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

Abstract

This disclosure relates to a control method, apparatus, electronic equipment, and storage medium for the automatic transfer of a wound yarn package. [Solution] The method for controlling the automatic transfer of a spool package includes monitoring whether the control button of a first PLC is in offline mode and whether the control button of a second PLC corresponding to the target work station is in online mode, and if the control button of the first PLC is in offline mode and the control button of the second PLC corresponding to the target work station is in online mode, the first PLC generates transfer instruction information for the target work station, and stores offline data in the offline buffer area. The transfer instruction information is a transfer permission, and the offline data is a transfer record that is stored when the connection between the first PLC and the MES is disconnected and should be synchronized with the MES.

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 production field of chemical fibers, an efficiently operating production line is the key to ensuring production capacity and efficiency. This production line consists of a large number of closely arranged cooperating workstations. Particularly important is the smooth flow of a huge number of winding packages in the production line. The transfer speed of the winding packages directly affects the overall production rhythm and efficiency and is 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. [[ID=第十三条]]

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

[0004] According to a first aspect of the present disclosure, a control method for automatic transfer of winding packages applied to a control system for automatic transfer of winding packages is provided. The control system for automatic transfer of winding packages 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 respectively. The plurality of second PLCs are respectively connected to the first PLC, and the first PLC is connectable to the MES. The control method for the automatic transfer of the said yarn package is: The system monitors whether the control button of the first PLC is in offline mode and whether the control button of the second PLC corresponding to the target workstation is in online mode. If the control button of the first PLC is in offline mode and the control button of the second PLC corresponding to the target work station is in online mode, the first PLC generates transfer instruction information for the target work station, and the offline data is stored in the offline buffer area. Here, offline data is stored when the connection between the first PLC and the MES is disconnected, and is a transfer record that should be synchronized with the MES, while transfer instruction information is a transfer permission.

[0005] According to a second aspect of the present disclosure, a control device for the automatic transfer of a yarn package is provided for application to a control system for the automatic transfer of a yarn package, the control system for the automatic transfer of a yarn package includes an MES, a first PLC, and a plurality of second PLCs, each of which is for controlling at least one work station, and the plurality of second PLCs are each 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 is in offline mode and the control button of the second PLC corresponding to the target work station is in online mode, When the control button of the first PLC is in offline mode and the control button of the second PLC corresponding to the target work station is in online mode, if the first PLC generates transfer instruction information for the target work station, the system includes a first control module for storing offline data in an offline buffer area. Here, offline data is stored when the connection between the first PLC and the MES is disconnected, and is a transfer record that should be synchronized with the MES, while transfer instruction information is a transfer permission.

[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 a computer to perform any of the embodiments of the present disclosure. [Effects of the Invention]

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

[0009] Please understand that the information provided in the Summary of the Invention does not limit the key points or important features of the embodiments of this disclosure, nor does it limit 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 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 of the process by which the first PLC according to the embodiment of this disclosure buffers offline data. [Figure 4] Figure 4 is a flowchart of the process in which the first PLC according to the embodiment of this disclosure buffers offline data and then returns offline forced transfer instruction information to the second PLC. [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, those skilled in the art should be aware 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] In addition, terms such as "first", "second", "third", etc. in the specification, claims, and the above drawings of this application are for distinguishing similar objects and are 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, a further explanation will be given regarding the technical terms that can be used in the present disclosure.

[0015] MES: A software system for monitoring and managing the manufacturing process, capable of collecting, processing, and analyzing production data in real time, and optimizing production planning and resource allocation. PLC: An industrial digital computer for controlling 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 serve as the basis for decision-making and control by MES and PLC. Transfer instruction information (also called transfer command): Generated after MES analyzes based on business data, and is command and parameter information for instructing equipment to execute a transfer task.

