CN109144006B - Real-time acquisition system for product quality data on production line - Google Patents
Real-time acquisition system for product quality data on production line Download PDFInfo
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Abstract
The invention discloses a real-time acquisition system of product quality data on a production line, which comprises a production management layer, a data acquisition layer and an object identification layer, wherein a signal end of the production management layer is connected with an industrial Ethernet through a wireless network, an output end of the production management layer is interactively connected with the data acquisition layer, the signal end of the data acquisition layer is interactively connected with the object identification layer, a terminal controller is arranged in the data acquisition layer, the signal end of the terminal controller is connected with a reader-writer and a bar code gun, an interactive port of the production management layer is connected with a cloud service platform, the system realizes the functions of visualization and transparence of the production process, meets the requirements of lean production on the real-time property and the accuracy of production site data, can effectively acquire the production data required by site monitoring in time and provides data support for upper-layer application and site management, and the synchronization of logistics and information flow is realized.
Description
Technical Field
The invention relates to the field of data real-time acquisition systems, in particular to a product quality data real-time acquisition system on a production line.
Background
At present, the barcode technology is the most mature and extensive identification technology. The barcode technology appeared in the 40 th century of the 20 th century, and started to be applied to the industrial field in the seventh and eighty years of the last century, and has been widely applied to material identification in the assembly manufacturing industry to the development so far, and has quite high technical maturity. The success rate of the first reading is more than 98 percent, the error rate of the reading is about one millionth, and the identification technology has the advantages of low cost, high information acquisition speed, high reading accuracy and wide application range.
Under a lean production mode, a bar code technology is introduced to a production field for producing element marks (bar code paper with element information printed is attached to object articles such as products in process, parts and finished products), bar codes are scanned by a bar code gun in the production process to obtain detailed production element data, the data are analyzed, the state of the production field and the assembly condition of the products are mastered, the production flow of each product can be tracked and recorded by utilizing the bar code technology, a product full life cycle tracking monitoring system is assisted to be established, a bottleneck link influencing the production process and restricting the assembly quality is found. And through the integration and statistical analysis of production data, bases are provided for planning, production scheduling and the like.
For example, the patent application No. 201710855286 discloses an invention patent for a cover glass production line product quality real-time monitoring system and method:
the production line robot and the intelligent equipment are monitored and controlled by the display module, a three-dimensional omnibearing intelligent visual workshop model is established, industrialization and informatization are tightly combined, effective and real-time industrial information internet is established, manufacturing becomes a production field informatization, visualization, precision and ecological intelligent manufacturing mode capable of fully acquiring manufacturing progress, field operation, quality inspection, equipment state and the like, data integration and analysis are realized with a workshop manufacturing execution system, and advanced control and real-time monitoring based on the model are realized in a key production link.
However, the existing real-time acquisition system for product quality data on the production line has the following defects:
(1) at present, the automatic identification of mass production elements and the real-time data acquisition in a lean production mode are not enough due to the limitation of the defects of the bar code: the industrial production environment is severe, and the bar code is easily damaged by oil stain pollution, scratch of hard and sharp articles, erosion of high-temperature and high-humidity air and the like, so that the bar code is caused to fall off, deform or stain, and the bar code information reading success rate and accuracy rate are reduced linearly;
(2) the bar code reading condition is harsh, close-range scanning is required within a short visual range, manual participation is often required, the workload of assembly workers is increased, and the reliability, real-time performance and accuracy of information acquisition are influenced;
(3) the information storage capacity of the bar code label is small, the bar code printer needs to be arranged in a complicated manufacturing process, and data are solidified after the bar code is manufactured, so that the data cannot be added and modified at will in the production process, and real-time data generated in the production process cannot be recorded.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides a real-time product quality data acquisition system on a production line, which can effectively solve the problems in the background art.
The technical scheme adopted by the invention for solving the technical problems is as follows:
the system comprises a production management layer, a data acquisition layer and an object identification layer, wherein a signal end of the production management layer is connected with an industrial Ethernet through a wireless network, an output end of the production management layer is interactively connected with the data acquisition layer, the signal end of the data acquisition layer is interactively connected with the object identification layer, a terminal controller is arranged inside the data acquisition layer, a signal end of the terminal controller is connected with a reader-writer and a bar code gun, and an interactive port of the production management layer is connected with a cloud service platform.
Furthermore, a server is arranged inside the production management layer, a management terminal is interactively connected with a signal end of the server, and the signal end of the server is interactively connected with a cloud service platform.
