CN114781661A - Fault management method, system, equipment and storage medium for automatic production line - Google Patents
Fault management method, system, equipment and storage medium for automatic production line Download PDFInfo
- Publication number
- CN114781661A CN114781661A CN202210310107.0A CN202210310107A CN114781661A CN 114781661 A CN114781661 A CN 114781661A CN 202210310107 A CN202210310107 A CN 202210310107A CN 114781661 A CN114781661 A CN 114781661A
- Authority
- CN
- China
- Prior art keywords
- fault
- equipment
- alarm
- information
- abnormal
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Images
Classifications
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q10/00—Administration; Management
- G06Q10/20—Administration of product repair or maintenance
-
- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
- G06Q50/00—Systems or methods specially adapted for specific business sectors, e.g. utilities or tourism
- G06Q50/04—Manufacturing
-
- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B25/00—Alarm systems in which the location of the alarm condition is signalled to a central station, e.g. fire or police telegraphic systems
- G08B25/01—Alarm systems in which the location of the alarm condition is signalled to a central station, e.g. fire or police telegraphic systems characterised by the transmission medium
- G08B25/08—Alarm systems in which the location of the alarm condition is signalled to a central station, e.g. fire or police telegraphic systems characterised by the transmission medium using communication transmission lines
-
- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B31/00—Predictive alarm systems characterised by extrapolation or other computation using updated historic data
Abstract
The invention provides a fault management method, a system, equipment and a storage medium of an automatic production line. The fault management method of the automatic production line comprises the following steps: step S1: and monitoring the real-time fault condition of the automatic production line. Step S2: and (5) counting historical fault information of the automatic production line. Step S3: and counting the fault alarm trend of the automatic production line according to the historical fault information. Step S4: according to the fault alarm trend, one or more of alarm information of a line body in a workshop, alarm information of stations, alarm information of equipment and alarm information of equipment types are counted respectively to obtain corresponding fault counting results, and the fault counting results are pushed to a user. In the fault management method, the working state condition of each device can be determined by counting the alarm trend. For the equipment with failure frequency or failure accumulated duration continuously increased, a user can be informed to increase troubleshooting patrol work so as to reduce the failure frequency of the equipment.
Description
Technical Field
The invention belongs to the technical field of flexible manufacturing, and particularly relates to a fault management method, a fault management system, equipment and a storage medium of an automatic production line.
Background
With the development of science and technology, the integration level and complexity of modern automatic production line equipment are increased day by day, and the maintenance cost and difficulty brought by the modern automatic production line equipment are also increased dramatically; the inefficient and costly conventional manual maintenance method is no longer applicable in the face of the large number of complex automated production line equipment. A fault management system needs to be built for an automatic production line so as to implement real-time fault monitoring on equipment on the automatic production line, and thus find and solve faults in time.
However, the existing fault management system of the automatic production line usually only sends the corresponding fault type, the corresponding fault equipment number, and the like to the main control center, and lacks the application of performing integration statistics or predictive analysis on fault information, and cannot provide an effective fault information management function for users.
Disclosure of Invention
In order to overcome the defects of the prior art, the invention provides a fault management method, a fault management system, equipment and a storage medium of an automatic production line, so as to solve the problem that the fault management system in the prior art lacks the application of integrating statistics or predictive analysis on fault information and cannot provide an effective fault information management function for a user.
One embodiment of the invention provides a fault management method of an automatic production line, which comprises the following steps:
step S1: monitoring real-time fault conditions of an automatic production line;
step S2: counting historical fault information of the automatic production line;
step S3: counting the fault alarm trend of the automatic production line according to historical fault information; and
step S4: according to the fault alarm trend, one or more of alarm information of a line body in a workshop, alarm information of stations, alarm information of equipment types and alarm information of equipment are counted respectively to obtain corresponding fault counting results, and the fault counting results are pushed to a user.
In one embodiment, the fault management method includes the following fault recording procedures:
the collector receives the fault signal to trigger newly added fault information, and the fault timing is started;
pushing the fault information to a user;
after fault processing is carried out, the collector receives fault clearing and automatic equipment operation signals to jointly trigger fault ending information, and fault timing is ended;
and analyzing the fault treatment.
In one embodiment, the process of analyzing the failure process includes:
judging whether the fault processing record needs to be put in storage:
if so, manually compiling the fault processing process information into fault information to form fault record information, and then storing the fault record information into a database; if not, directly storing the fault information into a database;
and/or the fault information comprises a line body, a station, an equipment type, equipment, fault starting time and fault ending time;
and/or the fault record information comprises a line body, a station, an equipment type, equipment, fault starting time, fault ending time, a maintenance person, a fault phenomenon, a fault processing process, a fault reason, a field picture and fault follow-up solution information.
In one embodiment, step S1 specifically includes the following steps:
constructing an equipment layout according to the equipment plane layout position;
displaying real-time fault conditions of equipment; and
and displaying the change of the running state of the equipment.
In one embodiment, displaying real-time failure conditions of a device includes displaying one or more of:
the alarm equipment number is used for helping maintenance personnel to find out the fault alarm equipment in time;
the alarm number is used for helping maintenance personnel to find out a maintenance guide document corresponding to the alarm number in time;
the alarm content is used for displaying the specific fault content of the corresponding equipment;
the alarm time is used for displaying the equipment failure occurrence time;
and the current alarm accumulated time length is used for displaying the current duration from the fault of the equipment.