[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 the real-time business data of the target work station and provides it to the first PLC. The first PLC is responsible for interacting with the second PLC and obtaining the second business data from the second PLC. The first PLC also plays a role in interacting with MES, sending the first business data to MES, receiving the transfer instruction information distributed by MES based on the first business data, and notifying 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 sent 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 the 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 operational data is a collection of data collected and processed by the first PLC, 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 request type. This data is of significant importance in monitoring the operating status of the production line and in authorizing decisions regarding transfer permission.

[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 can continue 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 is in offline mode and the control button of the second PLC corresponding to the target workstation is in online mode. S202: When the control button of the first PLC is in offline mode and the control button of the second PLC corresponding to the target work station is in online mode, if the first PLC generates transport instruction information for the target work station, offline data is stored in the offline buffer area, where the offline data is transport record that was stored when the connection between the first PLC and the MES was disconnected and should be synchronized with the MES, and the transport instruction information is transport permission.

[0027] In some embodiments, the first PLC has two operating modes: in online mode, the first PLC maintains a connection with the MES and can synchronize data to the MES in real time; and in offline mode, the connection between the first PLC and the MES is not disconnected, and data cannot be synchronized to the MES in real time.

[0028] In some embodiments, the second PLC has two operating modes: in offline mode, the second PLC requests a compulsory transport; and in online mode, the second PLC performs the transport process based on transport instruction information (transport permitted or transport prohibited) transmitted from the MES or the first PLC.

[0029] In some embodiments, the offline buffer area is a temporary storage area for storing data that is generated in a first PLC offline mode and should be synchronized with the MES.

[0030] In some embodiments, the system detects whether the operating mode of the first PLC is offline mode and whether the second PLC corresponding to the target workstation is online mode. This step ensures the accuracy and timeliness of data synchronization.

[0031] In some embodiments, when the first PLC is in offline mode and the second PLC is in online mode, the first PLC stores offline data in the offline buffer area when it generates transfer instruction information (i.e., transfer permission) for the target work station. The first PLC stores transfer records (offline data) to be synchronized with the MES in the offline buffer area. This offline data includes, but is not limited to, the serial number of the yarn package, target work station information, and transfer time. When the first PLC is reconnected to the MES, or when a point set in the system is reached, the offline data in the offline buffer area is synchronized with the MES system to ensure data integrity and consistency. After synchronization is complete, the status information of the relevant yarn package in the MES system is updated to facilitate subsequent production management and scheduling, and the status information of the relevant yarn package includes the location of the yarn package, processing progress, etc.

[0032] In the technical solution according to the embodiment of this disclosure, when the control button of the first PLC is in offline mode and the control button of the second PLC corresponding to the target workstation is in online mode, if the first PLC generates transfer instruction information for the target workstation, the offline data is stored in the offline buffer area. Thus, the offline buffer mechanism ensures the temporary storage of important data and subsequent synchronization even when the connection between the first PLC and the MES is disconnected, improving the efficiency and reliability of data synchronization. When the first PLC is in offline mode, it can still generate transfer instruction information for the target workstation, and the offline buffer mechanism ensures data integrity and reduces production interruptions due to data synchronization problems.

[0033] In some embodiments, when a first PLC generates transfer instruction information for a target work station, storing offline data in an offline buffer area includes first transmitting the transfer instruction information to a second PLC corresponding to the target work station so that the second PLC controls the target work station based on the transfer instruction information to perform the transfer task of the yarn package, and then storing the offline data in an offline buffer area.

[0034] In some embodiments, when the first PLC decides to generate transfer instruction information for a target work station, it first transmits this information via a network or communication line to a second PLC that directly corresponds to the target work station. After receiving the transfer instruction information, the second PLC controls the target work station based on pre-configured logic and rules to perform the transfer operation of the corresponding winding package.

[0035] In some embodiments, simultaneously with or after transmitting transfer instruction information, the first PLC stores offline data related to the current transfer operation (e.g., winding package identifier, transfer time, target work station information, etc.) in an offline buffer area. This offline data is important for synchronization with the MES when the connection between the first PLC and the MES is restored, in the event that the connection between the first PLC and the MES is lost or data cannot be synchronized in real time.

