Intelligent point inspection system for production line

Abstract

The utility model provides an intelligent point inspection system for a production line, which comprises a PLC module, a relay module, a touch screen module, a communication module, a switch and a power supply module, the switch is respectively connected with the PLC module and the touch screen module, the PLC module is connected with the relay module, the relay module is connected with a safety sensor on the production line, the communication module is connected with the PLC module, and the power supply module is connected with the PLC module. The communication module is in communication connection with a production line control system; and the PLC module is also directly connected with a safety sensor on the production line. During point inspection, the relay module in the system can simulate triggering of the safety sensor, and reset of the safety sensor is controlled through the PLC module. In the process, a control system of the production line judges the change condition of a safety sensor signal and feeds back the change condition to the PLC module. And the PLC module judges whether the point inspection of the safety sensor is abnormal or not according to the change condition of the signal. Through the spot inspection system, manual spot inspection can be replaced, the spot inspection efficiency of the safety sensor is improved, and the problem of missing inspection can be solved.

Description

Technical Field

[0001] The utility model relates to the technical field of safety sensor spot-check, in particular to an intelligent spot-check system for a production line. Background Art

[0002] A safety sensor is a device used for automatic detection and automatic control in industry and applications. It usually consists of a sensitive element that directly responds to the measured quantity, a conversion element that generates an available signal output, and corresponding electronic circuits. A sensor that meets safety standards is called a safety sensor. These sensors play an important role in industrial automation, and their products include safety switches, safety gratings (safety light curtains), safety door locks, emergency stop buttons, maintenance switches, etc. Usually, many safety sensors are installed on an automated production line. The main functions of installing safety sensors in the production line include protecting operators, preventing equipment damage, improving production safety, and meeting safety standards.

[0003] In order to timely discover potential safety hazards, the safety sensors on the production line need to be spot-checked regularly to timely discover and solve safety hazards, avoid the occurrence of accidents, and ensure the personal safety of employees.

[0004] For the spot-check of safety sensors on the production line, the existing method is manual spot-check, that is, it is necessary to manually walk along the production line and trigger the safety sensors one by one, which is time-consuming and laborious. For an automated production line with a total length of several hundred meters or more than one kilometer, it takes at least 1-2 days to spot-check all the safety sensors by manually triggering them one by one. Moreover, there is also the problem of missed inspection when using the method of manually triggering safety sensors. Content of the Utility Model

[0005] The technical problem to be solved by the utility model is to provide a new intelligent spot-check system for a production line, which can replace manual spot-check and improve the efficiency of safety sensor spot-check.

[0006] The utility model is realized as follows:

[0007] In the first aspect, the utility model provides an intelligent spot-check system for a production line, including a PLC module, a relay module for simulating the triggering of safety sensors, a touch screen module for human-computer interaction, a communication module, a switch, and a power module for supplying power to the spot-check system. The switch is respectively connected to the PLC module and the touch screen module. The PLC module is connected to the relay module. The relay module is connected to the safety sensors on the production line. The communication module is connected to the PLC module. The communication module is communicatively connected to the production line control system;

[0008] The PLC module is also directly connected to the safety sensors on the production line for resetting the triggered safety sensors.

[0009] During inspection, the PLC module controls the relay module to emit an analog signal to simulate the triggering of the safety sensor and controls the reset of the analog signal through the PLC module. During this process, the production line control system judges the change of the analog safety sensor signal and feeds it back to the PLC module. The PLC module judges whether there is any abnormality in the entire safety control loop according to the change of the signal.

[0010] Furthermore, the safety sensors on the production line include safety light curtains respectively arranged at the partition board, the top board, the pallet loading position, the stacking exit and the packing machine. The safety sensors on the production line also include a first safety door, a second safety door and a third safety door.

[0011] The PLC module includes a second PLC and a third PLC.

[0012] The relay module includes a first relay module, a second relay module and a third relay module. The second PLC is connected to the first relay module and the second relay module. The first relay module is connected to the first safety door, the second safety door, the third safety door and the safety light curtain arranged at the partition board. The second relay module is connected to the safety light curtains arranged at the partition board, the top board and the pallet loading position.

[0013] The third PLC is connected to the third relay module. The third relay module is connected to the safety light curtains arranged at the pallet loading position, the stacking exit and the packing machine.

[0014] Furthermore, the third PLC is also connected to the first safety door, the second safety door, the third safety door and the safety light curtains arranged at the stacking exit and the packing machine for resetting the first safety door, the second safety door, the third safety door and the safety light curtains arranged at the stacking exit and the packing machine.