Furthermore, a radio frequency identification system is arranged inside the data acquisition layer, a data acquisition card is arranged inside the radio frequency identification system, a command end of the data acquisition card is connected with a radio frequency controller, an input end of the radio frequency controller is connected with a radio frequency module, a signal end of the radio frequency module is connected with an antenna, and an output end of the radio frequency controller is interactively connected with a driving module.
Furthermore, the output end of the radio frequency controller is interactively connected with an electronic tag, a receiving antenna is arranged inside the electronic tag, the output end of the receiving antenna is connected with a storage through a control chip, an interactive port of the storage is connected with an encoder, and the output end of the encoder is connected with the receiving antenna through a modulator.
Furthermore, a signal end of the server is connected with a server cluster, a data server and a management server are arranged inside the server cluster, the signal end of the data server is connected with a first node of the server, the signal end of the first node of the server is interactively connected with a second node of the server, a signal output end of the management server is interactively connected with a special inspection acquisition point through a wireless access point, the signal end of the special inspection acquisition point is interactively connected with a wireless receiving node, an input end of the wireless receiving node is interactively connected with a wireless transmission module, and a signal input end of the wireless transmission module is interactively connected with a digital caliper.
Furthermore, a cloud computing service cluster is arranged inside the cloud service platform, a signal end of the cloud computing service cluster is interactively connected with a hybrid cloud storage, an output end of the cloud computing service cluster is interactively connected with a cloud platform supporting environment platform through a polymorphic cloud network, and a signal end of the cloud platform supporting environment platform is interactively connected with a heterogeneous database.
Further, a radio frequency module is interactively connected to a signal end of the heterogeneous database.
Further, the object identification layer comprises a microcontroller and an Ethernet controller, signal ends of the microcontroller are connected with the Ethernet controller in an interactive mode, signal ends of the Ethernet controller are connected with the production management layer through an Ethernet transmission network, and signal ends of the microcontroller are connected with a human-computer interaction platform in an interactive mode.
Compared with the prior art, the invention has the beneficial effects that:
(1) the real-time product quality data acquisition system on the production line realizes the visualization and transparentization functions of the production process, meets the requirements of lean production on the real-time property and the accuracy of production field data, can effectively acquire the production data required by field monitoring in time, provides data support for upper-layer application and field management, and realizes the synchronization of logistics and information flow;
(2) the system for acquiring the product quality data on the production line in real time collects relevant state information of each production element on a manufacturing site in real time by relying on an information fusion interaction platform built by an object identification layer and a data acquisition layer, creates a visual monitoring interface in the production process and realizes transparent management on the production site;
(3) the real-time product quality data acquisition system on the production line adopts a time-series friendly data structure, provides high-speed read-write performance and microsecond-level resolution, greatly reduces a large number of data points without additional values occupying disk space, and meets the requirement of mass data access processing on storage efficiency.
Drawings
FIG. 1 is a schematic view of the overall structure of the present invention;
FIG. 2 is a schematic diagram of a production management layer module according to the present invention;
FIG. 3 is a schematic view of a data acquisition layer module of the present invention;
fig. 4 is a schematic diagram of a cloud service platform module according to the present invention.
Reference numbers in the figures:
1-production management layer; 2-a data acquisition layer; 3-an object recognition layer; 4-industrial ethernet; 5-a cloud service platform;
101-a server; 102-a management terminal; 103-server cluster; 104-a management server; 105-a data server; 106-a server first node; 107-a server second node; 108-digital display calipers; 109-a wireless receiving node; 110-spot collection; 111-a wireless transmission module;
201-terminal controller; 202-bar code gun; 203-a reader-writer; 204-a radio frequency identification system; 205-data acquisition card; 206-a radio frequency controller; 207-a drive module; 208-a radio frequency module; 209-antenna; 210-an electronic tag; 211-a control chip; 212-a receiving antenna; 213-a modulator; 214-an encoder; 215-a memory;
301-a microcontroller board; 302-a human-computer interaction platform; 303-ethernet controller;
501-cloud computing service cluster; 502-polymorphic cloud network; 503-a cloud platform support environment platform; 504-hybrid cloud storage; 505-heterogeneous databases.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
As shown in fig. 1 to 4, the present invention provides a real-time product quality data acquisition system on a production line, which includes a production management layer 1, a data acquisition layer 2 and an object identification layer 3, and is characterized in that: the signal end of the production management layer 1 is connected with an industrial Ethernet 4 through a wireless network, the output end of the production management layer 1 is interactively connected with a data acquisition layer 2, the signal end of the data acquisition layer 2 is interactively connected with an object recognition layer 3, a terminal controller 201 is arranged inside the data acquisition layer 2, the signal end of the terminal controller 201 is connected with a reader-writer 203 and a bar code gun 202, the interactive port of the production management layer 1 is connected with a cloud service platform 5, a server 101 is arranged inside the production management layer 1, the signal end of the server 101 is interactively connected with a management terminal 102, and the signal end of the server 101 is interactively connected with the cloud service platform 5.