[0036] This method, which transmits transfer instruction information before storing offline data, ensures continuous operation of the production line and temporary data storage even if the connection between the first PLC and the MES is disconnected, improving the flexibility and reliability of the system. When the first PLC is reconnected to the MES, it can quickly retrieve and synchronize previously stored offline data from the offline buffer area, reducing the possibility of data loss and repetitive work, and improving the efficiency of data synchronization. By transmitting transfer instruction information in a timely manner and storing offline data, it ensures that each stage in the production flow is tightly connected to one another, avoiding production stagnation or delays due to waiting for data synchronization.

[0037] In some embodiments, when a first PLC generates transfer instruction information for a target work station, storing offline data in an offline buffer area includes first storing the offline data in the offline buffer area, and then transmitting the transfer instruction information to a second PLC corresponding to the target work station.

[0038] In some embodiments, when the first PLC decides to generate transfer instruction information for a target work station, it first stores the offline data related to this transfer operation in an offline buffer area. This is to ensure that important production data is properly saved even if the system is disconnected from the MES or if data cannot be synchronized in real time.

[0039] In some embodiments, after storing offline data, the first PLC transmits transfer instruction information to a second PLC corresponding to the target work station via a network or communication line. This step is to enable the second PLC to control the target work station based on the information to perform the transfer operation of the corresponding spool package.

[0040] Thus, by storing offline data before transmitting transport instruction information, data security is improved by ensuring that offline data is not lost even if a communication failure or interruption occurs during the transmission of instruction information. By storing important data before triggering the next step in the production flow, it is possible to ensure that the data flow in the production line matches the actual flow, and production delays or errors due to data asynchronous can be reduced. According to this embodiment, even if the system faces unexpected situations such as network failure or system maintenance, a certain level of production capacity can be maintained, improving the flexibility and fault tolerance of the system.

[0041] 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.

[0042] 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 should now perform the transfer operation of the spool package). 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).

[0043] 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.

[0044] 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.

[0045] 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.

[0046] 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), and polyester staple fibers (PSF).

[0047] 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.

[0048] 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.

[0049] 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.

[0050] 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.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] In embodiments of the present disclosure, the control method for the automatic transfer of the winding package further includes 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.

[0056] 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.

[0057] 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.

[0058] 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.

[0059] 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 transport control flow in offline mode. Subsequently, the first PLC sends a transport instruction message to the second PLC, indicating "transport permitted," to ensure that the spool package can be smoothly moved from the current work station to the next work station.

[0060] 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, helping to find and resolve 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.

[0061] In embodiments of the present disclosure, the method for controlling the automatic transfer of the winding package further includes 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.

[0062] 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.).

[0063] 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.

[0064] 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. If, one day, the communication link between the first PLC and the MES is interrupted due to a network failure, the first PLC's communication status monitoring module 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.

[0065] 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.

[0066] 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.

[0067] 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 do not rely on real-time data in order to maintain the normal operation of the system.

[0068] 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.

[0069] 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 tracking of subsequent data. The recorded content may include key fields of all or part of the first business data, and information such as a timestamp when the data was received. If successful, 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] In some embodiments, the transfer instruction information is information indicating whether the yarn package in the production line is permitted to be transported to the next work station for further processing. Depending on the determination of the transfer conditions, the transfer instruction information may be "transfer permitted" or "transfer prohibited."

[0075] 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.

[0076] In some embodiments, the MES further analyzes the target string data obtained through analysis by comparing it with pre-set transfer conditions. These transfer 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 transfer conditions, the MES determines that the transfer instruction information is "transfer permitted," indicating that the spool package is permitted to 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 transfer conditions, the MES determines that the transfer instruction information is "transfer prohibited," and may notify on-site staff to inspect and process the package by triggering a corresponding alarm mechanism.

[0077] 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.