In one embodiment, the operation state change of the display device is displayed by the change of a frame with different colors, wherein the color frame comprises:
the first color frame is used for indicating that the equipment is in a fault state;
the second color frame is used for indicating that the equipment is in an automatic cycle running state;
and the third color frame is used for indicating that the equipment is in a material waiting state in an automatic cycle or in a manual control state.
In one embodiment, step S2 includes the following steps:
querying historical fault information of corresponding equipment in the historical fault records according to the limiting conditions;
and deriving historical fault information of the inquired equipment.
In one embodiment, step S3 includes the following steps:
counting the accumulated fault time of each line body in the workshop;
counting the failure times of each line body in the workshop;
counting the fault duration of each line in a workshop in a plurality of time units to obtain the alarm trend of the line;
and/or counting the failure times of each line body in the workshop in a plurality of time units to obtain the line body alarm trend.
In one embodiment, the failure statistics process of step S4 is as follows:
analyzing alarm information of a line body in a workshop to obtain an abnormal line body;
analyzing alarm information of stations in the abnormal line body to obtain abnormal stations;
analyzing alarm information of equipment in an abnormal station to obtain abnormal equipment;
and/or analyzing the alarm information of the workshop according to the same equipment type to obtain the type of the abnormal equipment.
In one embodiment, the process of analyzing the alarm information of the in-plant line body comprises the following steps:
counting the fault frequency, the fault accumulated time, the duty ratio of the fault duration of each category and the duty ratio of the fault frequency of each category of each line in the workshop;
counting the fault duration or fault frequency of the line body by time units, and when the counted fault duration or fault frequency of the line body is increased progressively in a plurality of time units, determining that the line body is an abnormal line body;
and obtaining the long-stop abnormal reason type of the abnormal line body according to the fault time length ratio or fault frequency ratio of each type.
In one embodiment, the process of analyzing the alarm information of the workstation in the wire body comprises the following steps:
counting the failure frequency, the failure accumulated time, the occupation ratio of the failure time length of each category and the occupation ratio of the failure frequency of each category of each station in the line body;
counting the fault duration or the fault frequency of the station by time units, and when the counted fault duration or the counted fault frequency of the station is increased progressively in a plurality of time units, determining the station as an abnormal station;
and obtaining the long-stop abnormal reason type of the abnormal station according to the fault time length proportion or the fault frequency proportion of each type.
In one embodiment, the process of analyzing the alarm information of the equipment in the station comprises the following steps:
counting the failure frequency, the failure accumulated time, the occupation ratio of the failure time length of each category and the occupation ratio of the failure frequency of each category of each equipment in the station;
counting the fault duration or fault frequency of the equipment by time units, and when the counted fault duration or fault frequency of the equipment is increased progressively in a plurality of time units, determining the equipment as abnormal equipment;
and obtaining the long-stop abnormal reason category of the abnormal equipment according to the fault time length ratio or the fault frequency ratio of each category.
One embodiment of the present invention further provides a fault management system for an automatic production line, which can be used to implement the fault management method in any one of the embodiments, including:
the fault monitoring module is used for monitoring the real-time fault condition of the automatic production line;
the fault counting module is used for counting historical fault information of the automatic production line;
the fault analysis module is used for analyzing historical fault information to obtain a fault alarm trend of the automatic production line;
and the alarm information statistics module is used for respectively counting one or more of in-plant line body alarm information, station alarm information, equipment alarm information and equipment type alarm information according to the fault alarm trend to obtain a corresponding fault statistics result, and pushing the fault statistics result to a user.
In one embodiment, the alarm information statistical module comprises a line body alarm statistical unit, a station alarm statistical unit, an equipment alarm statistical unit and an equipment type alarm statistical unit;
the line body alarm statistical unit is used for counting the fault frequency, the fault accumulated time, the occupation ratio of fault duration of each category and the occupation ratio of fault frequency of each category of each line body in the workshop; obtaining the abnormal or bottleneck line body and the long-term stopping abnormal reason category;
the station alarm statistical unit analyzes the fault of the abnormal line body obtained by the line body alarm statistical unit, and counts the fault frequency, fault accumulated time, fault duration ratio of each category and fault frequency ratio of each category of each station in the line body to obtain the abnormal or bottleneck station and long-stop abnormal reason category;
the equipment alarm statistical unit analyzes the fault of the abnormal station obtained by the station alarm statistical unit, and counts the fault frequency, fault accumulated time, fault duration ratio of each category and fault frequency ratio of each category of the single equipment in the station to obtain the abnormal or bottleneck equipment and the reason category of the long-stop abnormal;
the equipment type alarm statistical unit counts the fault frequency, the fault accumulated time, the proportion of the fault duration of each type and the proportion of the fault frequency of each type of equipment in the workshop to obtain the type of abnormal or bottleneck equipment and the type of reasons of long-term shutdown abnormality.
One embodiment of the present invention further provides a fault management device, including:
at least one processor; and
a memory communicatively coupled to the at least one processor; wherein the memory has stored thereon instructions executable by at least one processor, the instructions being executable by the at least one processor to enable the at least one processor, when executing, to implement a fault management method as in any one of the above embodiments.
One embodiment of the present invention further provides a computer storage medium, on which an application program of a fault management device is stored, and the application program of the fault management device implements the steps of the fault management method according to any one of the above embodiments when being processed and executed.
