PLC-based PCB code reading, leakage detection and alarm system

Abstract

The utility model relates to a kind of PCB board code reading leak detection and alarm system based on PLC, including rack, connection platform, code reader, PLC controller, position sensor and alarm device.The utility model effectively solves the production interruption and quality problem caused by PCB board code reading leak in prior art, realizes real-time detection, interception and alarm of full automation, significantly improves the intelligent level of production line and production efficiency.

Description

Technical Field

[0001] This utility model relates to the field of industrial automation production technology, specifically to a PLC-based PCB board code reading and leakage prevention detection and alarm system. Background Technology

[0002] In the electronics manufacturing industry, PCBs typically require unique identification barcodes (such as 1D or 2D barcodes) during production and assembly for tracking and management throughout the process. Transfer stations are commonly used conveyor devices connecting different processes. As PCBs are transported on these stations, they are read by barcode readers. However, existing barcode reading processes have significant drawbacks: reading failures frequently occur due to barcode contamination, damage, positional errors, excessively high transfer speeds on the transfer station, or unstable reader performance. Traditional transfer stations lack effective feedback mechanisms; even if reading fails, the PCB is still conveyed to the next process. This leads to serious problems in downstream processes, such as production interruptions, product mixing, or data inconsistencies, requiring manual intervention and significantly impacting production efficiency and product quality traceability. Therefore, there is an urgent need for an intelligent system capable of real-time monitoring of barcode reading status, automatic interception of unread PCBs, and immediate alarm activation. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the existing technology and provide a PLC-based PCB board code reading leak prevention detection and alarm system to automatically intercept and alarm PCB boards that fail to read codes, thus preventing them from flowing into the next process.

[0004] To achieve the above objectives, the present invention adopts the following technical solution: A PLC-based PCB board code reading leak prevention detection and alarm system includes a frame, a docking station, a code reader, a PLC controller, a position sensor, and an alarm device. The docking station is located on the rack and is used to transfer PCB boards; The barcode reader is installed above the barcode reading station on the docking station and is used to read barcode information on the PCB board; The position sensor is installed on the downstream side of the barcode reader to detect whether the PCB board has reached the predetermined position. The PLC controller and alarm device are also mounted on the frame. The PLC controller is electrically connected to the code reader, position sensor, alarm device, and drive motor of the docking station. When the position sensor detects the arrival of the PCB board and the PLC controller does not receive a successful code reading signal from the code reader, the PLC controller immediately controls the docking station to stop running. Then, if the docking station stops running for a longer period than the alarm delay time preset by the PLC controller, the alarm device will be activated.

[0005] Furthermore, the alarm time is an adjustable delay time, ranging from 1 to 10 seconds.

[0006] Furthermore, the alarm device is an audible and visual alarm, which includes a three-color alarm light and a buzzer.

[0007] Furthermore, the position sensor is a photoelectric sensor.

[0008] This utility model also includes a touch screen that is electrically connected to the PLC controller. The touch screen is used for setting system parameters and monitoring status.

[0009] By adopting the above technical solution, the beneficial effects of this utility model are as follows: This invention employs a PLC controller for control, using a successful code reading signal from the code reader as the permission condition for the transfer station to continue transmission. When the PCB board passes the code reading station, if the code reading fails and the PLC controller does not receive a successful code reading signal, it will immediately stop the transfer station transmission, causing the PCB board to stop at the preset position sensor position. If the PCB board remains stationary for longer than the PLC controller's preset alarm delay time (e.g., 3 seconds), the PLC controller will determine it as a code reading failure and trigger the alarm device. This invention effectively solves the production interruption and quality problems caused by missed code readings from PCB boards flowing into the next process in existing technologies, achieving fully automated real-time detection, interception, and alarm, significantly improving the intelligence level and production efficiency of the production line. Attached Figure Description

[0010] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments: Figure 1 This is a schematic diagram of the overall structure of the PLC-based PCB board code reading leakage prevention detection and alarm system of this utility model; Figure 2 This is a schematic diagram of the circuit control of this utility model. Detailed Implementation