In this embodiment, the data acquisition layer 2 is composed of a data acquisition device and a terminal controller, and is a channel for exchanging production field data with production management layer information, and mainly realizes acquisition, fusion and transmission of production real-time information, the terminal controller realizes real-time information exchange with an upper management system through a communication network, uploads the field acquired data to the production management system, receives an instruction of the upper system, and controls the data acquisition device such as a reader-writer and a bar gun to work through a communication port, so that in order to realize automatic identification and remote reading and writing of the RFID electronic tag with the least cost and the optimal effect, the field environment and antenna configuration need to be fully considered, and a reasonable and appropriate position is selected to arrange information acquisition points.
In this embodiment, the production management layer 1 is a realization layer of an assembly process monitoring management function, and collects relevant state information of each production element in a manufacturing field in real time by relying on an information fusion interaction platform built by an object identification layer and a data acquisition layer, creates a visual monitoring interface of a production process, and realizes transparent management of the production field.
The data acquisition layer 2 is internally provided with a radio frequency identification system 204, the radio frequency identification system 204 is internally provided with a data acquisition card 205, a command end of the data acquisition card 205 is connected with a radio frequency controller 206, an input end of the radio frequency controller 206 is connected with a radio frequency module 208, a signal end of the radio frequency module 208 is connected with an antenna 209, and an output end of the radio frequency controller 206 is interactively connected with a driving module 207.
The output end of the radio frequency controller 206 is interactively connected with an electronic tag 210, a receiving antenna 212 is arranged inside the electronic tag 210, the output end of the receiving antenna 212 is connected with a memory 215 through a control chip 211, an interactive port of the memory 215 is connected with an encoder 214, and the output end of the encoder 214 is connected with the receiving antenna 212 through a modulator 213.
In this embodiment, data in an agreed format can be written in a data storage area in a tag of a product body, and the tag is bound to a marker and used as an electronic identifier of a target object; the reader-writer 203 is an information interaction device for reading and writing label data, can remotely and automatically read and write the label data, can simultaneously operate a plurality of labels for reading and writing, and interacts with the data management system through a communication network so as to complete the identification, reading and writing, decoding and management of the electronic label; the data management system is an information interaction channel between the acquired tag data and the upper management system, and the data management system mainly performs data reading and writing operations on the tag through a reader and completes primary processing of field data such as integration, storage, management and the like of the tag data information.
In this embodiment, the rfid system 204 utilizes a bidirectional communication technology of wireless wave energy to perform non-contact communication, and realizes wireless connection between the electronic tag and the reader/writer through the coupling element, and transmits energy and data according to the time sequence, thereby realizing the functions of automatic identification and data exchange of the electronic tag by the reader/writer.
The signal end of the server 101 is connected with a server cluster 103, a data server 105 and a management server 104 are arranged inside the server cluster 103, the signal end of the data server 105 is connected with a first server node 106, the signal end of the first server node 106 is interactively connected with a second server node 107, the signal output end of the management server 104 is interactively connected with a special inspection acquisition point 110 through a wireless access point, the signal end of the special inspection acquisition point 110 is interactively connected with a wireless receiving node 109, the input end of the wireless receiving node 109 is interactively connected with a wireless transmission module 111, and the signal input end of the wireless transmission module 111 is interactively connected with a digital caliper 108.
The cloud service platform 5 is internally provided with a cloud computing service cluster 501, a signal end of the cloud computing service cluster 501 is interactively connected with a hybrid cloud storage 504, an output end of the cloud computing service cluster 501 is interactively connected with a cloud platform supporting environment platform 503 through a polymorphic cloud network 502, a signal end of the cloud platform supporting environment platform 503 is interactively connected with a heterogeneous database 505, and a signal end of the heterogeneous database 505 is interactively connected with a radio frequency module 208.
In this embodiment, the cloud service platform 5 provides basic cloud environments such as computing, storage, and networks of the cloud service platform, and forms a quality data set to be input to the core service layer to drive the core service after the quality data is subjected to data cleaning by the technical tool layer ETL (extract-transform-load) in the modes of a sensor, an RFID, an intelligent cloud terminal, and the like.
