Control method, apparatus, electronic equipment, and storage medium for automatic transfer of yarn packages.

Abstract

This disclosure provides a control method, apparatus, electronic device, and storage medium for the automatic transfer of a wound yarn package. [Solution] As a proposed technology, a system for automatic transfer control of a wound yarn package includes an MES, a first PLC, and a plurality of second PLCs. The method for controlling the automatic transfer of a wound yarn package includes, when the control button of the first PLC is switched from offline mode to online mode and communication between the first PLC and the MES is restored, detecting that offline data is stored in the offline buffer area, synchronizing the offline data with the MES. The offline data is a transfer record that was stored when the first PLC and the MES were disconnected and should be synchronized with the MES. According to the proposed technology of this disclosure, automated synchronization management of the offline transfer record of the wound yarn package can be realized, and the transfer efficiency of the wound yarn package can be improved.

Description

Technical Field

[0001] The present disclosure relates to the technical field of intelligent chemical fibers, and particularly to a control method, apparatus, electronic device, and storage medium for automatic transfer of winding packages.

Background Art

[0002] In the field of chemical fiber production, an efficiently operating production line is the key to ensuring production capacity and efficiency. This production line has a large number of closely arranged cooperating work stations. Particularly important is that a huge number of winding packages flow smoothly through the production line, and the transfer speed of these winding packages is directly related to the overall production rhythm and efficiency, and has become one of the inescapable bottlenecks in improving production capacity. Therefore, how to achieve rapid transfer of winding packages in the production line is an important issue that needs to be urgently solved in the current innovation of chemical fiber production technology.

Summary of the Invention

Problems to be Solved by the Invention

[0003] The present disclosure provides a control method, apparatus, electronic device, and storage medium for automatic transfer of winding packages.

Means for Solving the Problems

[0005] According to a second aspect of this disclosure, a control device for automatic transfer of a yarn package is provided, which is applied to a control system for automatic transfer of a yarn package. The automated transfer control system for spooled yarn packages includes a Manufacturing Execution System (MES), a first Programmable Logic Controller (PLC), and a plurality of second PLCs, each controlling at least one work station, wherein the plurality of second PLCs are connected to the first PLC, and the first PLC is connectable to the MES. The control device for the automatic transfer of the yarn package is: A monitoring module for monitoring whether the control button of the first PLC has been switched from offline mode to online mode and whether communication between the first PLC and the MES has been restored, When the control button of the first PLC is switched from offline mode to online mode and communication between the first PLC and the MES is restored, and it is detected that offline data is stored in the offline buffer area, the system includes a first control module for synchronizing the offline data with the MES. Offline data is stored when the connection between the first PLC and the MES is disconnected, and it is a transport record that should be synchronized with the MES.

[0006] According to a third aspect of this disclosure, an electronic device is provided, and the electronic device is At least one processor, Includes memory that is communicably connected to at least one processor, The memory stores instructions that can be executed by the at least one processor, and these instructions are executed by the at least one processor so that the at least one processor can perform any of the embodiments of the present disclosure.

[0007] A fourth aspect of the present disclosure provides a non-temporary, computer-readable storage medium in which computer commands are stored, the computer commands being used to cause the computer to perform any of the methods of the embodiments of the present disclosure. [Effects of the Invention]

[0008] The technology disclosed herein enables automated synchronized management of offline transfer records of yarn packages and improves the transfer efficiency of yarn packages.

[0009] The information provided in the Summary of the Invention should be understood as not limiting the key points or important features of the embodiments of this disclosure, nor limiting the scope of this disclosure. Other features of this disclosure will be readily apparent from the following description.

[0010] The above and other features, advantages and aspects of each embodiment of this disclosure will become more apparent by referring to the following detailed description together with the accompanying drawings. In the drawings, the same or similar reference numerals indicate the same or similar elements. [Brief explanation of the drawing]

[0011] [Figure 1] Figure 1 is a schematic diagram of a control system for the automatic transfer of a wound yarn package according to an embodiment of the present disclosure. [Figure 2] Figure 2 is a flowchart 1 of a control method for the automatic transfer of a wound yarn package according to an embodiment of the present disclosure. [Figure 3] Figure 3 is a flowchart 2 of the control method for the automatic transfer of a wound yarn package according to an embodiment of the present disclosure. [Figure 4] Figure 4 is a flowchart showing the process by which the first PLC according to the embodiment of this disclosure uploads offline transport records to the MES. [Figure 5] Figure 5 is a schematic diagram of the configuration of a control device for automatic transfer of a wound yarn package according to an embodiment of the present disclosure. [Figure 6] Figure 6 is a block diagram of electronic equipment for realizing the control method for the automatic transfer of a wound yarn package according to an embodiment of the present disclosure. [Modes for carrying out the invention]

[0012] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the drawings, and various details of the embodiments of the present disclosure will be provided for the sake of ease of understanding, but it should be understood that these are illustrative only. Accordingly, it will be seen that various changes and modifications can be made to the embodiments described herein without departing from the scope and spirit of the present disclosure. Similarly, for clarity and conciseness, descriptions of known functions and structures have been omitted in the following description.

[0013] Note that terms such as "first", "second", "third", etc. in the specification, claims, and drawings of this application are for distinguishing similar objects and not for explaining a specific order or sequence. Also, terms such as "comprising" and "having" and any variations thereof are intended to cover non-exclusive inclusion, for example, covering the inclusion of a series of steps or units. A method, system, product, or device is not necessarily limited to including the explicitly listed steps or units, and may also include those not explicitly listed or other steps or units specific to these processes, methods, products, or devices.

[0014] Before explaining the technical solutions according to the embodiments of the present disclosure, further explanations will be given on the technical terms that can be used in the present disclosure.

[0015] MES: A software system for monitoring and managing the manufacturing process, which can collect, process, and analyze production data in real time and optimize production planning and resource allocation. PLC: An industrial digital computer used to control automation equipment such as mechanical devices and robots on the production line. It can perform logical operations and processing on input signals according to a pre-set program and output control signals to control the operation of the equipment. Business data: Data related to operations generated in the manufacturing process, such as equipment status, product quantity, production progress, etc. These data form the basis for decision-making and control by MES and PLC. Transfer instruction information (also called transfer command): It is generated after MES analyzes based on business data, and is command and parameter information for instructing equipment to execute transfer tasks.

[0016] FIG. 1 shows a schematic diagram of a control system for automatic transfer of winding packages. As shown in FIG. 1, the control system for automatic transfer of winding packages includes MES, a first PLC, and a plurality of second PLCs. The plurality of second PLCs are respectively connected to the first PLC, and the first PLC is connected to MES. Each second PLC is responsible for controlling at least one work station. Here, the second PLC mainly collects and processes real-time business data of the target work station and provides it to the first PLC. The first PLC interacts with the second PLC and is responsible for obtaining second business data from the second PLC. The first PLC interacts with MES, transmits first business data to MES, receives transfer instruction information distributed by MES based on the first business data, and notifies the second PLC to execute the transfer instruction information for the target work station.

[0017] In some embodiments, MES is configured to determine transfer instruction information for the target work station based on the first business data transmitted from the first PLC and return the transfer instruction information to the first PLC.

[0018] In some embodiments, the first PLC is configured to obtain first business data for the target work station based on the second business data for the target work station obtained from the second PLC.

[0019] In some embodiments, each second PLC is configured to obtain and store the second business data of the target work station managed by the second PLC.

[0020] Here, the first business data is collected and processed by the first PLC and is a data set related to information such as the real-time state of the target work station, the processing progress of the winding package, the detection result of the quality of the winding package, and the required type. These data are of great significance in monitoring the operating state of the production line and permitting transfer decision-making.

[0021] Here, the second operational data is collected and processed by the second PLC and is a data set containing information such as the real-time status of the target work station, the processing progress of the yarn package, the quality detection results of the yarn package, and the barcode of the yarn package. This data is of great importance in monitoring the operating status of the production line.

[0022] The automated transfer control system for yarn packages according to the embodiment of this disclosure enables the MES to monitor the status of each work station in real time and adjust and optimize as needed through real-time communication and data processing between the MES, the first PLC, and the second PLC. This automated control reduces manual intervention, improves the efficiency and accuracy of yarn package transfer, reduces material waste and downtime due to human error, and lowers production costs. This automated control ensures the stability and consistency of yarn packages during the transfer process, contributing to an improvement in overall production rhythm and efficiency. By making the first PLC an intermediate layer between the MES and multiple second PLCs, the automated transfer control system for yarn packages has significant advantages in terms of centralized management, data integration, reduced MES load, improved system scalability, improved safety and stability, and simplified network structure.