[0078] 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.

[0079] 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 operational efficiency of the production line.

[0080] 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.

[0081] 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 avoiding 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 work station, so that the second PLC can accurately return the corresponding data.

[0082] 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.

[0083] 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.

[0084] 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.

[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 predetermined 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, since it conforms to a predetermined data storage format, subsequent processing and transmission can be facilitated. 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, the predetermined data storage format and format conversion process ensure consistency and accuracy in the exchange and processing of data from different sources. By assigning a fixed storage address to each variable, the data access and processing process can be simplified, improving the overall system performance. The allocation of data storage area and the definition of the format have a certain degree of flexibility, so they can be expanded and adjusted 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 intended to store data that should be synchronized in the event that 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 predetermined 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 workstations 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, thereby 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 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.

[0096] Figure 3 shows a flowchart of the process by which the first PLC buffers offline data. As shown in Figure 3, the flow includes the following steps:

[0097] S301: The system is starting up. S302: Determine whether DB6101.MI_RESPONSE.AVI_RESPONSE1 is an empty string. If the result is No, execute S303. If the result is Yes, execute S308. Here, 6101 is the number of the target work station, and DB6101 indicates the DB block that the ME-PLC has assigned to work station 6101. DB6101.MI_RESPONSE.AVI_RESPONSE1 is a variable that the ME-PLC has assigned to work station 6101 and is used to store the MES response message. If DB6101.MI_RESPONSE.AVI_RESPONSE1 is not an empty string, it indicates that the previous request was not completed, and in this case, S303 is executed.

[0098] S303: The IT-PLC parses RESPONSE1 into IT_RES_1, and then executes S304. Here, IT_RES_1 (an abbreviation for IT_MSG.UDT_IT_MSG_1.IT_RES_1) indicates the storage location where the IT-PLC has analyzed the MES response information according to the rules.

[0099] S304: Determine whether IT_RES_1 contains an error code. If the result is YES, execute S305. If the result is NO, execute S319. Here, the Error Code is usually represented as EC.

[0100] S305: Send IT_RES_1 containing the error code to the ME-PLC using the PUT command.

[0101] S306: Determine whether the ERROR in the PUT command is 0. If the result is NO, execute S307. If the result is YES, execute S326.

[0102] S307: Call FB64001 and write error code 3560, then return to S305. In this context, the FB64001 is an integrated module that writes various error codes, such as 3560. Here, 3560 indicates that ERROR≠0 in the PUT command, meaning that an error occurred in the execution of the PUT command.

[0103] S308: The IT-PLC periodically retrieves ME_CTRL_WRD from the DB block of the corresponding workstation in the ME-PLC. Here, ME_CTRL_WRD indicates the control digit of the target work station. Furthermore, to ensure data integrity and accuracy, the ME-PLC should check the ME_MSG.ME_AVI_MSG file that it has written to the DB block of its corresponding workstation. For example, ME_CTRL_WRD is obtained from DB6101.ME_MSG.ME_CTRL_WRD. Here, 6101 is the number of the target workstation, and DB6101.ME_MSG indicates the DB block that the ME-PLC has assigned to workstation number 6101. DB6101.ME_MSG.ME_CTRL_WRD is the one that the ME-PLC has assigned to workstation number 6101, and it is a variable used to store the control digit of that workstation in the DB block.

[0104] S309: Determine whether DB6101.ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE_FORCE is 1. If the result is YES, execute S310; otherwise, continue executing S309. Here, the IT-PLC retrieves ME_CTRL_WRD.ASSY_COMPLETE_FORCE from the DB block of the corresponding workstation in the ME-PLC. Here, ME_CTRL_WRD.ASSY_COMPLETE_FORCE=1 indicates that the ME-PLC has already set and initiated forced transfer. DB6101.ME_MSG.ME_CTRL_WRD.ASSY_COMPLETE_FORCE is a variable in the DB block that the ME-PLC has assigned to the work station number 6101 and that the ME-PLC has already set up and initiated the forced transfer.

