parameters input by the staff, including molding parameters, clay refining parameters, clay pressing parameters, edge washing parameters, demolding parameters, blanking parameters, and drying parameters. Match the mechanical specifications according to the ceramic product model; According to the stated mechanical specifications, perform the corresponding automatic mechanical configuration.

5. The integrated control method for a ceramic chain automatic rolling line according to claim 4, characterized in that, According to the aforementioned mechanical specifications, the corresponding automatic mechanical configuration is performed, specifically including the following steps: Determine whether the configuration execution conditions are met. If the scan analysis result is a safe and normal scan analysis result, confirm that the execution conditions for automatic mechanical configuration are met. If the scan analysis result contains abnormal area location information, terminate the automatic mechanical configuration and output an abnormal area prompt message. After confirming that the configuration execution conditions are met, the mechanical specification data is parsed, the target configuration parameters corresponding to each actuator are extracted, and a virtual configuration parameter set is generated. The ceramic chain automatic rolling line is controlled to run each station in sequence without adding mud, and the actual motion data of each actuator is collected during the no-load operation to obtain no-load operation data. The pre-action state baseline of each safety monitoring area before automatic mechanical configuration is obtained from the output of the safety area scanning analysis. The difference between the no-load operation data and the pre-action state baseline is calculated to obtain the measured configuration change of each actuator. The measured configuration changes of each actuator are compared one by one with the target configuration parameters corresponding to the virtual configuration parameter set. If the deviations between the measured configuration changes and the target configuration parameters are within the preset allowable range, a qualified configuration judgment result is generated; otherwise, an unqualified configuration judgment result is generated, which includes the positioning information of the actuators with excessive deviations. If the mechanical configuration qualification judgment result is qualified, a mechanical automatic configuration completion signal is output; if the mechanical configuration qualification judgment result is unqualified, a configuration anomaly signal containing actuator positioning information with excessive deviation is output, and the mechanical automatic configuration is completed; wherein, the mechanical automatic configuration completion signal simultaneously triggers the re-execution of the safety area scan analysis.

6. The integrated control method for a ceramic chain automatic rolling line according to claim 5, characterized in that, The automatic operation control for continuous production includes the following steps: The control of continuous production of mud preparation and supply includes mud preparation start-up, mud loading step-by-step, mud discharge, mud cutting, mud taking, turning and retesting; Sludge pressing control for continuous production; The control of continuous production roll forming includes positioning, spindle and roller rotation, multi-stage descent, synchronous action, pressure holding, rising and demolding, vacuum breaking, displacement and return, and main chain rotation by one step; Demolding and blank turning control, including servo blank picking, auxiliary air blowing, blank turning and dust blowing after demolding; Edge washing control includes turntable positioning, centering, edge washing, air blowing cleaning, and retraction; Control of billet output and stacking, including billet taking, billet placement, billet stacking and finished product conveying; Drying adjustment and control are synchronized with the production cycle.

7. The integrated control method for a ceramic chain automatic rolling line according to claim 6, characterized in that, During the production and processing process, real-time fault monitoring is performed, and different fault scenarios are automatically handled and early warning notifications are issued. Specifically, the following steps are included: During the production and processing process, real-time fault monitoring is carried out to obtain fault monitoring data; The fault monitoring data is analyzed to determine the type of fault. For recoverable faults, an automatic reset attempt will be performed; For unrecoverable faults, the system will be shut down immediately and a warning notification will be issued.