[0015] The PLC module also includes a first PLC. The first PLC is connected to the safety light curtains respectively arranged at the partition board, the top board and the pallet loading position for resetting the safety light curtains arranged at the partition board, the top board and the pallet loading position.

[0016] Furthermore, the PLC module is also connected to an alarm lamp and a buzzer.

[0017] Furthermore, there is also a control cabinet. The PLC module, the relay module, the communication module, the switch and the power module are arranged in the control cabinet.

[0018] Furthermore, the model of the power module is DC 24V / 10A EDR-120-24.

[0019] In a second aspect, the present utility model provides an intelligent inspection method for a production line. Based on the intelligent inspection system for the production line in the first aspect, it includes the following steps:

[0020] S1. The PLC module controls the relay module to act, enabling the relay module to sequentially simulate triggering the safety sensors located on the production line;

[0021] S2. As each safety sensor is simulated and triggered, the control system of the production line sequentially determines whether the safety sensor signal and the corresponding safety zone signal have changed, and feeds back the signal change situation of each safety sensor to the PLC module. If the signal of a certain safety sensor or the corresponding safety zone signal has not changed, the PLC module determines that the inspection of this safety sensor is abnormal;

[0022] S3. After a safety sensor is simulated and triggered by the relay module, the PLC module controls the reset of this safety sensor, and the control system of the production line determines the change of this safety sensor signal and the corresponding safety zone signal again, and feeds back the output signal of each safety sensor to the PLC module again;

[0023] S4. Based on the two input signals to the safety sensor and the two output signals of the safety sensor fed back to the PLC module, the PLC module determines whether the input and output of the safety sensor are synchronized. If not, the PLC module determines that the inspection of this safety sensor is abnormal

[0024] S5. In steps S2 and S4, if the PLC module determines that the inspection of a certain safety sensor is abnormal, after the inspection of all the safety sensors on the production line is completed, the PLC module controls the alarm light and the buzzer to start, and feeds back the signal of full machine safety shutdown to the control system of the production line.

[0025] The present utility model has the following advantages: During inspection, the relay module in this system can simulate the triggering of the safety sensor, and the PLC module controls the reset of the safety sensor. During this process, the control system of the production line determines the change situation of the safety sensor signal and feeds it back to the PLC module. The PLC module determines whether the inspection of the safety sensor is abnormal according to the change situation of the signal and displays it on the touch screen module. Through this inspection system, manual inspection can be replaced, the inspection efficiency of the safety sensor can be improved, and the problem of missed inspection can also be overcome. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] The following further describes the present utility model with reference to the accompanying drawings in conjunction with embodiments.

[0027] Figure 1 It is a schematic connection structure diagram of the intelligent inspection system for the production line of the present utility model.

[0028] Figure 2 Schematic diagram of the connection structure between the power supply module and the terminal block of the present utility model.

[0029] Figure 3 First PLC wiring diagram of the present utility model.

[0030] Figure 4 Second PLC wiring diagram of the present utility model.

[0031] Figure 5 Third PLC wiring diagram of the present utility model.

[0032] Figure 6 First relay module wiring diagram of the present utility model.

[0033] Figure 7 Second relay module wiring diagram of the present utility model.

[0034] Figure 8 Third relay module wiring diagram of the present utility model.

[0035] Figure 9 Switch wiring diagram of the present utility model.

[0036] Figure 10 Touch screen module wiring diagram of the present utility model.

[0037] Explanation of the reference numerals in the figure:

[0038] 1. PLC module; 11. First PLC; 12. Second PLC; 13. Third PLC; 2. Relay module; 21. First relay module; 22. Second relay module; 23. Third relay module; 3. Touch screen module; 4. Communication module; 5. Switch; 6. Power supply module; 7. Safety sensor; 8. Control cabinet; Specific implementation mode

[0039] Example 1, please refer to Figure 1-10, the utility model provides an intelligent production line inspection system, which includes a PLC module 1, a relay module 2, a touch screen module 3 for human-machine interaction, a communication module 4, a switch 5, and a power supply module 6 for supplying power to the inspection system. The power supply module 6 is used to convert 220V mains electricity into 24V direct current. The power supply module 6 is connected to the PLC module 1, the relay module 2, the touch screen module 3, the communication module 4, and the switch 5 through a terminal block and supplies power to them. The switch 5 is respectively connected to the PLC module 1 and the touch screen module 3. The PLC module 1 and the touch screen module 3 are communicatively connected through the switch 5. The PLC module 1 is connected to the relay module 2. The relay module 2 is connected to a safety sensor 7 on the production line. The communication module 4 is connected to the PLC module 1. The communication module 4 is communicatively connected to the production line control system;

[0040] The PLC module 1 is also directly connected to the safety sensor 7 on the production line and is used to reset the triggered safety sensor 7.