[0105] S310: The IT-PLC sets a control digit and clears the data buffer area to ensure that the current flow is not affected by residual data from other flows, and then executes S311.

[0106] S311: The IT-PLC retrieves the ME_AVI_TAG from the DB block of the corresponding workstation in the ME-PLC. For example, ME_AVI_TAG is obtained from DB6101.ME_MSG.ME_AVI_TAG. Here, 6101 is the number of the target work station, DB6101.ME_MSG represents the DB block that the ME-PLC has assigned to work station number 6101, DB6101.ME_MSG.ME_AVI_MSG represents a variable that the ME-PLC has assigned to work station number 6101 and stores the second business data written by the ME-PLC, and ME_MSG.ME_AVI_MSG represents the second business data written by the ME-PLC, such as the two-dimensional code information and request type of the spool package. The ME-PLC should check whether the ME_MSG.ME_AVI_TAG, which it has written to the corresponding DB block of the workstation, was written correctly.

[0107] S312: Determine whether the ERROR in the GET command is 0. If the result is NO, execute S313. If the result is YES, execute S314. Here, the GET command is a command for the IT-PLC to retrieve the ME_AVI_TAG from the DB block of the corresponding workstation in the ME-PLC.

[0108] S313: Call FB64001 and write error code 3539, then return to S311. In this context, the FB64001 is an integrated module that writes various error codes, such as 3539. Here, 3539 indicates that ERROR ≠ 0 in the GET command.

[0109] S314: The IT-PLC sets DB6101.IT_MSG.IT_CTRL_WRD.ASSY_COMPLETE_RECEIVED, and then executes S315. Here, DB6101.IT_MSG indicates the DB block that the IT-PLC has assigned to workstation 6101. DB6101.IT_MSG.IT_CTRL_WRD.ASSY_COMPLETE_RECEIVED is a variable that the IT-PLC has assigned to workstation 6101 and stores the fact that the IT-PLC has confirmed that it has received a message from the ME-PLC indicating that it has already set up and initiated forced transfer. Here, IT_MSG.IT_CTRL_WRD.ASSY_COMPLETE_RECEIVED indicates that the IT-PLC has received a message indicating that the ME-PLC has already set and initiated the forced transfer.

[0110] S315: The conditions for realizing an offline buffer are that the IT-PLC operates in "offline" mode, STATION_CFG.TR=1, WITH_PLC=1, and AUTO_MODE=1, all of which must be met simultaneously. Here, the offline condition is that the control button on the IT-PLC is switched to offline mode, or that communication between the IT-PLC and the MES is interrupted. STATION_CFG.TR=1 indicates that transfer recording should be enabled for the current work station. WITH_PLC=1 indicates that the IT-PLC is in online mode, meaning that communication between the IT-PLC and the ME-PLC is functioning correctly. AUTO_MODE=1 indicates that the ME-PLC is in online mode. Here, the IT-PLC reads AUTO_MODE from DB6101.ME_MSG.ME_CTRL_WRD.AUTO_MODE of the ME-PLC.

[0111] S316: Count the number of times the offline switch is toggled. Here, Count1 indicates the number of times the offline switch has been toggled.

[0112] S317: Determine whether Count1 is 1 and Count2 is 0. If the result is NO, execute S318. If the result is YES, execute S319. Here, Count2 represents the number of offline forced transfers. Count2 = 0 indicates that the number of offline forced transfers is equal to 0.

[0113] S318: Call FC64023 to initialize offline buffer areas DB6241~DB6248, and then execute S319. In this context, the FC64023 is an integrated module that has the function of initializing the offline buffer area. Here, DB6241 to DB6248 are the eight DB blocks assigned by the IT-PLC to store offline data. It is understood that the numbers and quantities representing the offline buffer area DBs can be set or adjusted as needed.