8. The integrated control method for a ceramic chain automatic rolling line according to claim 7, characterized in that, During the production and processing process, real-time fault monitoring is conducted to acquire fault monitoring data, specifically including: Collect real-time operating parameters of each actuator under the current production cycle; align and merge the real-time scan data and the real-time operating parameters according to a unified timestamp to generate multi-source fusion fault monitoring data; From the multi-source fusion fault monitoring data, the drive current value, actual position value, actual speed value and actual pressure value of each actuator under the current production cycle are extracted and used as the current characteristic value, position characteristic value, speed characteristic value and pressure characteristic value of each actuator, respectively, to obtain the operating characteristic value of each actuator; The operating characteristic values ​​of each actuator are compared one by one with the corresponding reference current value, reference position value, reference speed value and reference pressure value in the pre-action state reference of each safety monitoring area. The current deviation, position deviation, speed deviation and pressure deviation are calculated respectively. The calculated deviations are summarized to generate the characteristic deviation data of each actuator. Each deviation in the characteristic deviation data of each actuator is compared with the corresponding preset fault threshold. If all deviations do not exceed the corresponding preset fault threshold, it is determined to be a normal operating state. If any deviation exceeds the corresponding preset fault threshold but does not exceed the preset emergency stop threshold, it is determined to be a recoverable fault. If any deviation exceeds the corresponding preset emergency stop threshold, it is determined to be an unrecoverable fault, thus obtaining the identified fault type and the corresponding severity level. If the fault type is a recoverable fault, the corresponding actuator will be automatically reset; if the fault type is an unrecoverable fault, a full-line emergency stop will be triggered and a warning notification will be output, and the graded fault response execution result will be obtained. Record the multi-source fusion fault monitoring data, operating characteristic values, characteristic deviation data, identified fault types and severity, and graded fault response execution results generated during this fault monitoring process. Summarize and generate fault monitoring records, and use the data in the fault monitoring records as fault monitoring data.

9. The integrated control method for a ceramic chain automatic rolling line according to claim 8, characterized in that, The fault monitoring data is analyzed to determine the type of fault, specifically including the following steps: The characteristic deviation data of each actuator is obtained from the fault monitoring data, and classified according to the actuator type and deviation type to generate the current fault characteristic pattern; The similarity between the current fault feature pattern and each historical fault feature pattern in the historical fault feature library is calculated one by one. All historical fault feature patterns with similarity exceeding the preset matching threshold are selected. The fault types corresponding to each selected historical fault feature pattern are used as candidate fault types, and the matching similarity of each candidate fault type is recorded. Obtain the deviation propagation time sequence relationship between upstream and downstream stations in the ceramic chain automatic rolling line. Based on the deviation propagation time sequence relationship and the matching similarity corresponding to the candidate fault types, identify the primary fault type and the secondary fault type from the candidate fault types according to the preset propagation chain inference rules, and obtain the fault root cause tracing result. The system acquires real-time scanning data of each safety monitoring area from the output of the safety area scanning analysis. It then correlates and verifies the location of the actuator corresponding to the primary fault type located in the root cause tracing results with the real-time status of the corresponding actuator location in the real-time scanning data. If there is abnormal intrusion or abnormal equipment status at the actuator location in the real-time scanning data, the root cause tracing results are confirmed as valid. Otherwise, the root cause tracing results are marked as pending confirmation, and the fault status verification results are obtained. If the fault status verification result is valid, the primary fault type in the fault root cause tracing result will be output as the final determined fault type; if the fault status verification result is pending confirmation, the fault type with the highest matching similarity among the candidate fault types will be output as the final determined fault type, thus obtaining the fault type determined after fault monitoring data analysis.

10. The integrated control method for a ceramic chain automatic rolling line according to claim 9, characterized in that, Upon receiving a processing stop request, the system stops material feeding, performs gradual emptying and shutdown control, and records and backs up production operation data. Specifically, this includes the following steps: Receive processing stop request; Implement stop feeding control, including stopping the rotation of the mud rack and stopping the cutting blade; Perform chain clearing and workstation control; Direct shutdown control includes shutting down the molding machine, the ply mill, the edge washing machine, the demolding / bulk ejection robot, the pressing cylinder, and the blowing valve; Implement drying delay shutdown control; Record production operation data and save backups to the historical database.

11. An integrated control system for a ceramic chain automatic rolling line, characterized in that, The system employs the integrated control method for a ceramic chain automatic rolling line as described in any one of claims 1-10, and the system comprises: The integrated self-test processing unit is used to receive production and processing requests, perform integrated self-test processing, perform safety area scanning analysis, and perform fully automatic reset when the integrated self-test and area scanning are normal. The processing parameter processing unit is used to generate interactive control menus, receive production processing parameters input by staff, and perform corresponding automatic mechanical configurations. An automatic operation control unit is used to automatically control continuous production according to the aforementioned production and processing parameters; The fault monitoring and processing unit is used to monitor faults in real time during the production and processing process, and to automatically handle and issue early warnings for different fault conditions. The processing stop unit is used to receive processing stop requests, control the material feeding to stop, perform gradual emptying and shutdown control, and record production operation data for backup.

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