Yarn Spindle Station-Passing Control With Offline PLC Data Caching
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Solution Overview
Problem
The challenge in chemical fiber production is the inefficient station-passing of yarn spindles, which acts as a bottleneck in improving output capacity due to the need for rapid and smooth flow through production stations.
Innovation Solution
A system involving a Manufacturing Execution System (MES), a first Programmable Logic Controller (PLC), and multiple second PLCs, with an intermediate first PLC managing data communication and caching offline station-passing records to ensure seamless operation even in disconnected states, enhancing data synchronization and reducing manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the first PLC operates in offline mode without MES connection, then the production line can continue operating independently, but data synchronization with MES is delayed or lost
Solution Approach 1:
The system performs preliminary actions by storing station-passing records in an offline cache area before MES connection is lost. This allows data to be preserved and synchronized later when connection is restored, preventing information loss while maintaining production continuity during offline operation
Solution Approach 2:
The offline cache area acts as an intermediary storage between the first PLC and MES. It temporarily holds station-passing records when MES is unavailable, enabling data to be buffered and transferred later, thus resolving the conflict between offline operation and data synchronization
2Productivity
If manual intervention is used for station-passing control, then system complexity is reduced, but production efficiency and accuracy decrease
Solution Approach 1:
The system implements self-service by enabling the first PLC to automatically generate station-passing indication information and manage offline caching without manual intervention. This automated approach improves productivity while the modular design keeps complexity manageable through clear separation of functions
3Measurement precision
If the first PLC continuously synchronizes data with MES, then data accuracy is maintained, but system response time during disconnection increases
Solution Approach 1:
The system uses periodic action by implementing conditional synchronization - data is synchronized with MES during connection, and automatically transferred from offline cache when connection is restored. This periodic synchronization approach maintains data accuracy while minimizing time loss during disconnection periods
Data Source
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AI summary
Provided are a method and apparatus for controlling automatic station-passing of a yarn spindle, an electronic device and a storage medium, relating to the technical field of chemical fiber intelligent manufacturing. The method includes: monitoring (S201) whether a control button of a first PLC is in an offline mode and whether a control button of a second PLC corresponding to a target station is in an online mode; and storing (S202) offline data to an offline cache area if the first PLC generates station-passing indication information for the target station, responsive to determining that the control button of the first PLC is in the offline mode and the control button of the second PLC corresponding to the target station is in the online mode.