CN117217723A - Method, device, system and storage medium for monitoring gluing process - Google Patents
Method, device, system and storage medium for monitoring gluing process Download PDFInfo
- Publication number
- CN117217723A CN117217723A CN202210597615.1A CN202210597615A CN117217723A CN 117217723 A CN117217723 A CN 117217723A CN 202210597615 A CN202210597615 A CN 202210597615A CN 117217723 A CN117217723 A CN 117217723A
- Authority
- CN
- China
- Prior art keywords
- glue
- gluing
- cylinder pressure
- material cylinder
- filling time
- 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
- 238000004026 adhesive bonding Methods 0.000 title claims abstract description 126
- 238000000034 method Methods 0.000 title claims abstract description 110
- 230000008569 process Effects 0.000 title claims abstract description 49
- 238000012544 monitoring process Methods 0.000 title claims abstract description 40
- 238000003860 storage Methods 0.000 title claims abstract description 9
- 239000003292 glue Substances 0.000 claims abstract description 216
- 239000000463 material Substances 0.000 claims abstract description 164
- 238000004513 sizing Methods 0.000 claims abstract description 72
- 238000000576 coating method Methods 0.000 claims abstract description 45
- 239000011248 coating agent Substances 0.000 claims abstract description 42
- 238000012797 qualification Methods 0.000 claims abstract description 17
- 239000002699 waste material Substances 0.000 claims abstract description 13
- 238000004364 calculation method Methods 0.000 claims abstract description 6
- 230000007480 spreading Effects 0.000 claims description 16
- 238000003892 spreading Methods 0.000 claims description 16
- 238000010073 coating (rubber) Methods 0.000 claims description 8
- 238000012806 monitoring device Methods 0.000 claims description 6
- 230000007547 defect Effects 0.000 abstract description 6
- 238000007726 management method Methods 0.000 description 19
- 230000007246 mechanism Effects 0.000 description 9
- 238000012423 maintenance Methods 0.000 description 7
- 238000010586 diagram Methods 0.000 description 5
- 238000007711 solidification Methods 0.000 description 5
- 230000008023 solidification Effects 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 230000006870 function Effects 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 238000004891 communication Methods 0.000 description 3
- 238000013500 data storage Methods 0.000 description 3
- 238000010252 digital analysis Methods 0.000 description 3
- 238000005516 engineering process Methods 0.000 description 3
- 230000007774 longterm Effects 0.000 description 3
- 230000002265 prevention Effects 0.000 description 3
- 230000003449 preventive effect Effects 0.000 description 3
- 230000002159 abnormal effect Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 238000007405 data analysis Methods 0.000 description 2
- 238000007599 discharging Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 230000000007 visual effect Effects 0.000 description 2
- 239000004902 Softening Agent Substances 0.000 description 1
- 230000005856 abnormality Effects 0.000 description 1
- 238000005299 abrasion Methods 0.000 description 1
- 230000009471 action Effects 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 230000004913 activation Effects 0.000 description 1
- 238000010835 comparative analysis Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000001514 detection method Methods 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 230000004044 response Effects 0.000 description 1
Landscapes
- Application Of Or Painting With Fluid Materials (AREA)
Abstract
The invention provides a method, a device, a system and a storage medium for monitoring a gluing process. The method comprises the following steps: acquiring and storing a gluing process number from a gluing system, and for each gluing process, gluing results, material cylinder pressure and a motor average torque of a quantitative motor; acquiring and storing the glue filling time for each glue application program from the robotic system; acquiring and storing glue barrel replacement time, glue barrel capacity and effective glue coating amount from a glue coating system data box; calculating effective utilization rate, sizing material allowance and qualification rate according to the data, generating a material cylinder pressure curve, calculating a material cylinder pressure trend value, generating an average moment curve, calculating an average moment trend value, generating a filling time curve, calculating a filling time trend value, and alarming when the trend value exceeds a threshold value; and displaying the calculation result and the curve. The method effectively reduces equipment shutdown, reduces spare part cost consumption, reduces gluing quality defects and reduces glue waste.
Description
Technical Field
Embodiments of the present invention relate generally to the field of automotive glue manufacturing technology, and more particularly, to a glue process monitoring method, device, system, and storage medium.
Background
The maintenance and management of the gluing equipment, especially in the automobile production process, mainly has the following problems:
(1) Equipment problems. The main equipment failure problems are sizing material solidification (including solidification of pipelines and material cylinders) and the failure of a quantitative machine driving mechanism; the traditional personnel spot inspection mode can not know the solidification condition and the working state of the driving mechanism, can not effectively monitor the degradation process, and can only use a rough management mode of periodical glue discharging and periodical rotation, so that the efficiency is low, and the material consumption cost is high.
(2) And the gluing quality is improved. When the gluing quality problem occurs on site, the gluing quality problem cannot be known quickly, the accumulated qualification rate data cannot be counted, and effective management of the gluing quality cannot be achieved.
(3) The effective utilization rate of sizing materials is improved. The number of scrapped sizing materials is large, and the effective utilization rate of the sizing materials and the effective period of the sizing materials cannot be monitored and managed, so that the wasted bottleneck points are difficult to find, and the scrapping of the sizing materials is difficult to effectively reduce.