[0041] During inspection, the PLC module in this system can control the relay module to send out an analog signal to simulate the triggering of the safety sensor (shielding the safety sensor signal at this time), and control the reset of the analog signal through the PLC module (the safety sensor resumes normal operation after reset). During this process, the control system of the production line judges the change of the analog safety sensor signal and feeds it back to the PLC module. The PLC module judges whether there is an abnormality in the entire safety control loop according to the change of the signal. Through this inspection system, manual inspection can be replaced, the inspection efficiency of the safety sensor can be improved, and the problem of missed inspection can also be overcome.

[0042] Specifically, the safety sensor 7 on the production line includes safety light curtains respectively arranged at the partition board, the top board, the pallet loading place, the unloading outlet, and the packing machine. The safety light curtains arranged at the partition board, the top board, the pallet loading place, and the unloading outlet have two internal and external contacts, and all the safety light curtains also have emergency stop contacts. Therefore, the contacts of the safety light curtains on the production line are divided into: partition light curtain external contact, partition light curtain internal contact, partition light curtain emergency stop contact, top board light curtain external contact, top board light curtain internal contact, top board light curtain emergency stop contact, pallet light curtain external contact, pallet light curtain internal contact, pallet light curtain emergency stop contact, unloading place light curtain external contact, unloading place light curtain internal contact, unloading place light curtain emergency stop contact, packing machine place light curtain contact, and packing machine place light curtain emergency stop contact;

[0043] The safety sensor 7 on the production line further includes a first safety door, a second safety door, and a third safety door; each safety door has a safety door protection contact and an emergency stop contact. Therefore, the safety door contacts of the production line are divided into: a first safety door protection contact, a first safety door emergency stop contact, a second safety door protection contact, a second safety door emergency stop contact, a third safety door protection contact, and a third safety door emergency stop contact.

[0044] The PLC module 1 includes a second PLC 12 and a third PLC 13; as shown in the figure, the models of the second PLC 12 and the third PLC 13 are both Siemens 6ES7222-1BH32-0XB0.

[0045] The relay module 2 includes a first relay module 21, a second relay module 22, and a third relay module 23. As shown in the figure, each relay module contains eight relays; the relay has 2 pairs of normally closed auxiliary contacts. Each relay controls 2 input signals of a safety sensor 7 (safety light curtain, safety door, or emergency stop button); each relay is controlled by a separate PLC output point;

[0046] The second PLC 12 is connected to the first relay module 21 and the second relay module 22. The first relay module 21 is connected to the first safety door, the second safety door, the third safety door, and the safety light curtain provided at the partition. More specifically, the eight relays in the first relay module 21 are respectively connected to the first safety door protection contact, the first safety door emergency stop contact, the second safety door protection contact, the second safety door emergency stop contact, the third safety door protection contact, the third safety door emergency stop contact, the outer contact of the partition light curtain, and the emergency stop contact of the partition light curtain;

[0047] The second relay module 22 is connected to the safety light curtains provided at the partition, the top plate, and the pallet loading area; more specifically, the relays in the second relay module 22 are respectively connected to the inner contact of the partition light curtain, the outer contact of the top plate light curtain, the inner contact of the top plate light curtain, the emergency stop contact of the top plate light curtain, the outer contact of the pallet light curtain, and the emergency stop contact of the pallet light curtain;

[0048] The third PLC 13 is connected to the third relay module 23. The third relay module 23 is connected to the safety light curtains provided at the pallet loading area, the discharging exit, and the packing machine. The third relay module 23 is respectively connected to the inner contact of the pallet light curtain, the outer contact of the discharging light curtain, the inner contact of the discharging light curtain, the emergency stop contact of the discharging light curtain, the light curtain contact at the packing machine, and the emergency stop contact of the light curtain at the packing machine;

[0049] Specifically, the third PLC 13 is also connected to the first safety door, the second safety door, the third safety door, and the safety light curtains provided at the lower stack exit and the packing machine, and is used to reset the first safety door, the second safety door, the third safety door, and the safety light curtains provided at the lower stack exit and the packing machine;

[0050] The PLC module 1 further includes a first PLC 11, and the model of the first PLC 11 is Siemens 6ES7215-1AG40-0XB0. The first PLC 11 is connected to the safety light curtains respectively provided at the partition board, the top board, and the pallet loading position, and is used to reset the safety light curtains provided at the partition board, the top board, and the pallet loading position.