The fault management method, system, device and storage medium for the automatic production line provided by the above embodiments of the present invention have the following beneficial effects:
1. in the fault management method for the automatic production line provided by the above embodiment, historical fault information of the automatic production line is counted by monitoring a real-time fault condition of the automatic production line, a fault alarm trend of the automatic production line is counted according to the fault information, one or more of alarm information of a line body in a workshop, alarm information of a station, alarm information of a device type and alarm information of a device can be respectively counted according to the historical fault alarm trend to obtain a corresponding fault statistical result, and the fault statistical result is pushed to a user, so that the user can conveniently strengthen fault troubleshooting and inspection on an abnormal line body, station, device and device type according to the fault statistical result.
2. In the fault management method for the automatic production line provided by the above embodiment, the production line is divided into the equipment modules, the equipment layout is constructed according to the plane layout position of the equipment, and then the fault condition of each equipment is displayed on the equipment layout in real time, so that the position of the fault equipment is visually displayed, a manager can monitor the current running condition of each equipment in real time, and the management efficiency is improved.
3. In the fault management method for an automatic production line provided in the above embodiment, the operating state of each device may be determined by counting the trend of the alarm. For the equipment with failure frequency or failure accumulated duration continuously increased, a user can be informed to increase troubleshooting patrol work so as to reduce the failure frequency of the equipment.
Drawings
In order to more clearly illustrate the embodiments or technical solutions of the present invention, the drawings used in the embodiments or technical solutions of the prior art will be briefly described below, it is obvious that the drawings in the following description are only some embodiments of the present invention, and for those skilled in the art, other drawings can be obtained according to the structures shown in the drawings without creative efforts.
Fig. 1 is a schematic flow chart illustrating a fault management method for an automatic production line according to an embodiment of the present invention;
FIG. 2 is a schematic diagram illustrating a fault recording process of an automated manufacturing line according to an embodiment of the present invention;
FIG. 3 is a schematic flow chart illustrating the step S1 of monitoring real-time fault conditions of the automation line;
FIG. 4 is a schematic flow chart of the warning information trend generation process of step S3;
fig. 5 is a schematic flow chart of the statistical warning information of step S4;
FIG. 6 is a block diagram of a fault management system for an automated manufacturing line, according to one embodiment of the present invention;
FIG. 7 is a schematic diagram of the alarm information statistics module of FIG. 6;
fig. 8 is a schematic block diagram of a fault management device of an automation line according to an embodiment of the present invention.
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.
It should be noted that if directional indications (such as up, down, left, right, front, and back … …) are involved in the embodiment of the present invention, the directional indications are only used for explaining the relative position relationship between the components, the motion situation, and the like in a specific posture, and if the specific posture is changed, the directional indications are changed accordingly.
In addition, if there is a description relating to "first", "second", etc. in the embodiments of the present invention, the description of "first", "second", etc. is for descriptive purposes only and is not to be construed as indicating or implying relative importance or to implicitly indicate the number of technical features indicated. Thus, a feature defined as "first" or "second" may explicitly or implicitly include at least one of the feature. In addition, if the expression "and/or" and/or "is used throughout, the meaning includes three parallel schemes, for example," A and/or B ", including scheme A, or scheme B, or a scheme satisfying both schemes A and B. In addition, technical solutions between various embodiments may be combined with each other, but must be realized by a person skilled in the art, and when the technical solutions are contradictory or cannot be realized, such a combination should not be considered to exist, and is not within the protection scope of the present invention.
In order to better describe the technical solutions in the present application, some technical terms are explained below:
a wire body: a line body refers to a production line in a plant, and one plant may contain a plurality of production lines.
Station: a production line is divided into a plurality of stations, and each station is a fixed area used for processing a specific process.
Time unit: the time range customized by the user is used as a time unit for fault statistics, the time unit can be defined as every day or every shift according to actual production requirements, wherein the day can be divided into a plurality of shifts, and the number of the shifts and the starting and ending time can be customized by the user.
Referring to fig. 1, an embodiment of the present invention provides a fault management method for an automatic production line, including the following steps:
step S1: monitoring real-time fault conditions of an automatic production line;
step S2: counting historical fault information of the automatic production line;
step S3: counting the fault alarm trend of the automatic production line according to historical fault information; and
step S4: according to the fault alarm trend, one or more of alarm information of a line body in a workshop, alarm information of stations, alarm information of equipment types and alarm information of equipment are counted respectively to obtain corresponding fault counting results, and the fault counting results are pushed to a user.
In the fault management method for the automatic production line provided by the above embodiment, the real-time fault condition of the automatic production line is monitored; counting historical fault information of the automatic production line; and according to the fault information, counting the fault alarm trend of the automatic production line, visually seeing the accumulated fault duration and the accumulated fault times of faults in the workshop, and simultaneously seeing the trend change of daily alarm in the workshop. According to the fault alarm trend, one or more of the alarm information of the workshop, the alarm information of the line body, the alarm information of the station, the alarm information of the equipment type and the alarm information of the equipment are counted respectively to obtain a corresponding fault counting result, and the fault counting result is pushed to a user. When an abnormal line body, an abnormal station, abnormal equipment or an abnormal equipment type is found in the fault statistical result, a message is pushed to a user, and maintenance personnel can conveniently strengthen troubleshooting and routing inspection on the abnormal line body, the abnormal station, the abnormal equipment and the abnormal equipment type according to the fault statistical result.
In one embodiment, the fault management method includes the following fault recording procedures:
the collector receives the fault signal to trigger newly added fault information, and the fault timing is started;
pushing the fault information to a user;
after fault processing is carried out, the collector receives fault clearing and automatic equipment operation signals to jointly trigger fault ending information, and fault timing is ended;
and analyzing the fault treatment.