[0023] If the MES communicates directly with multiple second PLCs, it will need to process a large amount of real-time data and requests, potentially increasing the load on the MES and impacting its performance. On the other hand, by using a first PLC as an intermediate layer, the MES only needs to communicate with the first PLC, reducing its processing burden. Without a first PLC as an intermediate layer, the MES would need to establish direct communication connections with each second PLC, resulting in a complex and difficult-to-manage network configuration. By using a first PLC as a relay, the network configuration can be significantly simplified, making the entire communication process clearer and more orderly. The first PLC acts as a safety barrier, verifying and filtering data from the second PLCs to prevent malicious or erroneous data from entering the MES system. Furthermore, the redundancy and fault tolerance mechanisms of the first PLC improve system stability and reliability, ensuring that the production line continues to operate normally even if some equipment fails.

[0024] As production lines expand and are upgraded, it may be necessary to add more second PLCs. If the MES communicates directly with each second PLC, the MES will need to be reconfigured and modified with each expansion. On the other hand, by using the first PLC as an intermediate layer, support for new second PLCs only needs to be added to the first PLC, eliminating the need to change the MES configuration. The first PLC can centrally receive operational data from multiple second PLCs and perform unified processing and analysis. This approach allows for more centralized and orderly control of the entire production line, reducing the complexity and confusion that arises when the MES communicates directly with multiple second PLCs. The first PLC can integrate data from different second PLCs to form a more comprehensive production view, allowing the MES to make decisions based on more comprehensive data and further optimize production planning and resource allocation. The first PLC can also pre-process and filter the data, reducing the amount of data transmitted to the MES and improving communication efficiency.

[0025] Embodiments of the present disclosure provide a method for controlling the automatic transfer of a yarn package, Figure 2 being a flowchart of the method for controlling the automatic transfer of a yarn package according to an embodiment of the present disclosure, the method for controlling the automatic transfer of a yarn package can be applied to a control device for the automatic transfer of a yarn package, the control device for the automatic transfer of a yarn package is installed in electronic equipment applied to the control system for the automatic transfer of a yarn package, the electronic equipment includes, but is not limited to, fixed equipment and / or mobile equipment. For example, fixed equipment includes, but is not limited to, a server, and the server may be a cloud server or a general-purpose server. For example, mobile equipment includes, but is not limited to, a mobile phone, a tablet computer, a laptop computer, etc. In some possible embodiments, the method for controlling the automatic transfer of a yarn package may be implemented by a processor calling computer-readable commands stored in memory. As shown in Figure 2, the method for controlling the automatic transfer of a yarn package includes the following steps.

[0026] S201: Monitors whether the control button of the first PLC has been switched from offline mode to online mode, and whether communication between the first PLC and the MES has been restored. S202: When the control button of the first PLC is switched from offline mode to online mode and communication between the first PLC and the MES is restored, if it is detected that offline data is stored in the offline buffer area, the offline data is synchronized with the MES, where the offline data is the transport record that is stored when the connection between the first PLC and the MES is disconnected and should be synchronized with the MES.

[0027] In some embodiments, monitoring the state of a control button on a first PLC involves reading the state signal of the control button via an input module of the first PLC and determining whether it has changed from offline mode (typically represented by one specific input value, e.g., 0) to online mode (represented by another specific input value, e.g., 1).

[0028] In some embodiments, monitoring the communication status between the first PLC and the MES includes periodically detecting whether the communication link between the first PLC and the MES is functioning correctly, using heartbeat detection or specific commands in the communication protocol. Heartbeat detection typically involves the first PLC periodically sending short signals to the MES, and the MES responding with an acknowledgment after receiving them, thereby confirming that both communications are functioning correctly.

[0029] In some embodiments, a storage medium connected to the inside or outside of the first PLC is provided with multiple offline buffer areas for storing offline data, such as transfer records, that occurred during a communication interruption period. The first PLC determines whether or not there is offline data to be synchronized by reading the state or contents of the area.

[0030] In some embodiments, synchronizing offline data with the MES involves the first PLC activating a data synchronization program once it has transitioned to online mode and confirmed that communication has been restored. This program reads all offline data in the offline buffer area and transmits this data to the MES system according to the MES data interface standard (e.g., an Application Programming Interface (API), a database interface, etc.). The synchronization process may require handling tasks such as data format conversion, data encryption, and error checking.

[0031] Assume that the packaging of the spooled yarn is automated and controlled by a first PLC and a second PLC, and that the first PLC and the MES system exchange production data in real time. One day, a network failure interrupts communication between the first PLC and the MES, and important data such as transfer records generated during that period are stored in the offline buffer area of ​​the first PLC. After the network failure is resolved, the first PLC detects that the control button has been switched from offline mode to online mode and that communication with the MES has been restored. In this case, the first PLC automatically starts a data synchronization program to synchronize the data such as transfer records in the offline buffer area with the MES system, ensuring the integrity and real-time nature of the production data.

[0032] In the technical invention of the embodiment of this disclosure, when the control button of the first PLC is switched from offline mode to online mode and communication between the first PLC and the MES is restored, if offline data is detected to be stored in the offline buffer area, the offline data is synchronized with the MES, thereby ensuring that important data in the production process is synchronized with the MES system in a timely manner, contributing to management being able to grasp the production status in real time and respond quickly. The offline buffer mechanism ensures the integrity and traceability of important data even if the connection is interrupted, and avoids the impact on production due to data loss. The automatic synchronization mechanism enables timely detection and resolution of communication failures, improving the stability and reliability of the system.

[0033] In some embodiments, before synchronizing offline data with the MES, the method further includes the following steps, as shown in Figure 3.

[0034] S301: The first PLC obtains the second business data for the target work station from the second PLC corresponding to the target work station, and obtains the first business data for the target work station based on the second business data. S302: If the connection between the first PLC and the MES is disconnected, the first PLC records first operational data and transmits the transfer instruction information to the second PLC so that the second PLC controls the target work station based on the transfer instruction information to perform the transfer task of the spool package. Here, the transfer instruction information is a transfer permission. S303: The first PLC stores offline data in an offline buffer area, where this offline data is stored when the connection between the first PLC and the MES is disconnected, and is a transport record that should be synchronized with the MES.

[0035] Here, the first operational data is converted by the first PLC from the second operational data obtained from the second PLC corresponding to the target work station. This second operational data typically includes information such as the real-time production status, parameters, and results of the target work station. If the connection between the first PLC and the MES is disconnected, the first PLC records this first operational data converted from the second PLC. The first operational data is primarily used to support production control of the target work station, for example, to support the control of the winding package transfer task in this example. This data reflects the operating status of the target work station in real time or near real time.

[0036] Here, offline data, unlike primary operational data, is not directly converted from real-time data on the production floor, but rather refers to data that needs to be recorded for subsequent synchronization with the MES during periods when the connection between the primary PLC and the MES is lost. This data may include various production records, events, status changes, etc. When the connection between the primary PLC and the MES is lost, this data needs to be stored in an offline buffer area to maintain data continuity and integrity. The main use of offline data is to synchronize this data with the MES system after the network is restored or the connection with the MES is re-established, so that the data in the MES system is up-to-date and can reflect the actual situation on the production floor. This is extremely important for production management, data analysis, and reporting.

[0037] In some embodiments, each second PLC collects and processes relevant second operational data (e.g., location, status, and quantity of yarn packages) based on the state of the work station it controls, and stores this data in a data storage area, such as data blocks (DB blocks), that the second PLC assigns to the work station it is responsible for.

[0038] In some embodiments, the first PLC acquires second operational data for each work station from each second PLC and generates first operational data for each work station. This first operational data includes the status of all relevant work stations and information on operations that need to be performed. The MES analyzes the first operational data to determine the transfer instruction information for the target work station (i.e., the work station that needs to perform the transfer operation of the spool package at the moment). The transfer instruction information includes transfer permission and transfer prohibition. Here, if the transfer instruction information is a transfer permission, it may further include parameters such as the specific time of transfer, target position, and speed. The MES transmits the generated transfer instruction information to the first PLC via a network or other communication method such as a Management Interface (MI).

[0039] In some embodiments, the first PLC receives transfer instruction information from the MES, performs analysis processing, and extracts specific control commands and parameters. After completing the analysis, the first PLC transmits the analysis results (i.e., specific control commands and parameters) to a second PLC corresponding to the target work station via a communication interface or communication protocol. After receiving the analysis results, the second PLC controls the transfer equipment, such as machinery or robots at the target work station, based on the control commands and parameters in the analysis results to perform the transfer task of the spool package.