[0051] Specifically, the PLC module 1 is further connected to an alarm lamp and a buzzer. As shown in the figure, the alarm lamp and the buzzer are connected to the first PLC 11.

[0052] Specifically, it further includes a control cabinet 8, and the PLC module 1, the relay module 2, the communication module 4, the switch 5, and the power supply module 6 are arranged in the control cabinet 8.

[0053] Specifically, the model of the power supply module 6 is DC 24V / 10A EDR-120-24.

[0054] Embodiment 2, the present invention provides a method for intelligent spot-checking of a production line. Based on the intelligent spot-checking system in Embodiment 1, it includes the following steps:

[0055] S1. The PLC module 1 controls the relay module 2 to act, so that the relay module 2 sequentially simulates triggering the safety sensors 7 located on the production line;

[0056] S2. As each safety sensor 7 is simulated and triggered, the control system of the production line sequentially judges whether the signals of the safety sensors 7 and the corresponding safety zone signals change, and feeds back the signal change situation of each safety sensor 7 to the PLC module 1. If the signal of a certain safety sensor 7 or the corresponding safety zone signal does not change, the PLC module 1 judges that the spot-check of this safety sensor 7 is abnormal;

[0057] S3. After a safety sensor 7 is triggered by the relay module 2, the PLC module 1 controls the reset of this safety sensor 7, and the control system of the production line judges the change of the signal of this safety sensor 7 and the corresponding safety zone signal again, and feeds back the output signal of each safety sensor 7 to the PLC module 1 again;

[0058] S4, based on the two input signals to the safety sensor 7 and the two output signals of the safety sensor 7 fed back to the PLC module 1, the PLC module 1 determines whether the input and output of the safety sensor 7 are synchronized, if not, the PLC module 1 determines that the spot check of the safety sensor 7 is abnormal;

[0059] S5. In steps S2 and S4, if the PLC module 1 determines that a certain safety sensor 7 has an abnormal inspection, then after the inspection of all safety sensors 7 on the production line is completed, the PLC module 1 controls the alarm light and buzzer to start, and feeds back the signal of the safe shutdown of the entire machine to the control system of the production line.

[0060] A specific application of the utility model is:

[0061] The touch screen module 3 has a spot inspection screen, which has a "spot inspection start" button and a "spot inspection reset" button. Compared with the manual spot inspection in the prior art, the spot inspection system of the utility model has a one-key spot inspection function, and can only be used when the production line is in a normal shutdown state, all safety inputs are in a normal state, and there is no safety alarm. The "spot inspection reset" button can only work during the spot inspection process, and the function of this button is automatically eliminated after the spot inspection is completed.

[0062] Each safety sensor 7 has a separate status display: during the spot inspection, the normal indicator light is yellow, and the abnormal indicator light is red. During the non-spot inspection process, the sensor is triggered red, and the non-triggered sensor is green.

[0063] After pressing the "Inspection Start" button, each safety sensor 7 is inspected separately, and the PLC module 1 triggers the safety sensor 7 through the relay module. The inspection time of each safety sensor 7 is 3 seconds, including the relay action time of 1 second and the reset time of 1 second. After the relay is actuated, if the control system of the production line can determine that the input of the corresponding safety sensor 7 has changed from two "1" signals to "0" signals, and at the same time, the safety output of the corresponding safety partition has also changed from a "1" signal to a "0" signal (each safety output relay or contactor takes an auxiliary contact signal to connect to the PLC module 1); the control system of the production line determines whether the safety sensor 7 signal and the corresponding safety partition signal have changed one by one, and feeds back the signal change of each safety sensor 7 to the PLC module 1; if the safety sensor 7 and the safety partition signals have changed, the PLC module 1 determines that the inspection of the safety sensor 7 is normal; if a safety sensor 7 signal or the corresponding safety partition signal has not changed, the PLC module 1 determines that the inspection of the safety sensor 7 is abnormal;

[0064] After each safety sensor 7 is simulated and triggered, the PLC module 1 automatically resets the analog signal of the safety sensor to determine whether the output and input are synchronized. If any signal is incorrect, it is determined that the inspection point is abnormal. If any inspection point is abnormal, an alarm is given immediately after the total inspection is completed and the entire machine is safely shut down.

[0065] When an alarm occurs, the corresponding audible and visual alarm gives a red alarm message and sounds an alarm (i.e., the PLC module 1 controls the buzzer and the alarm light to work), and at the same time, there is a corresponding alarm message on the touch screen module.