[0114] S319: Call FC64007 to synthesize MI. Here, FC stands for Customized Functional Module. FC64007 is the number of the functional module for synthesizing MI. Here, MI represents the response string generated by the IT-PLC instead of the MES.

[0115] S320: Determine whether the length of MI is 78. If the result is NO, execute S321. If the result is YES, execute S325. Here, 78 is a pre-configured length rule for the response string, and the length of the MI must satisfy this length rule.

[0116] S321: Write error code 3568 to IT_RES_1, then execute S322. Here, 3568 indicates that the length of the MI generated by the IT-PLC is not equal to 78.

[0117] S322: Send IT_RES_1 containing the error code to the ME-PLC side via the PUT command, and then execute S323.

[0118] S323: Determine whether the ERROR in the PUT command is 0. If the result is NO, execute S324. If the result is YES, execute S326.

[0119] Call S324:FC64017 to store the message after offline processing in the offline buffer area. Here, FC is a customized functional module. FC64017 is the number of the functional module for storing messages after offline processing in the offline buffer area.

[0120] S325: The IT-PLC generates response data corresponding to IT_RES_1. Here, generating the response data corresponding to IT_RES_1 is: DB6101.IT_MSG.UDT_IT_MSG_1.IT_RES_1.RESPONSE_YARN1=DB6101.ME_MSG.ME_AVI_MSG.REQUEST_TARN, DB6101.IT_MSG.UDT_IT_MSG_1.IT_RES_1.RESPONSE_RESULT=1, DB6101.IT_MSG.UDT_IT_MSG_1.IT_RES_1.RESPONSE_ERROR=0 is included. Here, RESPONSE_YARN1 and REQUEST_TARN indicate the two-dimensional code information of the received yarn package for which transfer has been requested. Here, RESPONSE_RESULT=1 indicates that the transfer result was normal. Here, RESPONSE_ERROR=0 indicates that the error code for this transport is 0. In this case, IT_RES_1, which is constructed in an offline state, is normal transport information, and mainly it is constructed to indicate that the result is correct (RESPONSE_RESULT) and that there are no errors in the result (RESPONSE_ERROR).

[0121] S326: The IT-PLC clears and resets the control digit corresponding to the work station, resets the business data area corresponding to the work station, and then returns to S302. Here, the IT-PLC clearing and resetting the corresponding control digit may include the following: DB6101.IT_MSG.UDT_IT_MSG_1.IT_CTRL_WRD.ASSY_COMPLETE_RECEIVED=0, DB6101.IT_MSG.UDT_IT_MSG_1.IT_CTRL_WRD.MES_COMPLETE=0.

[0122] Here, DB6101.IT_MSG represents a data buffer area for storing various variables in the DB block, which the ME-PLC has assigned to the workstation number 6101. Here, IT_CTRL_WRD.ASSY_COMPLETE_RECEIVED is a variable used to confirm that the ME-PLC has already received confirmation that it has set and started transporting the data. Here, IT_CTRL_WRD.MES_COMPLETE indicates that the IT-PLC notifies the ME-PLC that data processing is complete.

[0123] Here, resetting the business data area that IT-PLC supports is: Call FC64006 to reset DB6101.ME_AVI_MSG, DB6101.IT_MSG.UDT_IT_MSG_1.IT_RES_1.RESPONSE_YARN1='', DB6101.IT_MSG.UDT_IT_MSG_1.IT_RES_1.RESPONSE_RESULT=0, DB6101.IT_MSG.UDT_IT_MSG_1.IT_RES_1.RESPONSE_ERROR=0 is included.

[0124] In this context, the FC64006 is an integrated module that has the function of resetting ME_AVI_MSG.

[0125] In addition to Figure 3, Figure 4 shows a flowchart of the process in which the first PLC buffers offline data and then returns offline forced transfer instruction information to the second PLC. As shown in Figure 4, this flow includes the following steps.