[0040] In some embodiments, the communication protocol and parameters between the first PLC and the second PLC are configured at system startup to ensure stable communication between them. The connection between the first PLC and the MES is configured to ensure that the first PLC can send first business data to the MES and receive transfer instruction information returned from the MES. The first PLC actively acquires second business data for the target work station (e.g., current operating status, number of spool packages awaiting processing, processing time, etc.) from the second PLC corresponding to the target work station. After acquiring the second business data, the first PLC converts this data into first business data (e.g., whether transfer conditions are met, estimated transfer time, etc.) according to a pre-configured algorithm or logic. If the connection between the first PLC and the MES is interrupted for any reason (e.g., network failure, MES maintenance, etc.), the first PLC automatically switches to offline operation mode. In this mode, the first PLC records the first operational data and transmits transfer instruction information (e.g., a signal such as "transfer permitted") to the second PLC. After receiving the transfer instruction information, the second PLC controls the target work station to perform the transfer task of the yarn package, including moving the yarn package to the next work station and updating status information. Once the connection between the first PLC and the MES is restored, the system can automatically synchronize the data and adjust subsequent operations based on the latest commands from the MES.

[0041] For example, suppose a production line has multiple work stations, each responsible for a different processing task. The first PLC periodically retrieves the second work data for the current work station from the second PLC. After processing a yarn package at a certain work station (e.g., a work station for measuring weight) is complete, it needs to proceed to the next step. If the MES system becomes temporarily unavailable, the first PLC sends a transfer instruction message, called "transfer permission," to the second PLC on behalf of the MES. The second PLC then sends a command to the transfer equipment (e.g., a conveyor or robotic arm) to transport the processed yarn package to the next work station (e.g., a work station for measuring winding diameter) for subsequent processing.

[0042] The main types of wound yarn packages relating to the technical proposals of the embodiments of this disclosure may include one or more types such as partially oriented yarns (POY), fully drawn yarns (FDY), and drawn textured yarns (DTY) (or referred to as low-elasticity yarns). For example, the yarn types may specifically include polyester partially oriented yarns, polyester fully drawn yarns, polyester drawn yarns, polyester low-elasticity yarns (Polyester Draw Textured Yarns), polyester staple fibers (PSF), etc.

[0043] In the technical inventions of the embodiments of this disclosure, real-time communication and data processing between the MES, a first PLC, and multiple second PLCs allows the MES to monitor the status of each work station in real time and adjust and optimize the transfer strategy as needed. Even if the connection between the first PLC and the MES is lost, the system can operate independently and complete the transfer task, thereby improving the stability and reliability of the system. Automatic offline forced transfer control reduces manual intervention, improves the transfer speed and accuracy of the spool package, and reduces production and time costs due to human error or delays.

[0044] In embodiments of the present disclosure, the second PLC controlling a target work station based on transfer instruction information to perform a transfer task of a spool package includes, if the transfer instruction information is a transfer permission, the second PLC notifying the transfer equipment to transport the processed spool package at the target work station to the next work station, or directly controlling the transfer equipment.

[0045] Here, transfer equipment refers to automated equipment such as conveyors, robotic arms, and automated guided vehicles used to transport materials (e.g., yarn packages) between different work stations on a production line. The above is merely an illustrative explanation and does not limit all possible equipment included in transfer equipment; it is not exhaustive.

[0046] In some embodiments, the transfer instruction information may include the evaluation result by the first PLC of whether the winding package at the target work station satisfies the transfer conditions, for guiding subsequent control operations.

[0047] In some embodiments, if the transfer instruction information is "transfer permission," the second PLC transmits a command or signal to the transfer equipment to inform it to prepare for transporting the processed spool packages at the target work station. After receiving the command from the second PLC, the transfer equipment transports the spool packages from the target work station to the next work station according to a pre-configured program or route. During the transport process, a series of actions may occur with respect to the spool packages, such as gripping, carrying, and placing, and all of these actions must be precisely controlled to ensure the safe and accurate transport of the spool packages.

[0048] In some embodiments, the second PLC continuously monitors the operating status of the transfer equipment and the transport status of the spool packages. Once transport is complete, the transfer equipment sends a feedback signal to the second PLC to confirm that the current spool package has successfully arrived at the next work station. The second PLC updates its internal state based on the feedback signal and prepares for subsequent control operations.

[0049] For example, suppose a production line has multiple work stations, each responsible for a different processing task. After processing of a yarn package at one work station (e.g., a work station for measuring weight) is complete, a second PLC receives the analysis results from that work station and determines "transfer permitted" if the forced transfer variable is 1, regardless of whether parameters such as weight, specifications, and lot number meet the requirements. The second PLC then sends a command to the transfer equipment (e.g., a conveyor or robotic arm) to transport the processed yarn package to the next work station (e.g., a work station for measuring winding diameter) for subsequent processing.

[0050] Thus, the first PLC and multiple second PLCs enable precise control of the yarn package transfer process, reducing waiting times and manual intervention, improving the overall efficiency of the production line, reducing errors due to human factors, and enhancing the stability and reliability of the production process. The PLC programming is flexible, allowing for quick adjustment of the control logic according to production needs and adapting to the processing of different types and specifications of yarn packages. By supporting forced transfer with the first PLC, the time yarn packages spend at the work station is significantly reduced, improving the overall smoothness of the production line and effectively reducing energy consumption and labor costs.

[0051] In embodiments of the present disclosure, the method for controlling the automatic transfer of the yarn package further includes the first PLC detecting that a control button corresponding to the first PLC has been rotated to offline mode, and determining that the connection between the first PLC and the MES has been disconnected.

[0052] In some embodiments, offline mode typically refers to a state in which the system operates independently without communicating with a higher-level management system (e.g., MES). In such mode, the system can perform control tasks according to its own logic and pre-configured parameters.

[0053] In some embodiments, a control button is a physical switch or knob for controlling the operating mode of the first PLC. The control button is used to switch the operating mode of the first PLC (e.g., online mode or offline mode). Offline mode is indicated by a specific position or mark on the control button, and when the button is rotated to that position, it indicates that offline mode has been selected to actively interrupt communication with the MES. Online mode is indicated by a specific position or mark on the control button, and when the button is rotated to that position, it indicates that online mode has been selected to maintain communication with the MES.

[0054] In some embodiments, the first PLC continuously monitors the state of a control button directly connected to it, which is typically mounted on an operation panel and allows an operator to manually switch the operating mode of the first PLC. When the first PLC detects that the control button has been rotated to the "offline mode" position, it immediately records this event and considers that the connection to the MES has already been disconnected or is about to be disconnected. Such a detection method is immediate and reliable because it relies primarily on hardware signals (e.g., the on / off state of the button). After determining that it is in offline mode, the first PLC retrieves second business data for the target work station from the second PLC according to a predetermined flow and converts it into first business data. Based on the processed first business data, the first PLC decides whether to send transfer instruction information to the second PLC to control the transfer task of the spool package. Generally, the first PLC sends transfer instruction information to the second PLC that reads "transfer permitted". The system is equipped with the capability to handle various abnormal situations and automatically synchronizes data and restores connectivity with the MES when conditions are restored.

[0055] Taking an automated packaging line in the chemical fiber industry as an example, a network failure may cause the MES to temporarily lose communication with the first PLC. In this case, the operator can go to the control panel where the first PLC is located and rotate the control button to "offline mode". After detecting this change, the first PLC automatically determines that the connection with the MES has already been lost and immediately activates the transfer control flow in offline mode. Subsequently, the first PLC sends a transfer instruction message to the second PLC, indicating "transfer permission," to ensure that the yarn package can be smoothly moved from the current work station to the next work station.

[0056] By introducing control buttons in this way, operators can directly intervene in the production flow in specific situations, improving the system's flexibility and ability to handle unexpected events. By allowing operators to manually switch the operating mode of the first PLC, the system can quickly adjust its operating state according to actual needs, improving the system's flexibility and adaptability. State detection for the control buttons provides intuitive indication of the connection status between the first PLC and the MES, contributing to the detection and resolution of connection problems, thus improving the system's reliability. If the MES is unavailable, operators can easily switch the first PLC to offline mode by rotating the control button, allowing the system to continue performing transport tasks, simplifying the operating process and reducing downtime.

[0057] In embodiments of the present disclosure, the method for controlling the automatic transfer of the winding package further includes the first PLC detecting that communication between the first PLC and the MES has been interrupted and determining that the connection between the first PLC and the MES has been disconnected.

[0058] In some embodiments, a communication interruption refers to a state in which, during the communication process, the communication link is unable to transmit data properly due to various causes (e.g., network failure, device failure, signal interference, etc.).

[0059] In some embodiments, the first PLC integrates a communication status monitoring module that continuously monitors the communication link with the MES. The monitoring includes, but is not limited to, key indicators such as the success rate of sending and receiving data packets, communication delay, and the number of timeouts. If an abnormality occurs in the communication link (e.g., failure to send multiple consecutive data packets, communication delay exceeding a predetermined threshold, or the number of timeouts reaching its upper limit), the PLC determines that communication has been interrupted. If communication has been interrupted, the first PLC immediately records this event and considers the connection with the MES to be disconnected. Subsequently, the first PLC switches to offline operation mode. In offline operation mode, the first PLC continues to acquire second business data for the target work station from the second PLC and converts it into first business data. Based on the processed first business data, the first PLC decides whether or not to send transfer instruction information to the second PLC to control the transfer task of the spool package. When the first PLC detects that the communication link with the MES has been successfully restored, it automatically switches to online operation mode. In online operation mode, the first PLC performs synchronization operations with the MES to ensure data consistency and accuracy.