In this embodiment, the cloud service platform 5 is internally provided with a real-time database and a high-level historical database, which are respectively oriented to data real-time recording and data processing and storage, the real-time database system meets the requirements of manufacturing real-time data on characteristics such as real-time performance, complexity, visibility, temporal consistency, data instantaneity, irreversibility and the like, can provide correct and timely data response for real-time applications (such as control feedback, real-time early warning and the like which are common in quality management), and ensures that possible quality problems are killed in a sprouting state, the high-level historical database technology adopts a time-series friendly data structure, provides high-speed read-write performance and microsecond-level resolution, greatly reduces a large number of non-added-value data points occupying a disk space, and meets the requirement of mass data access processing on storage efficiency.
The object identification layer 3 comprises a microcontroller 301 and an Ethernet controller 303, the signal end of the microcontroller 301 is interactively connected with the Ethernet controller 303, the signal end of the Ethernet controller 303 is connected with the production management layer 1 through an Ethernet transmission network, and the signal end of the microcontroller 301 is interactively connected with a human-computer interaction platform 302.
In this embodiment, the object recognition layer 3 is a basis for realizing visualization and transparency of the production process. The layer has the function of automatically identifying related production elements so as to meet the requirements of lean production on real-time performance and accuracy of production site data, organically combines the RFID electronic tag and the bar code on the basis of fully considering management requirements and implementation cost, selects proper production elements for identification, effectively collects production data required by site monitoring in time, provides data support for upper-layer application and site management, and realizes synchronization of logistics and information flow.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein. Any reference sign in a claim should not be construed as limiting the claim concerned.
Claims (1)
1. The utility model provides a real-time collection system of product quality data on production line, includes production management layer (1), data acquisition layer (2) and object recognition layer (3), its characterized in that: the signal end of the production management layer (1) is connected with an industrial Ethernet (4) through a wireless network, the output end of the production management layer (1) is interactively connected with a data acquisition layer (2), the signal end of the data acquisition layer (2) is interactively connected with an object recognition layer (3), a terminal controller (201) is arranged inside the data acquisition layer (2), the signal end of the terminal controller (201) is connected with a reader-writer (203) and a bar code gun (202), an interactive port of the production management layer (1) is connected with a cloud service platform (5), a cloud computing service cluster (501) is arranged inside the cloud service platform (5), the signal end of the cloud computing service cluster (501) is interactively connected with a mixed cloud storage (504), the output end of the cloud computing service cluster (501) is interactively connected with a cloud platform supporting environment platform (503) through a multi-state cloud network (502), a signal end of the cloud platform supporting environment platform (503) is interactively connected with a heterogeneous database (505), a signal end of the heterogeneous database (505) is interactively connected with a radio frequency module (208), the object identification layer (3) comprises a microcontroller (301) and an Ethernet controller (303), the signal end of the microcontroller (301) is interactively connected with the Ethernet controller (303), the signal end of the Ethernet controller (303) is connected with the production management layer (1) through an Ethernet transmission network, the signal end of the microcontroller (301) is interactively connected with a human-computer interaction platform (302), a server (101) is arranged in the production management layer (1), the signal end of the server (101) is interactively connected with a management terminal (102), the signal end of the server (101) is interactively connected with the cloud service platform (5), and a radio frequency identification system (204) is arranged in the data acquisition layer (2), the RFID system comprises a radio frequency identification system (204), a data acquisition card (205) is arranged in the radio frequency identification system (204), a command end of the data acquisition card (205) is connected with a radio frequency controller (206), an input end of the radio frequency controller (206) is connected with a radio frequency module (208), a signal end of the radio frequency module (208) is connected with an antenna (209), an output end of the radio frequency controller (206) is interactively connected with a driving module (207), an output end of the radio frequency controller (206) is interactively connected with an electronic tag (210), a receiving antenna (212) is arranged in the electronic tag (210), an output end of the receiving antenna (212) is connected with a memory (215) through a control chip (211), an interactive port of the memory (215) is connected with an encoder (214), and an output end of the encoder (214) is connected with the receiving antenna (212) through, the signal end of the server (101) is connected with a server cluster (103), a data server (105) and a management server (104) are arranged inside the server cluster (103), the signal end of the data server (105) is connected with a first server node (106), the signal end of the first server node (106) is interactively connected with a second server node (107), the signal output end of the management server (104) is interactively connected with a special detection acquisition point (110) through a wireless access point, the signal end of the special detection acquisition point (110) is interactively connected with a wireless receiving node (109), the input end of the wireless receiving node (109) is interactively connected with a wireless transmission module (111), and the signal input end of the wireless transmission module (111) is interactively connected with a digital caliper (108).
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| CN110989525B (en) * | 2019-12-09 | 2023-06-30 | 北京航空航天大学 | FPGA-based product intelligent assembly production line monitoring system and method |
| CN113204218B (en) * | 2021-04-12 | 2022-04-19 | 广州泰尔智信科技有限公司 | Intelligent manufacturing control unit |
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