[0066] After all inspections are completed, after pressing the reset button on the touch screen module, if the alarm message has not been processed, the buzzer can stop sounding first, that is, the buzzer stops sounding the alarm, but the alarm light remains lit. Only after all faults are processed can all resets be completed (including the reset of the light alarm and the information on the touch screen module). The reset of the light alarm means that the alarm light goes out, and the reset of the information on the touch screen module means that there is no corresponding alarm message on the touch screen module.

[0067] During normal production, the input signals of all safety sensors 7 change from a "1" signal to a "0" signal and from a "0" signal to a "1" signal within a cumulative period of normal production (depending on the different frequencies of being normally triggered during the production process, the cumulative time can be 8 hours to 1 week), excluding the changes during inspection. Otherwise, it is considered that the inspection point is abnormal and an alarm is given. The inspection operation is completed once a week, otherwise the entire machine will be safely shut down until the inspection work is completed.

[0068] At the same time, the following data is also recorded in this system: the time of the last data record reset, the number of inspections, the number of abnormal inspections, the number of normal entries into the equipment interior for each channel, and the number of abnormal entries into the equipment interior.

[0069] During inspection, the safety sensor can be triggered by the relay module in this system, and the reset of the safety sensor is controlled by the PLC module. During this process, the control system of the production line judges the change of the safety sensor signal and feeds it back to the PLC module. The PLC module judges whether the inspection of the safety sensor is abnormal according to the change of the signal and displays it on the touch screen module. Through this inspection system, manual inspection can be replaced, the efficiency of the safety sensor inspection can be improved, and the problem of missed inspection can also be overcome.

[0070] Although the specific embodiments of the present invention have been described above, those skilled in the art should understand that the specific embodiments we described are illustrative rather than used to limit the scope of the present invention. Equivalent modifications and variations made by those skilled in the art in accordance with the spirit of the present invention should be covered by the scope protected by the claims of the present invention.

Claims

1. An intelligent production line inspection system, characterized in that: It includes a PLC module, a relay module for simulating the triggering of safety sensors, a touch screen module for human-machine interaction, a communication module, a switch, and a power supply module. The switch is respectively connected to the PLC module and the touch screen module. The PLC module is connected to the relay module. The relay module is connected to the safety sensors on the production line. The communication module is connected to the PLC module. At the same time, the communication module is communicatively connected to the production line control system; The PLC module is also directly connected to the safety sensors on the production line to reset the triggered safety sensors; During inspection, the PLC module controls the relay module to send out analog signals to simulate the triggering of safety sensors and controls the reset of the analog signals through the PLC module. During this process, the production line control system judges the change of the analog safety sensor signals and feeds them back to the PLC module; The PLC module judges whether there is any abnormality in the entire safety control loop according to the change of the signals.

2. The intelligent spot-check system for a production line according to claim 1, wherein: The safety sensors on the production line include safety light curtains respectively arranged at the partition board, the top board, the pallet loading place, the stacking exit, and the packing machine. The safety sensors on the production line also include a first safety door, a second safety door, and a third safety door; The PLC module includes a second PLC and a third PLC; The relay module includes a first relay module group, a second relay module group, and a third relay module group. The second PLC is connected to the first relay module group and the second relay module group. The first relay module group is connected to the first safety door, the second safety door, the third safety door, and the safety light curtain arranged at the partition board. The second relay module group is connected to the safety light curtains arranged at the partition board, the top board, and the pallet loading place; The third PLC is connected to the third relay module group. The third relay module group is connected to the safety light curtains arranged at the pallet loading place, the stacking exit, and the packing machine.

3. The intelligent spot-check system for a production line according to claim 2, characterized in that: The third PLC is also connected to the first safety door, the second safety door, the third safety door, and the safety light curtains arranged at the stacking exit and the packing machine to reset the first safety door, the second safety door, the third safety door, and the safety light curtains arranged at the stacking exit and the packing machine; The PLC module also includes a first PLC. The first PLC is connected to the safety light curtains respectively arranged at the partition board, the top board, and the pallet loading place to reset the safety light curtains arranged at the partition board, the top board, and the pallet loading place.

4. The intelligent on-site inspection system for a production line according to claim 1, characterized in that: The PLC module is also connected to an alarm lamp and a buzzer.

5. An intelligent production line inspection system according to claim 1, characterized in that: It also includes a control cabinet. The PLC module, the relay module, the communication module, the switch, and the power supply module are arranged in the control cabinet.

6. The intelligent spot inspection system for a production line according to claim 1, wherein: The model of the power supply module is DC 24V / 10A EDR-120-24.

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