In the embodiment, the collector communicates with the field equipment in real time, collects all fault signals, triggers new fault information by receiving the fault signals, and starts fault timing; the fault information is pushed to a user, and the user carries out fault processing on fault equipment and stations according to the fault information; when the fault processing is finished, the collector receives the fault zero clearing signal and the equipment automatic operation signal to jointly trigger fault ending information, and the fault timing is ended; and analyzing the fault processing process and judging whether the fault processing information needs to be stored in a database.
In the process of pushing the fault information, the historical fault processing information corresponding to the newly added fault information is found by performing related search on the equipment database, the instruction manual database and the fault record database in the database.
Referring to fig. 2, in one embodiment, the process of analyzing the failure process includes:
judging whether the fault processing record needs to be put in storage:
if so, manually compiling the fault processing process information into fault information to form fault record information, and then storing the fault record information into a database; if not, directly storing the fault information into a database;
and/or the fault information comprises a line body, a station, equipment, an equipment type, fault starting time and fault ending time;
and/or the fault recording information comprises workshop, line body, station, equipment type, fault starting time, fault ending time, maintainer, fault phenomenon, fault processing process, fault reason, field picture and fault follow-up solution information.
In the embodiment, the main purpose of writing the fault processing process information into the fault information is to record important or typical faults on the site so as to check references when the same fault occurs again; the method comprises the steps that whether a fault processing record needs to be put in a warehouse or not is judged by retrieving and comparing newly-added fault information with fault records in a database, when the newly-added fault information can find the same historical fault record in the fault records in the database, the fault processing record does not need to be stored in the database, and the fault information only comprising a line body, stations, equipment types, fault starting time and fault ending time is stored in the database; if the same historical fault record cannot be found in the fault records in the database by the newly added fault information, the fault processing record is judged to need to be stored in the database, the fault record of complete information is manually filled in through a fault record window, and the fault record information comprising workshops, line bodies, stations, equipment types, fault starting time, fault ending time, maintenance personnel, fault phenomena, fault processing processes, fault reasons, field pictures and fault follow-up solution information is stored in the database.
Referring to fig. 3, in one embodiment, step S1 specifically includes the following steps:
constructing an equipment layout according to the equipment plane layout position;
displaying real-time fault conditions of equipment; and
the running state of the display device changes.
Specifically, in this embodiment, customized development or configuration of monitoring content is mainly performed with reference to a planar layout of a customer field device, and a device layout diagram corresponds to a device planar layout position, so that a specific position of a faulty device can be grasped visually, and a maintenance worker can handle the faulty device conveniently; meanwhile, a display area is arranged in an equipment schematic frame in the equipment layout diagram and is used for displaying real-time fault conditions of the equipment; and the outer side of the equipment schematic frame is a variable color frame, and the change of the running state of the equipment is represented by the color change.
In one embodiment, displaying real-time failure conditions of a device includes displaying one or more of:
the alarm equipment number is used for helping maintenance personnel to find out the fault alarm equipment in time;
the alarm number is used for helping maintenance personnel to find a maintenance guide document corresponding to the alarm number in time;
the alarm content is used for displaying the specific fault content of the corresponding equipment;
the alarm time is used for displaying the equipment failure occurrence time;
and the current alarm accumulated time length is used for displaying the current duration of the equipment from the fault.
Specifically, in this embodiment, the apparatus layout includes a line and a station in any workshop of the automatic production line. For example, in an automatic production line, the line bodies include a door line, a top cover line, a main welding 1, a main welding 2, a tool box, a floor line and a side bottom plate; the main welding 1 includes a plurality of stations such as MB200, MB190, MB180, and MB170, and the main welding 2 includes a plurality of stations such as MB020, MB030, MB040, MB050, and MB 060. Suppose that the MB180 is a fault unit, the internal display alarm content of the MB is a robot R1 fault or a system fault, and the accumulated alarm duration is 220 seconds. MB040 is a fault station, the alarm content displayed in the fault station is the fault of the robot R1 or the fault of a system, and the accumulated alarm time is 220 seconds. The production line is divided into the equipment modules, and then the fault conditions of the equipment are displayed in real time, so that a manager can monitor the current running condition of the equipment in real time, and the management efficiency is improved.
In one embodiment, the operation state change of the display device is displayed by the change of a frame with different colors, wherein the color frame comprises:
the first color frame is used for indicating that the equipment is in a fault state;
the second color frame is used for indicating that the equipment is in an automatic cycle running state;
and the third color frame is used for indicating that the equipment is in a material waiting state in an automatic cycle or in a manual control state.
In this embodiment, the first color border indicates that the device is in a failed state. The second color frame indicates that the device is in an automatic loop operation state. The third color frame indicates that the equipment is in a waiting state in an automatic cycle or the equipment is in a manual control state. The specific colors of the first color frame, the second color frame and the third color frame are different, and the first color frame, the second color frame and the third color frame can be freely changed. When the equipment fails, the frame is changed from a second color frame or a third color frame into a first color frame, and the number of the alarm equipment, the current alarm number, the corresponding alarm content and the current alarm accumulated time length are displayed in the equipment indicating frame. After the equipment failure is solved, the equipment alarms and resets, the content such as the serial number of the alarm equipment in the equipment indication frame is small, and the frame is changed from the first color frame to be recovered to a second color frame or a third color frame.
In one embodiment, step S2 includes the following steps:
inquiring historical fault information of corresponding equipment in the historical fault records according to a limited condition;
and deriving historical fault information of the inquired equipment.