[0060] Assume that in an automated production line, the first PLC is responsible for monitoring and managing the operating status of multiple yarn package processing work stations. One day, a network failure interrupts the communication link between the first PLC and the MES. The communication status monitoring module of the first PLC immediately detects this anomaly and determines that communication has been interrupted. Subsequently, the first PLC automatically switches to offline operation mode, continuing to acquire operational data from the second PLC and controlling the yarn package transfer task. After the network failure is resolved, the communication link is restored to normal, and the first PLC resumes synchronization operations with the MES to ensure data consistency and accuracy.

[0061] In this way, by automatically detecting communication interruptions and switching to offline operation mode, the system can continue performing control tasks when the MES becomes unavailable, eliminating the need for manual intervention and improving the degree of system automation. The automatic detection and handling mechanism for communication interruptions enables the system to handle various communication failures, improving system stability and reliability. After communication is restored, the system can automatically synchronize data and return to a normal operating state, reducing downtime due to communication problems.

[0062] In embodiments of the present disclosure, the method for controlling the automatic transfer of the winding package further includes the condition that, if the connection between the MES and the first PLC is disconnected, the MES does not perform the process for determining the online transfer conditions.

[0063] In some embodiments, when communication between the MES and the lower-level control system is interrupted, the MES performs a series of alternative processes that may not rely on real-time data in order to maintain the normal operation of the system.

[0064] In some embodiments, the online transfer condition determination process includes the MES evaluating and analyzing received operational data according to predetermined rules and algorithms to determine whether the target work station is permitted to perform the transfer operation. These conditions may include various factors such as production plans, equipment status, and material supply status.

[0065] In some embodiments, upon receiving first business data transmitted from a first PLC, the MES first performs data reception and initial verification. If the data format is accurate and includes valid mandatory transport variables, the MES fully records this data in its internal database or log system to facilitate traceability to subsequent data. The recorded content may include key fields of all or part of the first business data, and information such as a timestamp of the data's receipt. Under normal circumstances, the MES determines whether to permit transport at the target work station by performing an online transport condition determination process on the received business data based on predetermined rules and algorithms.

[0066] In some embodiments, a stable communication connection is established between the MES and the first PLC, and the status of this connection is continuously monitored. When the first PLC detects that communication with the MES has been interrupted, it notifies the MES using a predetermined communication protocol or heartbeat mechanism. Upon receiving the communication interruption notification from the first PLC, the MES immediately recognizes that the current connection with the first PLC is disconnected. The MES immediately stops executing any online transport condition determination processes that rely on real-time communication with the first PLC. The MES may initiate an offline processing strategy that may include recording the communication interruption event, sending an alarm to the system administrator, and (if applicable) performing some predictive processing based on predetermined rules or historical data. In any case, the MES does not perform any online transport condition determinations that require real-time data acquisition from the first PLC. When the first PLC detects that communication with the MES has been restored, it notifies the MES again. When the MES receives notification that communication has been restored, it re-establishes communication with the first PLC and resumes the process of determining the online transport conditions.

[0067] Taking an automated packaging line in the chemical fiber industry as an example, the MES (Manufacturing Execution System) is responsible for monitoring the entire production flow and determining whether the yarn package meets the transfer conditions based on real-time data. However, due to a network failure, communication between the MES and the first PLC (Programmable Logic Controller) may be suddenly interrupted. In such a case, the MES immediately stops executing the online transfer condition determination process and records this event in the system log. Moreover, the system administrator receives an alarm about the communication interruption and immediately begins investigating the fault. After the fault is resolved, communication is restored, the MES re-establishes its connection with the first PLC, and resumes the online transfer condition determination process.

[0068] In this way, during communication interruptions, the MES reduces the consumption of computing resources by not performing unnecessary online transport condition determinations. By avoiding processing that relies on real-time data during communication interruptions, it reduces potential system problems caused by data inconsistencies or errors. System administrators can receive timely alerts about communication interruptions and intervene as needed, improving system maintainability and user experience.

[0069] In embodiments of this disclosure, the online transfer condition determination process may include determining whether the spool package at the target work station satisfies the transfer conditions based on target string data corresponding to the target work station, determining that the transfer instruction information is transfer permitted if the transfer conditions are met, and determining that the transfer instruction information is transfer prohibited if the transfer conditions are not met. Here, the target string data is obtained by the MES analyzing the first business data.

[0070] In some embodiments, the transfer instruction information is information that indicates whether the yarn package in the production line can be subsequently transported to the next work station for processing. Depending on the determination of the transfer conditions, the transfer instruction information may be "transfer permitted" or "transfer prohibited."

[0071] In some embodiments, the MES first receives first operational data transmitted from a first PLC. This data typically includes status information of a target work station on the production line, processing progress of the yarn package, quality detection results, and the transfer request number. The MES includes a dedicated data analysis module for analyzing the received first operational data and extracting target string data corresponding to the target work station. This target string data may represent an encoded specific operational state or attribute.

[0072] In some embodiments, the MES further analyzes the target string data obtained through analysis by comparing it with pre-set transport conditions. These transport conditions may include whether the processing quality of the spool package has met the target, whether all processing tasks at the current work station have been completed, and whether there is any equipment failure or production abnormality. If the spool package at the target work station satisfies all pre-set transport conditions, the MES determines that the transport instruction information is "transport permitted," indicating that the spool package can be safely transported to the next work station for processing. If the spool package at the target work station does not meet any of the transport conditions, the MES determines that the transport instruction information is "transport prohibited," and may notify on-site staff to inspect and process the package by triggering a corresponding alarm mechanism.

[0073] In some embodiments, the MES transmits the determination result (transfer permitted or transfer prohibited) as transfer instruction information to a second PLC or other related control equipment via a communication interface. Based on the received transfer instruction information, these transfer equipment executes the corresponding control logic, for example, starting or stopping the transport operation of the spool package.

[0074] Taking an automated packaging line in the chemical fiber industry as an example, the first PLC detects that processing of a yarn package at a certain work station (e.g., a work station for measuring weight) is complete, and then transmits first operational data, including status information of the work station, to the MES. After receiving the data, the MES first obtains target string data (e.g., the QR code® of the yarn package for the transfer request, weight information) through analysis, and then compares it with pre-set transfer conditions (e.g., whether the weight of the yarn package of this standard is within the acceptable range; Grade A: within the acceptable range, Grade B: too light, Grade C: too heavy). If the quality level of the yarn package is Grade A, the MES determines that the transfer instruction information is "transfer permitted" and notifies the second PLC to start the transfer operation of the yarn package. If the quality level of the yarn package is Grade B or C, the MES determines that "transfer prohibited" and triggers an alarm mechanism.

[0075] Thus, by analyzing the first operational data and precisely determining the transport conditions using MES, it is possible to ensure that only spool packages that meet the requirements are transported, thereby improving the accuracy and reliability of production. Furthermore, by timely detection and prevention of the transport of spool packages that do not meet the transport conditions, abnormal situations in the production process, such as equipment failures and quality problems, can be reduced, thereby lowering production risks. By automatically determining and issuing instructions for transport information, manual intervention and waiting times can be reduced, improving the overall operating efficiency of the production line.

[0076] In the embodiments of this disclosure, the acquisition of second business data for a target work station by a first PLC from a second PLC corresponding to a target work station includes the first PLC periodically acquiring the second business data for a target work station from the second PLC.

[0077] In some embodiments, the first PLC is equipped with a timer for controlling the time interval for data acquisition. This time interval can be adjusted according to the actual needs of the production line to ensure that the latest data is acquired in a timely manner, while also preventing increased system load due to frequent data exchange. When the timer reaches the set time, the first PLC sends a data request signal to the second PLC. This signal includes information such as the type of data to be acquired and the identifier of the target workstation, so that the second PLC can accurately return the corresponding data.

[0078] In some embodiments, after receiving a data request from the first PLC, the second PLC retrieves the second operational data for the target work station from its own database or a real-time data buffer based on the information in the request and transmits it to the first PLC via a communication interface. This data may include the real-time status of the target work station, processing progress, quality detection results, etc.

[0079] In some embodiments, the first PLC acquires second business data, then analyzes and processes the second business data to extract information necessary for subsequent decision-making or control operations. This data may then be used to update related data or generate reports in the MES.