[0126] S327: Determine whether the RFIDTAG is an empty string. If the result is NO, execute S328. If the result is YES, execute S332. Here, the fact that RFIDTAG ≠ an empty string indicates that the RFIDTAG contains data for the yarn package.

[0127] S328: Write error code 3561 to IT_RES_1, then execute S329. Here, 3561 indicates that the RFIDTAG is empty.

[0128] S329: The PUT command sends IT_RES_1 containing the error code to the ME-PLC, and then S331 is executed.

[0129] S330: Determine whether the ERROR in the PUT command is 0. If the result is NO, execute S331. If the result is YES, execute S326.

[0130] S331: Call FB64001 and write error code 3562, then return to S329. Here, 3562 indicates that RFIDTAG is empty and ERROR≠0 in the PUT command.

[0131] S332: Call FC64001 to analyze the information of the winding package from the RFIDTAG. Here, FC stands for Customized Functional Module. FC64001 is the number of the functional module for analyzing information from the RFID Tag on the winding package.

[0132] Call S333:FC60157 to update the queue on the production line. Here, the FC60157 is a module that integrates functions for updating queues on the production line.

[0133] S334: The IT-PLC outputs IT_RES_1 information to the ME-PLC.

[0134] S335: Determine whether the ERROR in the PUT command is 0 and the STATUS is 0000H. If the result is NO, execute S336. If the result is YES, execute S337. Here, ERROR=0 indicates that there is no error in the PUT command. STATUS=0000H indicates that the status value is 0, where H represents a hexadecimal number. The PUT command is a command used by the IT-PLC to send data to the ME-PLC.

[0135] Call S336:FB64001 and write error code 3565. Here, the FB64001 is an integrated module that writes, for example, error code 3565. 3565 indicates that ERROR≠0 or STATUS≠0000H.

[0136] Set S337:DB6101.IT_MSG.IT_CTRL_WRD.MES_COMPLETE. DB6101.IT_MSG.IT_CTRL_WRD.MES_COMPLETE is a variable used to store the notification from the IT-PLC to the ME-PLC that data processing is complete in the DB block that the IT-PLC has assigned to the workstation number 6101. Here, IT_MSG.IT_CTRL_WRD.MES_COMPLETE indicates that the IT-PLC notifies the ME-PLC that data processing is complete.

[0137] S338: Determine whether DB6101.ME_MSG.ME_CTRL_WRD.MES_COMPLETE or ME_CTRL_WRD.ME_RESET is 1. If the result is YES, execute S326; otherwise, continue executing S338. Here, setting ME_MSG.ME_CTRL_WRD.MES_COMPLETE=1 indicates that the IT-PLC sets a variable to notify the ME-PLC that data processing is complete. Here, ME_CTRL_WRD.ME_RESET=1 indicates that the ME-PLC controls the transfer of the yarn package at the work station to complete, and then sets the control digit for that work station. Resetting DB6101.ME_AVI_MSG here is done to allow the previous data processing process to continue, taking into account situations where the condition was triggered incorrectly.

[0138] 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.

[0139] The schematic diagrams shown in Figures 1, 3, and 4 are illustrative, non-limiting, and expandable. Those skilled in the art can make various obvious changes and / or substitutions based on the examples in Figures 1, 3, and 4, and the resulting designs should be understood to still fall within the scope of the embodiments of this disclosure.

[0140] Embodiments of the present disclosure provide a control device for automatic transfer of a yarn package, which is applied to a control system for the automatic transfer of a yarn package, and the control device for automatic transfer of a yarn package 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, and as shown in Figure 5, the control device for automatic transfer of a yarn package may include a monitoring module 501 for monitoring whether the control button of the first PLC is in offline mode and the control button of the second PLC corresponding to the target work station is in online mode, and a first control module 502 for storing offline data in an offline buffer area if the first PLC generates transfer instruction information for the target work station when the control button of the first PLC is in offline mode and the control button of the second PLC corresponding to the target work station is in online mode. Here, the offline data is a transfer record that is stored when the connection between the first PLC and the MES is disconnected and should be synchronized with the MES, and the transfer instruction information is a transfer permission.