In this embodiment, according to any one or more fields of a workshop, a line body, a workstation, equipment, failure start time, failure end time, a maintainer, a failure phenomenon, a failure processing process and a failure reason, the corresponding historical failure information in the historical failure record is searched. And derives the historical failure information of the inquired equipment.
Referring to fig. 4, in one embodiment, step S3 includes the following steps:
counting the accumulated fault time of each line body in the workshop;
counting the failure times of each line body in the workshop;
counting the fault duration of each line body in a workshop in a plurality of time units to obtain the alarm trend of the line body;
and/or counting the failure times of each line body in the workshop in a plurality of time units to obtain the line body alarming trend.
In this embodiment, the accumulated time of faults of each line body in the workshop is counted. And counting the failure times of each line body in the workshop. Obtaining a workshop alarm trend according to the accumulated fault duration and the fault times of each line body in the workshop; and (4) counting the daily fault duration of each line body in the workshop to obtain the line body alarm trend.
Referring to fig. 5, in one embodiment, the fault statistics process of step S4 is as follows:
analyzing alarm information of a line body in a workshop to obtain an abnormal line body;
analyzing alarm information of stations in the abnormal line body to obtain abnormal stations;
analyzing alarm information of equipment in an abnormal station to obtain abnormal equipment;
and/or analyzing the alarm information of the workshop according to the same equipment type to obtain the type of the abnormal equipment.
In this embodiment, the alarm information of the line body in the workshop is analyzed, and an abnormal line body is obtained. And then analyzing the alarm information of the station in the abnormal line body to obtain the abnormal station. And analyzing the alarm information of the equipment type in the abnormal station to obtain the abnormal equipment type. And pushing the message to the user to remind the user that the equipment type has more faults and the troubleshooting and routing inspection work of the equipment type needs to be enhanced.
In one embodiment, the process of analyzing the alarm information of the in-plant line body includes:
counting the failure frequency, the failure accumulated time, the occupation ratio of the failure time length of each category and the occupation ratio of the failure frequency of each category of each line body in the workshop;
counting the fault duration or fault frequency of the line body by time units, and when the counted fault duration or fault frequency of the line body is increased progressively in a plurality of time units, determining that the line body is an abnormal line body;
and obtaining the long-stop abnormal reason type of the abnormal line body according to the proportion of the time length of each type of fault or the proportion of the frequency of each type of fault.
In the embodiment, the failure frequency, the failure accumulation time, the occupation ratio of the failure duration of each category and the occupation ratio of the failure frequency of each category are counted according to each line body in a workshop; counting the fault duration or the fault frequency of a line body by taking days as a unit, and when the counted fault duration or fault frequency of the line body is increased gradually every day within 5 days, determining that the line body is an abnormal line body; and pushing the message and the type of the reason of the long-stop abnormity to a user, and reminding the user that the fault of the line body is more and the troubleshooting and inspection work of the line body needs to be enhanced.
In one embodiment, the process of analyzing the alarm information of the workstation in the wire body comprises the following steps:
counting the failure frequency, the failure accumulated time, the occupation ratio of the failure duration of each category and the occupation ratio of the failure frequency of each category of each station in the line body;
counting the fault duration or the fault frequency of the station by time units, and when the counted fault duration or the counted fault frequency of the station is increased progressively in a plurality of time units, determining the station as an abnormal station;
and obtaining the long-stop abnormal reason category of the abnormal station according to the proportion of the time length of each category of faults or the proportion of the frequency of each category of faults.
In this embodiment, the abnormal line body is subjected to statistical analysis, and the failure frequency, the failure accumulation time, the proportion of the failure duration of each category and the proportion of the failure frequency of each category are counted according to each station in the line body; and counting the fault duration or the fault frequency of the stations by taking days as a unit, and when the counted fault duration or fault frequency of the stations is increased gradually every day within 5 days, determining the stations as abnormal stations, pushing a message and the types of the reasons of the abnormal long-stop to a user, and reminding the user that the line has more faults and the troubleshooting and routing inspection work of the line needs to be enhanced.
In one embodiment, the process of analyzing the alarm information of the equipment in the station comprises the following steps:
counting the failure frequency, the failure accumulated time, the occupation ratio of the failure time length of each category and the occupation ratio of the failure frequency of each category of equipment in a station;
counting the fault duration or fault frequency of the equipment by time units, and when the counted fault duration or fault frequency of the equipment is increased progressively in a plurality of time units, determining the equipment as abnormal equipment;
and obtaining the long-stop abnormal reason type of the abnormal equipment according to the fault time length proportion or the fault frequency proportion of each type.
In this embodiment, statistical analysis is performed on an abnormal workstation, and the failure frequency, the failure accumulated time, the proportion of the failure duration of each category, and the proportion of the failure frequency of each category are counted according to each device in the workstation; and counting the fault duration or the fault frequency of the equipment by taking days as a unit, and when the counted fault duration or fault frequency of the equipment is increased gradually every day within 5 days, judging the equipment as abnormal equipment, pushing the message and the types of the reasons of the abnormal long-stop to a user, and reminding the user that the equipment has more faults and the troubleshooting and routing inspection work of the equipment type needs to be enhanced.
In one embodiment, the process of analyzing the alarm information of the workshop according to the same equipment type comprises the following steps:
counting the fault frequency, the fault accumulated time, the occupation ratio of the fault duration of each category and the occupation ratio of the fault frequency of each category of the same equipment type in a workshop; and counting the fault duration or the fault frequency of the equipment type by a time unit, when the counted fault duration or the counted fault frequency of the equipment is increased gradually every day within 5 days, determining the equipment type as abnormal equipment, pushing a message and the type of a reason for abnormal long stop to a user, and reminding the user that the equipment has more faults and the troubleshooting and inspection work of the equipment type needs to be enhanced.