[0080] In this way, by periodically acquiring second operational data from the target work station from the second PLC, it is possible to monitor the status of the production line in real time, ensuring transparency and traceability of the production process. Based on real-time data, the MES or the first PLC can promptly detect abnormal conditions in the production process and take appropriate adjustment measures, such as stopping transfers or adjusting process parameters, to improve production efficiency and product quality. By analyzing historical and real-time data, it is possible to provide strong support for decision-making to optimize the production line, such as predicting production trends and optimizing production plans.

[0081] In embodiments of the present disclosure, the acquisition of first business data by a first PLC based on second business data of a target work station obtained from a second PLC corresponding to the target work station includes the first PLC converting the second business data into first business data in a data storage format according to a pre-configured data storage format, where the first business data is stored in a data storage area assigned by the first PLC to the target work station, and different types of variables in the first business data correspond to different fixed addresses in the data storage area.

[0082] Here, a data storage format is a specific format or specification used during the storage or transmission of data, and includes the data type, data units, data encoding, etc.

[0083] Here, the data storage area is a specific area within the first PLC for storing data.

[0084] Here, a fixed address is a unique and immutable memory location within the data storage area that is assigned to a different variable. Fixed addresses enable rapid access to and modification of variables.

[0085] In some embodiments, in an automated transfer control system for yarn packages, a first PLC is responsible for generating first operation data for a target work station based on second operation data for that work station. This data may include various types of information, such as status codes, numerical parameters, and timestamps. A predetermined data storage format is placed inside the first PLC to ensure that data can be efficiently exchanged and analyzed between different PLCs or between a PLC and an MES. The first PLC converts the second operation data according to this preset format. The conversion process may include conversion of data types (e.g., integer to floating-point), unification of data units (e.g., millimeter to inch), and decoding of encoded data (e.g., number system conversion). The converted data is first operation data and conforms to a predetermined data storage format, thus facilitating subsequent processing and transmission. The first PLC allocates a dedicated data storage area to each target work station in the production line. The first operation data is stored in the data storage area corresponding to the target work station. During storage, different variables (e.g., status codes, numerical parameters, etc.) are assigned to different fixed addresses in the storage area. When it is necessary to read or modify the value of a variable, it can be accessed directly using its corresponding address, thereby improving the efficiency of data processing.

[0086] In this way, pre-configured data storage formats and format conversion processes ensure consistency and accuracy in data exchange and processing flows from different sources. Assigning fixed storage addresses to each variable simplifies data access and processing, improving overall system performance. The allocation of data storage areas and the definition of the format offer a degree of flexibility, allowing for expansion and adjustment according to the actual needs of the production line.

[0087] In some embodiments, the method for controlling the automatic transfer of the spool package further includes a first PLC assigning multiple offline buffer areas and one offline control area to all target work stations, where the multiple offline buffer areas are shared by all target work stations, and the offline control area includes associated data digits and associated control digits for synchronizing offline data to the MES.

[0088] Here, the offline buffer area is a specific area partitioned in the first PLC or other storage device, and is used to store data awaiting synchronization in case communication between the first PLC and the MES is interrupted.

[0089] Here, the offline control area is a dedicated area set up in the second PLC and includes relevant data digits and control digits for controlling the synchronization process of offline data.

[0090] In some embodiments, the first PLC assigns multiple shared offline buffer areas to all target work stations. These areas are used to store offline data generated at each work station during interruptions in communication between the PLC and the MES, such as transfer records and production parameters.

[0091] In some embodiments, the first PLC is provided with a dedicated offline control area that includes relevant data digits and control digits for controlling the offline data synchronization process. These data digits and control digits are used to store important information such as the synchronization status, the address of the target MES, and the synchronization priority, so as to ensure that the offline data can be synchronized accurately and sequentially with the MES system.

[0092] In some embodiments, when communication between the first PLC and the MES is interrupted, the offline data generated by each target work station is automatically stored in a shared offline buffer area. Simultaneously, the relevant data digits and control digits in the offline control area are updated to reflect the current synchronization status and priority. When communication between the first PLC and the MES is restored, the first PLC checks the status information in the offline control area and determines, based on priority and synchronization strategy, which offline data needs to be synchronized with the MES system. The first PLC then transmits the offline data from the buffer area to the MES system according to a pre-configured format and protocol.

[0093] In some embodiments, the MES system performs verification and confirmation after receiving offline data. If the data reception and processing are successful, the MES system sends a synchronization confirmation signal to the first PLC. After receiving the confirmation signal, the first PLC updates the status information in the offline control area, clears the synchronized offline data, and frees up buffer space for subsequent use.

[0094] By assigning a shared offline buffer area to all target work stations in this way, it is possible to ensure that important data generated during periods of communication interruption is properly stored, thus avoiding the impact on production due to data loss. The installation of an offline control area allows the PLC to flexibly control the offline data synchronization process, including synchronization priority and the address of the target MES, thus meeting the needs of different production scenarios. Once communication is restored, the PLC can quickly synchronize the offline data with the MES system, ensuring that management can grasp the production status in real time and respond quickly, thereby improving production efficiency. Synchronization confirmation and leaning mechanisms ensure that synchronized offline data is deleted from the buffer area in a timely manner, avoiding excessive occupation of memory space resources.

[0095] In some examples, the main steps for synchronizing offline data to the MES are as follows:

[0096] System startup and status check: After the system starts up, the system continuously checks whether the first PLC is in online mode and whether the offline transfer record synchronization function is enabled.

[0097] Offline data check: If the conditions are met, check whether there are any queues (data) waiting to be processed in the offline buffer area.

[0098] Preparing the state of the control area: Ensure that the relevant data digits and control digits in the offline control area are in their initial state. If they are not in their initial state, perform a reset operation.

[0099] Data transmission and transfer control: The control digits are set to transmit the first queue data from the offline buffer area to the offline control area and instruct the second PLC to start the transfer process.

[0100] Request and response processing: The first PLC is triggered by a control digit to send a request (AVI_REQUEST) to the MES and waits for a response from the MES.

[0101] Response Verification and Data Processing: The format of the data returned by the MES is verified. If the format is correct, the data is parsed into the business data area (IT_RES_1) in the offline control area, and it is checked whether the response result is valid and free of errors.

[0102] Error handling and status update: Based on the response result, error handling or control digit updates are performed to indicate that data processing is complete.

[0103] Queue and data area reset: To ensure effective synchronization and processing of offline data, queue shifts are performed on the offline buffer area, and the associated control digits and business data areas in the offline control area are reset to prepare for the next round of synchronization. In some embodiments, offline data may be synchronized to the MES according to the following steps.

[0104] a. System startup; b. Determine whether the first PLC is in online mode and whether to enable synchronization of offline transport records. If the result of the determination is YES, perform step c; otherwise, continue performing step b; c. Determine whether the number of queues in the offline buffer area is 1 or greater. If the result is YES, execute step d; otherwise, continue executing step c. d. Determine whether the associated data digits and associated control digits in the offline control area are both in their initial state. If the result is YES, execute step e. If NO, clear and reset the associated data digits and reset the associated control digits. e. The relevant data of the winding package corresponding to the first queue in the offline buffer area is transmitted to a first position in the offline control area, which is for buffering the operational data read from the offline buffer area;

[0105] f. In the offline control area, set a control digit to indicate that the second PLC has started transporting; g. In the offline control area, check whether the value of the control digit indicating that the second PLC has started transporting is 1. If it is 1, perform step h; otherwise, continue performing step g; h. In the offline control area, set a control digit to indicate that the first PLC has written AVI_REQUEST, where AVI_REQUEST is a request message sent by the first PLC to the MES; i. In the offline control area, check whether the control digit indicating that the first PLC has received data returned from the MES is empty; if it is not empty, perform step j; otherwise, continue performing step i; j. In the offline control area, check whether the format for showing the data returned by the MES is correct. If the format is incorrect, execute step k; if the format is correct, execute step l.

[0106] Write an error code indicating that the format of k.AVI_RESPONSE1 is incorrect, and then execute step q; l. In the offline control area, set a control digit to indicate that the first PLC has received data returned from the MES; The data returned from m.MES is parsed into IT_RES_1, which represents the business data output by the first PLC; n. Check whether the RESPONSE_RESULT of IT_RES_1 is 1 and the RESPONSE_ERROR is 0. If the RESPONSE_RESULT of IT_RES_1 is 1 and the RESPONSE_ERROR is 0, execute step p; otherwise, execute step o. A RESPONSE_RESULT of 1 indicates that there is a response, and a RESPONSE_ERROR of 0 indicates that there are no errors in the response; o. Write an error code indicating that the processing result was not as expected, and then execute step q; p. In the offline control area, set a control digit to indicate that the first PLC has completed data processing; q. Perform a shift operation on the queue in the offline buffer area and reset the associated control digits and associated business data areas corresponding to the offline control area.