[0011] like Figure 1-2 As shown, this utility model discloses a PLC-based PCB board code reading leak detection and alarm system, which includes a frame 6, a docking station 1, a code reader 2, a PLC controller 3, a position sensor 4, and an alarm device 5. The connecting station 1 is located on the rack 6 and is used to transfer PCB boards; The barcode reader uses a high-performance industrial barcode scanner. The barcode reader 2 is installed above the barcode reading station on the docking station 1 and is used to read the barcode information on the PCB board. The position sensor 4 is installed on the downstream side of the barcode reader 2 (about 20cm away) to detect whether the PCB board has reached the predetermined position; The PLC controller 3 and the alarm device 5 are also installed on the rack 6 respectively; The PLC controller 3 is electrically connected to the code reader 2, the position sensor 4, the alarm device 5, and the drive motor of the docking station 1. When the position sensor 4 detects the arrival of the PCB board and the PLC controller 3 does not receive a successful code reading signal from the code reader 2, the PLC controller 3 immediately controls the docking station 1 to stop running. Then, if the docking station 1 stops running for a longer period than the alarm delay time preset by the PLC controller 3 (the alarm time is an adjustable delay time, ranging from 1 to 10 seconds), the PLC controller 3 will activate the alarm device 5.

[0012] Among them, the PLC controller 3 adopts Siemens S7-1200 series as the core controller; the alarm device 5 is an audible and visual alarm, which includes a three-color alarm light (red, yellow, and green) and a buzzer; the position sensor 4 is preferably a photoelectric sensor.

[0013] This utility model can also be configured with a touch screen (human-machine interface) electrically connected to the PLC controller 3. The touch screen is used for setting system parameters and monitoring status.

[0014] The specific control process of this utility model is as follows: The PCB board enters the receiving station 1 and is conveyed to the code reading station, where the code reader 2 begins reading the code. If the code reader 2 successfully reads the code, a success signal is sent to the PLC controller 3. The PLC controller 3 records the board information and allows the receiving station 1 to continue conveying the PCB board to the next process.

[0015] If the code reader 2 fails to read the code, the PCB board continues to move to the position sensor 4. The signal from the position sensor 4 is input to a digital input point of the PLC controller 3. The PLC controller 3 continuously scans the status of this input point and makes a judgment based on the code reading signal. Once it detects that the "position sensor is ON" and the "corresponding code reading success signal is OFF", the PLC controller 3 immediately cuts off the power supply to the drive motor of the docking station 1 through a digital output point (or sends a stop pulse), causing the docking station 1 to stop abruptly.

[0016] Simultaneously, a timer inside PLC controller 3 is activated, with the alarm delay time set to 3 seconds (this value can be modified via the touchscreen display). This means the system allows for a very short buffer time, but if the drive motor stop signal still exists after 3 seconds, it is confirmed as a stable fault state requiring manual intervention. PLC controller 3 then triggers another output point, illuminating the red alarm light on alarm 5 and sounding the buzzer.

[0017] Upon hearing the alarm, operators can go to the site to inspect and handle the stalled PCB board (such as wiping the barcode and scanning the barcode again).

[0018] The specific embodiments of this utility model have been described above. However, those skilled in the art should understand that this is only an example. Those skilled in the art can make various changes or modifications to this embodiment without departing from the principle and essence of this utility model, but all such changes and modifications fall within the protection scope of this utility model.

Claims

1. A PLC-based PCB board code reading leak detection and alarm system, characterized in that: It includes a rack (6), a docking station (1), a barcode reader (2), a PLC controller (3), a position sensor (4), and an alarm device (5); The connecting platform (1) is located on the frame (6) and is used to transfer PCB boards; The barcode reader (2) is installed above the barcode reading station of the connecting platform (1) and is used to read the barcode information on the PCB board; The position sensor (4) is installed on the downstream side of the barcode reader (2) to detect whether the PCB board has reached the predetermined position; The PLC controller (3) and alarm device (5) are also installed on the rack respectively; The PLC controller (3) is electrically connected to the code reader (2), position sensor (4), alarm device (5) and drive motor of the docking station (1); When the position sensor (4) detects the arrival of the PCB board and the PLC controller (3) does not receive a successful code reading signal from the code reader (2), the PLC controller (3) immediately controls the docking station (1) to stop running. Then, if the docking station (1) stops running for longer than the alarm delay time preset by the PLC controller (3), the alarm device (5) is activated.

2. The PLC-based PCB board code reading leak prevention detection and alarm system according to claim 1, characterized in that: The alarm delay time is an adjustable delay time, ranging from 1 to 10 seconds.

3. The PLC-based PCB board code reading leak prevention detection and alarm system according to claim 1, characterized in that: The alarm device (5) is an audible and visual alarm, which includes a three-color alarm light and a buzzer.

4. The PLC-based PCB board code reading leak prevention detection and alarm system according to claim 1, characterized in that: The position sensor (4) is a photoelectric sensor.

5. The PLC-based PCB board code reading leak prevention detection and alarm system according to claim 1, characterized in that: It also includes a touch screen that is electrically connected to the PLC controller (3), and the touch screen is used for setting system parameters and monitoring status.

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