Referring to fig. 6, an embodiment of the present invention further provides a fault management system 100 of an automatic production line, where the fault management system 100 of the automatic production line includes:
the fault monitoring module 110 is used for monitoring the real-time fault condition of the automatic production line;
a fault statistics module 120, configured to count historical fault information of the automatic production line;
the fault analysis module 130 is used for analyzing historical fault information to obtain a fault alarm trend of the automatic production line;
and the alarm information counting module 140 is used for respectively counting one or more of the in-plant line body alarm information, the station alarm information, the equipment alarm information and the equipment type alarm information according to the fault alarm trend to obtain corresponding fault counting results, and pushing the fault counting results to a user.
In this embodiment, real-time fault conditions of the automation line are monitored by the fault monitoring module 110. The historical fault information of the automatic production line is counted by the fault counting module 120. The historical fault information is analyzed by the fault analysis module 130 to obtain the fault alarm trend of the automatic production line. And analyzing workshop alarm information, line body alarm information and station alarm information in the fault alarm trend through the alarm information statistical module 140 so as to obtain a fault alarm trend statistical result, and when one or more of an abnormal line body, an abnormal station, abnormal equipment or an abnormal equipment type is found in the fault statistical result, pushing a message to a user so as to facilitate maintenance personnel to strengthen troubleshooting and routing inspection on the abnormal line body, the station, the equipment and the equipment type according to the fault statistical result.
Referring to fig. 7, in one embodiment, the alarm information statistics module 140 includes a line body alarm statistics unit 141, a workstation alarm statistics unit 142, an equipment alarm statistics unit 143, and an equipment type alarm statistics unit 144;
the line body alarm statistical unit 141 is used for counting the failure frequency, the failure accumulated time, the proportion of failure duration of each category and the proportion of failure frequency of each category of each line body in the workshop; obtaining the abnormal or bottleneck line body and the reason category of the long-term stopping abnormality;
the station alarm statistical unit 142 analyzes the fault of the abnormal line body obtained by the line body alarm statistical unit 141, and counts the fault frequency, fault accumulated time, fault duration ratio of each category and fault frequency ratio of each category of each station in the line body to obtain the abnormal or bottleneck station and long-stop abnormal reason category;
the equipment alarm statistical unit 143 performs fault analysis on the abnormal station obtained by the station alarm statistical unit 142, and performs statistics on the fault frequency, the fault accumulated time, the duty ratio of the fault duration of each category and the duty ratio of the fault frequency of each category of each single equipment in the station to obtain the categories of the reasons of the abnormal or bottleneck equipment and the long-stop abnormal;
the device type alarm statistical unit 144 calculates the failure frequency, the failure accumulation time, the percentage of the failure duration of each category, and the percentage of the failure frequency of each category of the same device type in the workshop, and obtains the category of the abnormal or bottleneck device and the category of the reason of the long-stop abnormal.
In this embodiment, the line body alarm counting unit 141 counts the failure frequency and the failure cumulative time of each line body in the workshop on a daily basis, and when the failure cumulative time or the failure frequency of the counted line body increases daily within 5 days, the line body is regarded as an abnormal line body. The station alarm statistical unit 142 counts the failure frequency and failure accumulated time of each station of the abnormal line body by taking days as a unit, and when the counted failure accumulated time or failure frequency of the station increases gradually every day within 5 days, the station is regarded as an abnormal station. The equipment alarm statistical unit 143 counts the failure frequency and the failure cumulative time of each equipment type of the abnormal station in units of days, and when the failure cumulative time or the failure frequency of the counted equipment type increases daily within 5 days, the equipment is regarded as abnormal equipment. The information is pushed to the user, so that maintenance personnel can conveniently strengthen troubleshooting and routing inspection on abnormal line bodies, stations and equipment types according to the fault statistical result, and the frequency of fault occurrence or fault accumulated time is reduced.
Furthermore, the equipment type alarm counting unit 144 counts the frequency of faults and the accumulated time of faults of the same equipment type in the workshop by taking days as a unit, obtains the type of abnormal or bottleneck equipment, and provides a data basis for maintenance planning, equipment health management, spare part ordering and the like.
And the category of the long-stop abnormal reasons of the line body, the station, the equipment or the equipment type can be obtained through the duty ratio statistics of the fault time length of each category. The inspection system is favorable for maintenance personnel to maintain the line body, the station, the equipment or the equipment type in the category in a targeted manner in the inspection process.
Referring to fig. 8, an embodiment of the present invention further provides a fault management apparatus 200 for an automation line, where the fault management apparatus 200 for an automation line includes:
at least one processor 210; and
a memory 220 communicatively coupled to the at least one processor 210; wherein the memory 220 stores instructions executable by the at least one processor 210, and the instructions are executed by the at least one processor 210, so that the at least one processor 210 can implement the fault management method according to any one of the above embodiments when executing the instructions. In the present embodiment, the memory 220 has stored thereon a computer program 240. The processor 210 and the memory 220 are connected by a communication bus 230.
One embodiment of the present invention further provides a computer storage medium, on which an application program of a fault management device is stored, and the application program of the fault management device implements the steps of the fault management method according to any one of the above embodiments when being processed and executed.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and all modifications and equivalents of the present invention, which are made by the contents of the present specification and the accompanying drawings, or directly/indirectly applied to other related technical fields, are included in the scope of the present invention.
