Yarn Spindle Station-Passing Control via PLC-MES Mediation
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Solution Overview
Problem
The challenge in chemical fiber production is the inefficient and inconsistent station-passing of yarn spindles, which affects overall production pace and efficiency, leading to bottlenecks and increased manual intervention.
Innovation Solution
A system involving a Manufacturing Execution System (MES), a first Programmable Logic Controller (PLC), and multiple second PLCs, where the first PLC acts as an intermediate layer to manage data exchange, reducing direct communication load on the MES and enhancing centralized control, ensuring accurate and efficient station-passing of yarn spindles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the MES directly manages data exchange with multiple second PLCs, then centralized control is achieved, but the communication load on the MES increases and efficiency decreases
Solution Approach 1:
The patent introduces a first PLC as an intermediary layer between the MES and multiple second PLCs. The first PLC receives data from second PLCs, processes it according to preset rules to generate first operational data, and then communicates with the MES. This mediator approach distributes the communication load from the MES to the first PLC, reducing the MES burden while maintaining centralized control through the hierarchical structure.
2Productivity
If manual intervention is used for station-passing control, then flexibility is maintained, but errors increase and efficiency decreases
Solution Approach 1:
The system implements automatic station-passing control where the first PLC autonomously processes operational data from multiple second PLCs, generates first operational data, and communicates with the MES without requiring manual intervention. The second PLCs automatically execute station-passing tasks based on control instructions from the first PLC, enabling the system to self-manage the station-passing process, thereby improving both efficiency and reducing human error.
3Measurement precision
If data processing is centralized at the MES level, then control accuracy is maintained, but processing time increases
Solution Approach 1:
The patent segments the data processing function into two levels: the first PLC handles preliminary data collection and processing from multiple second PLCs, generating first operational data locally; the MES then processes this consolidated data to generate control instructions. This segmentation reduces the amount of data the MES must process directly, thereby reducing processing time while maintaining accuracy through the structured data flow and preset processing rules at the first PLC level.
Data Source
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AI summary
Provided are a method and apparatus for controlling automatic station-passing of yarn spindle, and a storage medium, relating to the technical field of chemical fiber intellectualization. The method includes: obtaining (S201), by a first PLC, second operational data of a target station from a second PLC corresponding to the target station, and obtaining first operational data of the target station according to the second operational data; sending (S202), by the first PLC, the first operational data to an MES and receiving station-passing indication information determined by the MES based on the first operational data for the target station; and parsing (S203), by the first PLC, the station-passing indication information to obtain a parsing result and returning the parsing result to the second PLC corresponding to the target station, so that the second PLC controls the target station based on the parsing result to execute a yarn spindle station-passing task.