[0107] Furthermore, it can be understood that the above steps can be set or adjusted according to actual needs, for example, by adding or removing steps, or by changing the content of some of the steps.

[0108] In this way, by controlling detailed steps including checks on the number of queues in the offline buffer area, the state of the offline control area, and the format of the data returned by the MES, it is possible to avoid data errors or omissions by ensuring that only offline data that matches the requirements is synchronized to the MES system. The system can automatically start the synchronization process after communication between the first PLC and the MES is restored, and a cyclic check and wait mechanism can ensure that each step is performed correctly. Furthermore, the system can improve its fault tolerance and stability by presenting a clear error code for possible error situations (e.g., incorrect data format, unexpected processing results, etc.) and taking corresponding reset measures. The system can clear synchronized offline data in a timely manner through queue shifting and reset mechanisms, freeing up buffer space for subsequent use. This improves the system's response speed and performance while avoiding buffer overflow problems. This synchronization process employs a modular and deployable design philosophy, allowing for flexible adjustment of parameters such as synchronization strategy and priority by modifying relevant data and control digits in the offline control area, thus adapting to the needs of different production scenarios. Furthermore, this synchronization method can be easily integrated and expanded with other systems or modules. By synchronizing offline data with the MES system in real time, management can grasp the operating status of the production line and critical data in real time, enabling more accurate and timely decision-making. This not only improves production efficiency but also enhances data transparency and traceability, providing strong support for the company's continuous improvement and optimization.

[0109] In the following, using IT-PLC as an example to represent the first PLC and ME-PLC as the second PLC, we will explain the processing flow of the first PLC, which is the intermediate layer between the MES and the second PLC.

[0110] Figure 4 is a flowchart of the process by which the first PLC uploads the offline transport record to the MES. As shown in Figure 4, the flow includes the following steps.

[0111] S401: The system is starting up. S402: Determine whether IT-PLC ON LINE(I0.0) is 1 and DB6200.STATION_CFG.TRO is 1. If the result is YES, execute S403; otherwise, continue executing S402. Here, IT-PLC ON LINE(I0.0)=1 indicates that the IT-PLC control button is in "online mode," and STATION_CFG.TRO=1 indicates that synchronization of offline transport records is enabled. DB6200 is a DB block in which the IT-PLC stores the relevant control digits related to the synchronization of offline transport records.

[0112] S403: Determine whether DB6241.QTY_UNLOAD is 1 or greater. If the result is YES, execute S404; otherwise, continue executing S403. Here, QTY_UNLOAD indicates the number of queues in the offline buffer in DB6241. Here, DB6241-DB6248 are eight DB blocks allocated to all work stations for buffering offline records. DB6241 is the first of the eight DB blocks, and when DB6241 is full, it starts storing data in DB6242, and when DB6242 is full, it starts storing data in DB6243. Each of these eight DB blocks can store a predetermined number of queues. When uploading offline records synchronously, the eight DB blocks from DB6241 to DB6248 are uploaded in that order. For example, first, the offline data of the first target yarn package in DB6241 (the first yarn package in DB6241) is uploaded. After the upload of the offline data for the first target yarn package is complete, the offline data of that first target yarn package is cleared. Then, by shifting the offline data in all eight DB blocks from DB6241 to DB6248 forward by one data point, the offline data of the second yarn package in DB6241 is shifted forward by one data point, and the second yarn package in DB6241 becomes the new target yarn package.

[0113] S404: Call FC64007 to determine if the data in DB6200.ME_MSG.ME_AVI_MSG is empty, DB6200.ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE is 0, DB6200.IT_MSG.IT_CTRL_WRD.TR_SENT is 0, DB6200.IT_MSG.IT_CTRL_WRD.TS_RECEIVED is 0, and DB6200.IT_MSG.IT_CTRL_WRD.MES_COMPLETE is 0. If the result is YES, execute S405; otherwise, execute S418. Here, FC64007 is a pre-configured functional module that calls FC16 when synchronizing offline data to determine whether the DB6200.ME_MSG.ME_AVI_MSG area is empty or not. ME_MSG.ME_AVI_MSG represents business data read from the buffer, such as QR code (registered trademark) information and specifications on a yarn package, and FC16 is a functional module that determines whether the DB6200.ME_MSG.ME_AVI_MSG area is empty or not.

[0114] Here, IT_CTRL_WRD.TR_SENT is a variable that indicates whether or not the IT-PLC will set it after writing AVI_REQUEST. IT_CTRL_WRD.TR_SENT=1 means that the IT-PLC will set it after writing AVI_REQUEST, and IT_CTRL_WRD.TR_SENT=0 means that the variable is currently in its initial state.

[0115] Here, IT_CTRL_WRD.TS_RECEIVED is a variable that indicates whether or not the IT-PLC will set it after receiving MES data. IT_CTRL_WRD.TS_RECEIVED=1 means that the IT-PLC will set it after receiving MES data, and IT_CTRL_WRD.TS_RECEIVED=0 means that the variable is currently in its initial state.

[0116] Here, IT_CTRL_WRD.MES_COMPLETE is a variable that indicates whether the IT-PLC's current data processing is complete or not. IT_CTRL_WRD.MES_COMPLETE=1 means that the IT-PLC's current data processing is complete, and IT_CTRL_WRD.MES_COMPLETE=0 means that the variable is in its initial state.

[0117] S405: Call FC64005 to transmit the data content of the target winding package in DB6241-DB6248 to the corresponding location in DB6200.ME_MSG.ME_AVI_MSG. Here, the target winding package is the winding package whose memory position is the earliest in the eight DB blocks, DB6421 to DB6428. Here, FC64005 is a pre-configured functional module used to transmit content from DB6241 to DB6248 to the corresponding location in DB6200.ME_MSG.ME_AVI_MSG. Here, ME_MSG.ME_AVI_MSG represents the business data read by the IT-PLC from the buffer.

[0118] S406: The IT-PLC sets DB6200.ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE. Here, ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE indicates that the IT-PLC is starting to upload offline transport buffer data.

[0119] S407: Determine whether DB6200.ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE is 1. If the result is YES, execute S408; otherwise, continue executing S407. Here, ME_CTRL_WRD.ASSY_COMPLETE=1 indicates that the IT-PLC has already set and started synchronization.

[0120] S408: The IT-PLC sets DB6200.IT_MSG.IT_CTRL_WRD.TR_SENT, and then executes S409. Here, IT_MSG.IT_CTRL_WRD.TR_SENT=1 indicates that this value is set after the IT-PLC writes AVI_REQUEST.

[0121] After the IT-PLC completes S408, wait for the message returned from the MES.

[0122] S409: Determine whether DB6200.MI_RESPONSE.AVI_RESPONSE1 is not an empty string. If the result is YES, execute S410; otherwise, continue executing S409. Here, the fact that MI_RESPONSE.AVI_RESPONSE1 ≠ an empty string indicates that MES has already written the response information for this transport to AVI_RESPONSE1.

[0123] S410: Determines whether the format of DB6200.MI_RESPONSE.AVI_RESPONSE1 is correct. If the result is YES, execute S412; otherwise, continue executing S411. Here, the AVI_RESPONSE1 format can be set or adjusted according to the actual situation.

[0124] S411: Write error code 3548, then execute S418. Here, error code 3548 indicates that the format of MI_RESPONSE.AVI_RESPONSE1 is incorrect.

[0125] S412: The IT-PLC sets DB6200.IT_MSG.IT_CTRL_WRD.TS_RECEIVED. Here, IT_CTRL_WRD.TS_RECEIVED=1 indicates that this value is set after the IT-PLC receives the MES data.

[0126] S413: Call FC64004 to parse AVI_RESPONSE1 into the corresponding IT_RES_1. Here, IT_RES_1 (IT_MSG.IT_RES_1) shows the result of the IT-PLC analyzing the MES response information. Here, FC64004 is a module that has the function of analyzing AVI_RESPONSE1 into the corresponding IT_RES_1.

[0127] S414: Determine whether DB6200.IT_MSG.IT_RES_1.RESPONSE_RESULT is 1 and DB6200.IT_MSG.IT_RES_1.RESPONSE_ERROR is 0. If the result is YES, execute S416; otherwise, execute S415. IT_RES_1.RESPONSE_RESULT=1 indicates that the result in the response string information sent by the MES to the IT-PLC is normal. IT_RES_1.RESPONSE_ERROR=0 indicates that there is no error code in the response string information sent by the MES to the IT-PLC.

[0128] S415: Write error code 3549, then execute S418.

[0129] Here, error code 3549 is used to indicate at least one of the following: IT_RES_1.RESPONSE_RESULT≠1; IT_RES_1.RESPONSE_ERROR≠0.