Claims (16)
1. A fault management method of an automatic production line is characterized by comprising the following steps:
step S1: monitoring real-time fault conditions of an automatic production line;
step S2: counting historical fault information of the automatic production line;
step S3: counting the fault alarm trend of the automatic production line according to historical fault information; and
step S4: according to the fault alarm trend, one or more of alarm information of a line body in a workshop, alarm information of stations, alarm information of equipment types and alarm information of equipment are counted respectively to obtain corresponding fault counting results, and the fault counting results are pushed to a user.
2. The fault management method for an automated production line according to claim 1, wherein the fault management method comprises the following fault recording procedures:
the collector receives the fault signal to trigger newly added fault information, and the fault timing is started;
after fault processing is carried out, the collector receives fault clearing and automatic equipment operation signals to jointly trigger fault ending information, and fault timing is ended;
and analyzing the fault processing.
3. The method for managing faults of an automatic production line according to claim 2, wherein the process of analyzing the fault handling comprises:
judging whether the fault processing record needs to be put in storage:
if so, compiling the fault processing process information into fault information to form fault record information, and then storing the fault record information into a database; if not, directly storing the fault information into a database;
and/or the fault information comprises a line body, a station, an equipment type, equipment, fault starting time and fault ending time;
and/or the fault record information comprises a line body, a station, an equipment type, equipment, fault starting time, fault ending time, a maintenance person, a fault phenomenon, a fault processing process, a fault reason, a field picture and fault follow-up solution information.
4. The method for managing faults in an automatic production line according to claim 1, wherein the step S1 specifically includes the steps of:
constructing an equipment layout according to the equipment plane layout position;
displaying real-time fault conditions of equipment; and
the running state of the display device changes.
5. The method of fault management in an automated manufacturing line according to claim 4, wherein displaying real-time fault conditions of a device includes displaying one or more of:
the alarm equipment number is used for helping maintenance personnel to find out the fault alarm equipment in time;
the alarm number is used for helping maintenance personnel to find out a maintenance guide document corresponding to the alarm number in time;
the alarm content is used for displaying the specific fault content of the corresponding equipment;
the alarm time is used for displaying the equipment failure occurrence time;
and the current alarm accumulated time length is used for displaying the current duration of the equipment from the fault.
6. The method for managing faults of an automatic production line according to claim 4, wherein the change of the operating state of the display device is displayed through the change of a border with different colors, the border with colors comprising:
the first color frame is used for indicating that the equipment is in a fault state;
the second color frame is used for indicating that the equipment is in an automatic cycle running state;
and the third color frame is used for indicating that the equipment is in a material waiting state in an automatic cycle or in a manual control state.
7. The method for managing faults of an automatic production line according to claim 1, wherein the step S2 includes the steps of:
inquiring historical fault information of corresponding equipment in the historical fault records according to a limited condition;
and deriving historical fault information of the inquired equipment.
8. The method for managing faults of an automatic production line according to claim 1, wherein the step S3 includes the steps of:
counting the accumulated fault time of each line body in the workshop;
counting the failure times of each line body in the workshop;
counting the fault duration of each line in a workshop in a plurality of time units to obtain the alarm trend of the line;
and/or counting the failure times of each line body in the workshop in a plurality of time units to obtain the line body alarming trend.
9. The method for managing faults of an automatic production line according to claim 1, wherein the fault statistics process of step S4 is as follows:
analyzing alarm information of a line body in a workshop to obtain an abnormal line body;
analyzing alarm information of stations in the abnormal line body to obtain abnormal stations;
analyzing alarm information of equipment in an abnormal station to obtain abnormal equipment;
and/or analyzing the alarm information of the workshop according to the same equipment type to obtain the type of the abnormal equipment.
10. The method for managing faults of an automatic production line according to claim 9, wherein the process of analyzing the alarm information of the inline body in the plant comprises:
counting the fault frequency, the fault accumulated time, the duty ratio of the fault duration of each category and the duty ratio of the fault frequency of each category of each line in the workshop;
counting the fault duration or fault frequency of the line body by a time unit, and when the counted fault duration or fault frequency of the line body is increased progressively in a plurality of time units, determining that the line body is an abnormal line body;
and obtaining the long-stop abnormal reason type of the abnormal line body according to the fault time length ratio or fault frequency ratio of each type.
11. The method for managing faults of an automatic production line according to claim 9, wherein the process of analyzing alarm information of the internal work stations comprises:
counting the failure frequency, the failure accumulated time, the occupation ratio of the failure time length of each category and the occupation ratio of the failure frequency of each category of each station in the line body;
counting the fault duration or the fault frequency of the station by time units, and when the counted fault duration or the counted fault frequency of the station is increased progressively in a plurality of time units, determining the station as an abnormal station;
and obtaining the long-stop abnormal reason category of the abnormal station according to the fault time length proportion or the fault frequency proportion of each category.
12. The method for managing faults of an automatic production line according to claim 9, wherein the process of analyzing the alarm information of the equipment in the station comprises:
counting the failure frequency, the failure accumulated time, the occupation ratio of the failure time length of each category and the occupation ratio of the failure frequency of each category of each equipment in the station;
counting the fault duration or the fault frequency of the equipment by time units, and when the counted fault duration or the counted fault frequency of the equipment is increased progressively in a plurality of time units, determining the equipment as abnormal equipment;
and obtaining the long-stop abnormal reason category of the abnormal equipment according to the fault time length ratio or the fault frequency ratio of each category.