[0141] In some embodiments, the first control module 502 first transmits transfer instruction information to a second PLC corresponding to the target work station 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, and then stores the offline data in an offline buffer area.

[0142] In some embodiments, the first control module 502 first stores offline data in an offline buffer area, and then transmits transfer instruction information to a second PLC corresponding to the target work station 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.

[0143] 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.

[0144] 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.

[0145] In some embodiments, the control device for the automatic transfer of the winding package further includes a second 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.

[0146] In some embodiments, the control device for the automatic transfer of the spool package corresponds to a target work station and further includes a third 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 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, wherein the first business data is obtained based on second business data, and the second business data is business data acquired by the first PLC from a second PLC corresponding to the target work station.

[0147] In some embodiments, the control device for the automatic transfer of the spool package further includes a fourth control module (not shown in Figure 5) for controlling the first PLC to assign a plurality of offline buffer areas and one offline control area to all target work stations, the plurality of 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.

[0148] 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.

[0149] The control device for the automatic transfer of a wound yarn package according to the embodiment of this disclosure can achieve automated buffer management for offline transfer records of the wound yarn package and improve the transfer efficiency of the wound yarn package.

[0150] According to embodiments of the present disclosure, the present disclosure further provides electronic devices and readable storage media.

[0151] 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.

[0152] 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.

[0153] 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.

[0154] 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. Furthermore, the processor may be a processor capable of supporting an Advanced RISC Machine (ARM) architecture.

[0155] 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.

[0156] 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.

[0157] 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.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] 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 monitors whether the control button of the first PLC is in offline mode and whether the control button of the second PLC corresponding to the target work station is in online mode. If the control button of the first PLC is in offline mode and the control button of the second PLC corresponding to the target work station is in online mode, then if the first PLC generates transfer instruction information for the target work station, the offline data is stored in the offline buffer area. A method for controlling the automatic transfer of a wound yarn package, characterized in that the transfer instruction information is a transfer permission, and the offline data is a transfer record stored when the connection between the first PLC and the MES is disconnected, and which should be synchronized with the MES.

2. When the first PLC generates transfer instruction information for the target work station, the offline data is stored in the offline buffer area. The method according to claim 1, characterized in that the transfer instruction information is transmitted to the second PLC corresponding to the target work station so that the second PLC controls the target work station based on the transfer instruction information to perform a transfer task of the wound yarn package, and then the offline data is stored in the offline buffer area.

3. When the first PLC generates transfer instruction information for the target work station, the offline data is stored in the offline buffer area. The method according to claim 1, characterized in that the offline data is stored in the offline buffer area, and then the transfer instruction information is transmitted to the second PLC corresponding to the target work station so that the second PLC controls the target work station based on the transfer instruction information and performs the transfer task of the spool package.

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 the first PLC 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 characterized in 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 satisfies the transfer conditions based on the target string data corresponding to the target work station, determining that the transfer instruction information is transfer permission if the transfer conditions are met, and determining that the transfer instruction information is transfer prohibition if the transfer conditions are not met. The method according to claim 6, characterized in that the target string data is obtained by the MES analyzing the first business data of the target work station, the first business data is obtained based on second business data, and the second business data is business data obtained by the first PLC from a second PLC corresponding to the target work station.

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 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 device for the automatic transfer of the aforementioned winding package is: A monitoring module for monitoring whether the control button of the first PLC is in offline mode and the control button of the second PLC corresponding to the target work station is in online mode, If the control button of the first PLC is in offline mode and the control button of the second PLC corresponding to the target work station is in online mode, and the first PLC generates transfer instruction information for the target work station, the system includes a first control module for storing offline data in an offline buffer area. A control device for the automatic transfer of a wound yarn package, characterized in that 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, and the transfer instruction information is a transfer permission.

10. 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 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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