[0130] S416: The IT-PLC resets by clearing MI_RESPONSE.AVI_RESPONSE1. Here, MI_RESPONSE.AVI_RESPONSE1 represents the response string sent by the MES to the IT-PLC.

[0131] S417:DB6200.IT_MSG.IT_CTRL_WRD.MES_COMPLETE=1. Here, IT_MSG.IT_CTRL_WRD.MES_COMPLETE=1 indicates that data processing by the IT-PLC is complete.

[0132] S418: Call FC64021 to perform a shift operation on the queue in DB6241, the IT-PLC clears and resets the control digits corresponding to DB6200, resets the corresponding business data area, and then returns to S402. Here, the IT-PLC's action of clearing and resetting the corresponding control digit may include the following: DB6200.ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE=0; DB6200.IT_MSG.IT_CTRL_WRD.TR_SENT=0; DB6200.IT_MSG.IT_CTRL_WRD.TS_RECEIVED=0; DB6200.IT_MSG.IT_CTRL_WRD.MES_COMPLETE=0.

[0133] Here, ASSY_COMPLETE indicates that the IT-PLC has prepared to synchronize offline transport buffer information to the MES.

[0134] Here, TR_SENT indicates that the IT-PLC has sent one piece of offline transport buffer information to the MES.

[0135] Here, TS_RECEIVED indicates that the IT-PLC has received the correct response information returned from the MES.

[0136] Here, MES_COMPLETE indicates that the IT-PLC has successfully completed the offline transfer buffer information.

[0137] Resetting the corresponding business data area here may include the following:

[0138] Call FC11 to reset DB6200.ME_AVI_MSG;

[0139] Call FC14 to clear and reset the data used to store the target winding package in DB6241;

[0140] Call FC8 to shift the offline queue, ensuring that data is always read from the position of the first winding package in DB6241.

[0141] Resetting DB6101.ME_AVI_MSG here is done to continue executing the previous data processing process, taking into account situations where the condition was triggered incorrectly.

[0142] The above-mentioned work station number, error code number, DB block number, variable name, storage address name, FC function module name, and FB function module name are merely examples and not limiting; they can all be set or adjusted according to actual needs.

[0143] The schematic diagrams shown in Figures 1 and 4 are illustrative, not restrictive, and expandable. Those skilled in the art can make various obvious changes and / or substitutions based on the examples in Figures 1 and 4, and the resulting designs should be understood to still fall within the scope of the embodiments of this disclosure.

[0144] Embodiments of the present disclosure provide a control device for automatic transfer of yarn packages applied to a control system for automatic transfer of yarn packages, the control device for automatic transfer of yarn packages includes an MES, a first PLC and a plurality of second PLCs, each of which is connected to the first PLC, the first PLC is connected to the MES, and each second PLC is used to control at least one work station, as shown in Figure 5, the control device for automatic transfer of yarn packages A monitoring module 501 monitors whether the control button of the first PLC has been switched from offline mode to online mode and whether communication between the first PLC and the MES has been restored. When the control button of the first PLC is switched from offline mode to online mode and communication between the first PLC and the MES is restored, and it is detected that offline data is stored in the offline buffer area, the system includes a first control module 502 for synchronizing the offline data with the MES. Offline data is stored when the connection between the first PLC and the MES is disconnected, and it is a transport record that should be synchronized with the MES.

[0145] In some embodiments, the first control module 502 is used to synchronize offline data with the MES according to the following steps.

[0146] After the system starts up, it continuously checks whether the first PLC is in online mode and whether the offline transfer record synchronization function is enabled. If the conditions are met, check whether there is a queue waiting to be processed in the offline buffer area. Ensure that the relevant data digits and control digits in the offline control area are in their initial state. If they are not in their initial state, perform a reset operation. The control digits are set to transmit the first queue data in the offline buffer area to the offline control area and instruct the second PLC to start the transfer process. The first PLC is triggered by a control digit to send a request to the MES, and waits for a response from the MES. The system verifies the format of the data returned by MES, and if the format is correct, it parses the data into the business data area in the offline control area and checks whether the response result is valid and free of errors. Depending on the response result, error processing or updating of control digits indicates that data processing is complete. By performing a queue shift to the offline buffer area and resetting the related control digits and business data area in the offline control area, preparations are made for synchronization in the next round.

[0147] In some embodiments, the control device for the automatic transfer of the yarn package is A second control module (not shown in Figure 5) controls the first PLC to acquire second business data for the target work station from a second PLC corresponding to the target work station, and to acquire first business data for the target work station based on the second business data, If the connection between the first PLC and the MES is disconnected, the first PLC records the first business data and sends transfer instruction information, which is a transfer permission, to the second PLC, thereby controlling the second PLC to control the target work station based on the transfer instruction information to execute the transfer task of the spool package, and a third control module (not shown in Figure 5) controls this. The system further includes a recording module (not shown in Figure 5) for storing offline data, which is a transport record to be synchronized with the MES, in an offline buffer area when the connection between the first PLC and the MES is disconnected.

[0148] In some embodiments, the control device for the automatic transfer of the winding package further includes a first determination module (not shown in Figure 5) for determining that the connection between the first PLC and the MES has been disconnected when the first PLC detects that a control button corresponding to the first PLC has been rotated to offline mode.

[0149] In some embodiments, the control device for the automatic transfer of the yarn package further includes a second determination module (not shown in Figure 5) for determining that the connection between the first PLC and the MES has been disconnected when the first PLC detects that communication between the first PLC and the MES has been interrupted.

[0150] In some embodiments, the control device for the automatic transfer of the winding package further includes a fourth control module (not shown in Figure 5) for controlling the MES not to perform the online transfer condition determination process if the connection between the MES and the first PLC is disconnected.

[0151] In some embodiments, the control device for the automatic transfer of the spool package corresponds to a target work station and further includes a fifth control module (not shown in Figure 5) that determines whether the spool package at the target work station satisfies the transfer conditions based on target string data obtained by analyzing the first business data by MES, determines that the transfer instruction information is transfer permitted if the transfer conditions are met, and determines that the transfer instruction information is transfer prohibited if the transfer conditions are not met.

[0152] In some embodiments, the control device for the automatic transfer of the spool package further includes a sixth control module (not shown in Figure 5) for controlling the first PLC to assign multiple offline buffer areas and one offline control area to all target work stations, the multiple offline buffer areas being shared by all target work stations, and the offline control area including associated data digits and associated control digits for synchronizing offline data to the MES.

[0153] Those skilled in the art will understand that the functions of each processing module in the control device for automatic transfer of a wound yarn package according to the embodiments of the present disclosure can be understood by referring to the above-described method for controlling the automatic transfer of a wound yarn package, and that each processing module in the control device for automatic transfer of a wound yarn package according to the embodiments of the present disclosure may be implemented by analog circuits that implement the functions according to the embodiments of the present disclosure, or by the execution of software on an electronic device that performs the functions according to the embodiments of the present disclosure.

[0154] The control device for the automatic transfer of a wound yarn package according to the embodiment of this disclosure can achieve automated synchronized management of offline transfer records of the wound yarn package and improve the transfer efficiency of the wound yarn package.

[0155] According to embodiments of the present disclosure, the present disclosure further provides electronic devices and readable storage media.

[0156] Figure 6 is a block diagram of the configuration of an electronic device according to one embodiment of the present disclosure. As shown in Figure 6, the electronic device includes a memory 610 and a processor 620, the memory 610 storing a computer program that can be executed by the processor 620. The number of memories 610 and processors 620 may be one or more. The memory 610 may store one or more computer programs. When the one or more computer programs are executed by the electronic device, the electronic device can perform the method provided in the above embodiment of the method. The electronic device may further include a communication interface 630 for communicating with external devices and exchanging and transmitting data.

[0157] If the memory 610, processor 620, and communication interface 630 are separate components, they can be connected to each other and communicate with each other via a bus. This bus may be an ISA (Industry Standard Architecture) bus, a PCI (Peripheral Component Interconnect) bus, an EISA (Extended Industry Standard Architecture) bus, etc. This bus can be divided into an address bus, a data bus, a control bus, etc. For convenience, Figure 6 shows only one thick line, but this does not mean that only one bus or one type of bus exists.

[0158] If, as a selective and specific implementation, the memory 610, processor 620, and communication interface 630 are integrated onto a single chip, the memory 610, processor 620, and communication interface 630 can communicate with each other via an internal interface.

[0159] The processor may be a Central Processing Unit (CPU), a general-purpose processor, a Digital Signal Processing (DSP), an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA), or other programmable logic devices, discrete gates, transistor logic devices, discrete hardware components, etc. The general-purpose processor may be a microprocessor or any ordinary processor. The processor may also be a processor that supports the ARM (Advanced RISC Machine) architecture.