13. A fault management system of an automated production line, which is adapted to implement the fault management method according to any one of claims 1 to 12, comprising:
the fault monitoring module is used for monitoring the real-time fault condition of the automatic production line;
the fault counting module is used for counting historical fault information of the automatic production line;
the fault analysis module is used for analyzing historical fault information to obtain a fault alarm trend of the automatic production line;
and the alarm information statistics module is used for respectively counting one or more of in-plant line body alarm information, station alarm information, equipment alarm information and equipment type alarm information according to the fault alarm trend to obtain a corresponding fault statistics result, and pushing the fault statistics result to a user.
14. The fault management system of claim 13, wherein the alarm information statistics module comprises a line alarm statistics unit, a station alarm statistics unit, an equipment alarm statistics unit, and an equipment type alarm statistics unit;
the line body alarm statistical unit is used for counting the fault frequency, the fault accumulated time, the occupation ratio of the fault duration of each category and the occupation ratio of the fault frequency of each category of each line body in the workshop; obtaining the abnormal or bottleneck line body and the reason category of the long-term stopping abnormality;
the station alarm statistical unit analyzes the fault of the abnormal line body obtained by the line body alarm statistical unit, and counts the fault frequency, fault accumulated time, fault duration ratio of each category and fault frequency ratio of each category of each station in the line body to obtain the abnormal or bottleneck station and long-stop abnormal reason category;
the equipment alarm statistical unit carries out fault analysis on the abnormal stations obtained by the station alarm statistical unit, counts fault frequency, fault accumulated time, fault duration proportion of each category and fault frequency proportion of each category of single equipment in the stations, and obtains abnormal or bottleneck equipment and long-stop abnormal reason categories;
the equipment type alarm statistical unit counts the fault frequency, the fault accumulated time, the proportion of fault duration of each type and the proportion of fault frequency of each type of equipment in the workshop to obtain the type of abnormal or bottleneck equipment and the type of reasons for long-term shutdown abnormality.
15. A fault management device, comprising:
at least one processor; and
a memory communicatively coupled to the at least one processor; wherein the memory has stored thereon instructions executable by at least one processor, the instructions being executable by the at least one processor to enable the at least one processor, when executing, to implement the fault management method of any one of claims 1-12.
16. A computer storage medium, characterized in that the computer readable storage medium has stored thereon an application program of a fault management device, which when processed, implements the steps of the fault management method according to any one of claims 1 to 12.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210310107.0A CN114781661A (en) | 2022-03-28 | 2022-03-28 | Fault management method, system, equipment and storage medium for automatic production line |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210310107.0A CN114781661A (en) | 2022-03-28 | 2022-03-28 | Fault management method, system, equipment and storage medium for automatic production line |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN114781661A true CN114781661A (en) | 2022-07-22 |
Family
ID=82425530
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210310107.0A Pending CN114781661A (en) | 2022-03-28 | 2022-03-28 | Fault management method, system, equipment and storage medium for automatic production line |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN114781661A (en) |
-
2022
- 2022-03-28 CN CN202210310107.0A patent/CN114781661A/en active Pending
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| US6760639B2 (en) | System and method for determining the effectiveness of production installations, fault events and the causes of faults | |
| US5327349A (en) | Method and apparatus for analyzing and recording downtime of a manufacturing process | |
| JP6474532B2 (en) | Method and apparatus for monitoring driving part of body assembly line | |
| CN105956734A (en) | Method and system for dynamically setting performance index threshold of IT equipment | |
| EP1895376A2 (en) | Dynamic maintenance management system | |
| CN114781659A (en) | Fault condition monitoring method, system, equipment and storage medium | |
| CN108599977B (en) | System and method for monitoring system availability based on statistical method | |
| CN107302469B (en) | Monitoring device and method for data update of distributed service cluster system | |
| JPH1170445A (en) | Manufacturing process change controller and manufacturing process change controlling method | |
| CN112712186B (en) | Equipment full-life-cycle management method based on intelligent substation digital twin system | |
| CN111159487A (en) | Predictive maintenance intelligent system for automobile engine spindle | |
| CN116595756A (en) | Digital twinning-based intelligent operation and maintenance method and device for data center | |
| DE102008050167A1 (en) | Method and system for analyzing operating conditions | |
| CN111598491B (en) | Data monitoring method applied to AOI detection and electronic equipment | |
| CN114781661A (en) | Fault management method, system, equipment and storage medium for automatic production line | |
| KR101917477B1 (en) | Pre-sensing apparatus for abnormal of coiling equipment | |
| CN109032899A (en) | The method and apparatus of indicating equipment state | |
| CN116339266A (en) | Composite monitoring method and system for pipe production | |
| CN116263734A (en) | Industrial robot state monitoring method, system and prompt terminal | |
| CN112182233A (en) | Knowledge base for storing equipment fault records and method and system for assisting in locating equipment fault by using knowledge base | |
| CN111861113A (en) | MES system-based server manufacturing system and method | |
| CN111913431A (en) | Megametric management device, control method, control system and readable storage medium | |
| CN212623707U (en) | Megametric equipment management system | |
| JP2005071200A (en) | Manufacturing information management program | |
| CN117132243A (en) | Visual power plant equipment monitoring management system |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PB01 | Publication | ||
| PB01 | Publication | ||
| SE01 | Entry into force of request for substantive examination | ||
| SE01 | Entry into force of request for substantive examination |