[0160] Furthermore, the memory may selectively include read-only memory and random access memory, or non-volatile random access memory. The memory may be volatile memory or non-volatile memory, or may include both volatile and non-volatile memory. Non-volatile memory may include ROM (Read-Only Memory), Programmable ROM (PROM), Erasable PROM (EPROM), Electrically EPROM (EEPROM), or flash memory. Volatile memory may include Random Access Memory (RAM) used as an external cache. The above description is illustrative and not restrictive. Many forms of RAM are available. For example, static random access memory (Static RAM, SRAM), dynamic random access memory (DRAM), synchronous dynamic random access memory (Synchronous DRAM, SDRAM), double data rate synchronous dynamic random access memory (Double Data Date SDRAM, DDR SDRAM), enhanced synchronous dynamic random access memory (Enhanced SDRAM, ESDRAM), synchlink dynamic random access memory (Synchlink DRAM, SLDRAM), and direct memory bus random access memory (Direct RAM BUS RAM, DR RAM) may be used.

[0161] In the embodiments described above, all or part of the embodiments may be implemented by software, hardware, firmware, or any combination thereof. If implemented by software, all or part of the embodiments may be implemented in the form of a computer program product. The computer program product includes one or more computer instructions. When the computer instructions are loaded and executed on a computer, all or part of the flows or functions described in the embodiments of this disclosure are generated. The computer may be a general-purpose computer, a dedicated computer, a computer network, or other programmable device. The computer instructions may be stored on a computer-readable storage medium or transmitted from one computer-readable storage medium to another. For example, the computer instructions may be transmitted from one website, computer, server, or data center to another website, computer, server, or data center via a wired connection (e.g., coaxial cable, optical fiber, digital subscriber line, DSL) or wireless connection (e.g., infrared, Bluetooth®, microwave, etc.). The computer-readable storage medium may be any available medium accessible by a computer, or it may be a data storage device such as a server or data center that includes one or more available media. The available media may be magnetic media (e.g., floppy disks, hard disks, or magnetic tapes), optical media (e.g., Digital Versatile Discs (DVDs)), semiconductor media (e.g., Solid State Disks (SSDs)), etc. The computer-readable storage medium according to this disclosure may also be a non-volatile storage medium, in other words, a non-temporary storage medium.

[0162] Those skilled in the art will understand that all or part of the steps for realizing the above embodiment may be completed by hardware, or by a program that instructs the relevant hardware, and that the program may be stored in a computer-readable storage medium, the storage medium may be a read-only memory, a magnetic disk, or an optical disk, etc.

[0163] In the descriptions of the embodiments of this disclosure, the terms “one embodiment,” “several embodiments,” “examples,” “specific examples,” or “several examples” mean that the specific features, structures, materials, or characteristics described in relation to such embodiment or example are included in at least one embodiment or example of this disclosure. Furthermore, the specific features, structures, materials, or characteristics described may be combined in an appropriate manner in any one or more embodiments or examples. Furthermore, a person skilled in the art may combine different embodiments or examples and features in different embodiments or examples described herein, provided that they do not conflict with each other.

[0164] In the description of the embodiments of this disclosure, unless otherwise specified, " / " means "or," for example, "A / B" can represent "A" or "B." The "and / or" statements in this specification are merely related relationships that describe related subjects and mean that there are three possible relationships, for example, "A and / or B" can indicate three situations: "A" exists alone, "A" and "B" exist together, and "B" exists alone.

[0165] In the description of the embodiments of this disclosure, the terms “first” and “second” are for distinction purposes only and should not be understood to indicate or imply relative importance or the number of designated constituent elements. Thus, features limited by “first” and “second” may explicitly or implicitly include one or more such features. In the description of the embodiments of this disclosure, unless otherwise specified, “multiple” means two or more.

[0166] The foregoing are merely illustrative examples of the Disclosure and do not limit the Disclosure. Any modifications, equivalent substitutions, or improvements made to the spirit and principles of the Disclosure should be included within the scope of the claims of the Disclosure.

Claims

1. In a control method for the automatic transfer of yarn packages applied to a control system for the automatic transfer of yarn packages, The control system for the automatic transfer of the yarn package includes a Manufacturing Execution System (MES), a first Programmable Logic Controller (PLC), and a plurality of second PLCs for controlling at least one work station, each of which is connected to the first PLC, and the first PLC is connectable to the MES. The control method for the automatic transfer of the aforementioned winding package is as follows: The system detects whether the control button of the first PLC has been switched from offline mode to online mode and whether communication between the first PLC and the MES has been restored. When the control button of the first PLC is switched from offline mode to online mode, and communication between the first PLC and the MES is restored, if it is detected that offline data is stored in the offline buffer area, the offline data is synchronized with the MES. A method for controlling the automatic transfer of a wound yarn package, wherein the offline data is stored when the connection between the first PLC and the MES is disconnected, and is a transfer record to be synchronized with the MES.

2. Synchronizing the aforementioned offline data with the MES means After the system is started, the system continuously checks whether the first PLC is in online mode and whether the synchronization function for offline transport records is enabled. If the conditions are met, it checks whether there is a queue waiting to be processed in the offline buffer area, ensures that the relevant data digits and control digits in the offline control area are in their initial state, and if they are not in their initial state, performs a reset operation. The first queue data in the offline buffer area is transmitted to the offline control area, the control digits are set, and the second PLC is instructed to start the transfer process. The first PLC is triggered by a control digit to send a request to the MES, and then waits for a response from the MES. The system verifies the format of the data returned from the MES, and if the format is correct, it parses the data into the business data area in the offline control area, checks whether the response result is valid and whether there are any errors in the response result, and, based on the response result, performs error processing or updates the control digits to indicate that data processing is complete. The method according to claim 1, further comprising performing a queue shift on the offline buffer area and resetting the associated control digits and business data area in the offline control area in preparation for synchronization of the next round.

3. The above method, before synchronizing the offline data with the MES, The first PLC acquires second business data for the target work station from a second PLC corresponding to the target work station, and acquires first business data for the target work station based on the second business data. The method according to claim 1, further comprising the first PLC recording the first business data and transmitting transfer instruction information, which is a transfer permission, to the second PLC, so that the second PLC controls the target work station based on the transfer instruction information to perform a transfer task of the spool package, if the connection between the first PLC and the MES is disconnected.

4. The control method for the automatic transfer of the aforementioned winding package is as follows: The method according to claim 1, further comprising the first PLC determining that the connection between the first PLC and the MES has been disconnected when the first PLC detects that a control button corresponding to the first PLC has been rotated to offline mode.

5. The control method for the automatic transfer of the aforementioned winding package is as follows: The method according to claim 1, further comprising determining that the connection between the first PLC and the MES has been disconnected when the first PLC detects that communication between the first PLC and the MES has been interrupted.

6. The control method for the automatic transfer of the aforementioned winding package is as follows: The method according to claim 4 or 5, further comprising the fact that if the connection between the MES and the first PLC is disconnected, the MES does not perform the online transport condition determination process.

7. The process for determining online transfer conditions is as follows: This includes determining whether the winding package at the target work station meets the transfer conditions based on the target string data corresponding to the target work station, determining that the transfer instruction information is transfer permitted if the transfer conditions are met, and determining that the transfer instruction information is transfer prohibited if the transfer conditions are not met. The method according to claim 6, wherein the target string data is obtained by the MES analyzing the first business data.

8. The control method for the automatic transfer of the aforementioned winding package is as follows: The first PLC further includes assigning multiple offline buffer areas and one offline control area to all target work stations, The aforementioned multiple offline buffer areas are shared by all target work stations. The method according to claim 1, wherein the offline control area includes associated data digits and associated control digits for synchronizing offline data with the MES.

9. In a control device for automatic transfer of yarn packages, applied to a control system for the automatic transfer of yarn packages, The system for automatic transfer control of the winding package includes a Manufacturing Execution System (MES), a first Programmable Logic Controller (PLC), and a plurality of second PLCs for controlling at least one work station, each of which is connected to the first PLC, and the first PLC is connectable to the MES. The control device for the automatic transfer of the aforementioned winding package is: A monitoring module for monitoring whether the control button of the first PLC has been switched from offline mode to online mode and whether communication between the first PLC and the MES has been restored, When the control button of the first PLC is switched from offline mode to online mode, and communication between the first PLC and the MES is restored, if it is detected that offline data is stored in the offline buffer area, the system includes a first control module for synchronizing the offline data with the MES. The aforementioned offline data is stored when the connection between the first PLC and the MES is disconnected, and is a transport record that should be synchronized with the MES. Control device.

10. At least one processor, Includes memory that is communicably connected to at least one processor, An electronic device wherein the memory stores instructions that can be executed by the at least one processor, and the instructions are executed by the at least one processor so that the at least one processor can perform the method according to claim 1.

11. A non-temporary computer-readable storage medium, characterized in that it stores computer commands used to cause a computer to perform the method described in claim 1.

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