These problems cannot be effectively monitored and managed using conventional personnel record tracking.
Disclosure of Invention
To solve at least some of the above problems in the prior art, in a first aspect, an embodiment of the present invention provides a method for monitoring a gluing process, the method comprising: acquiring and storing a gluing process number from a gluing system, and for each gluing process, gluing results, material cylinder pressure and a motor average torque of a quantitative motor; acquiring and storing the glue filling time for each glue application program from the robotic system; acquiring and storing glue barrel replacement time, glue barrel capacity and effective glue coating amount from a glue coating system data box; calculating effective utilization rate according to the replacement time of the rubber barrel, the effective rubber coating amount and the capacity of the rubber barrel; calculating the sizing material allowance according to the size of the rubber barrel and the effective gluing amount; generating a material cylinder pressure curve according to the material cylinder pressure, calculating a material cylinder pressure trend value, and generating a material cylinder pressure alarm signal when the material cylinder pressure trend value exceeds a material cylinder pressure trend threshold value; generating an average moment curve according to the average moment of the quantitative electromechanical machine, calculating an average moment trend value, and generating an average moment alarm signal when the average moment trend value exceeds an average moment trend threshold value; generating a filling time curve according to the filling time of the sizing material, calculating a filling time trend value, and generating a filling time alarm signal when the filling time trend value exceeds a filling time trend threshold value; obtaining a qualification rate according to the percentage of the qualified result in the gluing result to the whole result; displaying the effective utilization, the stock remaining, the material cylinder pressure curve, the average moment curve, the fill time curve, and the yield via a human-machine interface.
In some embodiments, the method further comprises: generating a glue spreading amount alarm signal according to the effective glue spreading amount and the upper and lower glue spreading amount threshold values, if the effective glue spreading amount exceeds the upper and lower glue spreading amount threshold values; and displaying a comparison graph of the effective glue coating amount and upper and lower limit thresholds of the glue coating amount through the man-machine interface.
In some embodiments, the method further comprises: the material cylinder pressure comprises a material cylinder average pressure and/or a material cylinder maximum pressure.
In some embodiments, the method further comprises: acquiring and storing a set capacity, a gluing capacity and a capacity deviation from the gluing system; displaying the set capacity, the glue application capacity and the capacity deviation via the human-machine interface.
In some embodiments, the method further comprises: acquiring a sizing material valid period associated with the replacement time of the sizing barrel from the data box of the gluing system; displaying the replacement time of the rubber barrel and the effective period of the rubber material through the man-machine interface; and when the current time exceeds the valid period of the sizing material, generating and displaying a sizing barrel replacement prompt message.
In some embodiments, the method further comprises: determining the waste amount of the sizing material according to the replacement time of the sizing barrel, the effective sizing amount and the capacity of the sizing barrel; displaying the amount of wasted gum material via the human-machine interface.
In a second aspect, an embodiment of the present invention proposes a glue process monitoring device, the device comprising: the gluing system data acquisition module is configured to acquire and store a gluing process number from the gluing system, and gluing results, material cylinder pressure and motor average torque of the quantitative motor for each gluing process; the system comprises a robot system data acquisition module, a glue filling module and a glue filling module, wherein the robot system data acquisition module is configured to acquire and store glue filling time for each glue coating program from a robot system; the data box data acquisition module is configured to acquire and store glue barrel replacement time, glue barrel capacity and effective glue coating amount from a glue coating system data box; the effective utilization rate calculating module is configured to calculate the effective utilization rate according to the replacement time of the rubber bucket, the effective rubber coating amount and the capacity of the rubber bucket; the sizing material allowance calculation module is configured to calculate sizing material allowance according to the size of the rubber barrel and the effective gluing amount; the pressure trend determining module is configured to generate a material cylinder pressure curve according to the material cylinder pressure, calculate a material cylinder pressure trend value and generate a material cylinder pressure alarm signal when the material cylinder pressure trend value exceeds a material cylinder pressure trend threshold; the average moment trend determining module is configured to generate an average moment curve according to the average moment of the quantitative motor, calculate an average moment trend value and generate an average moment alarm signal when the average moment trend value exceeds an average moment trend threshold value; the filling time trend determining module is configured to generate a filling time curve according to the filling time of the sizing material, calculate a filling time trend value and generate a filling time alarm signal when the filling time trend value exceeds a filling time trend threshold; the qualification rate determining module is configured to obtain qualification rate according to the percentage of qualified results in the gluing results to the whole results; the display module is configured to display the effective utilization, the sizing material allowance, the material cylinder pressure curve, the average moment curve, the filling time curve and the qualification rate via a human-machine interface.
In a third aspect, an embodiment of the present invention provides a glue coating process monitoring system, where the glue coating process monitoring system includes a glue coating system, a robot system, a glue coating system data box, and a service terminal. The gluing system is used for transmitting a gluing program number to the service terminal, and gluing results, material cylinder pressure and motor average moment of the quantitative motor for each gluing program. The robotic system is configured to transmit a glue filling time for each glue application program to the service terminal. The gluing system data box is used for transmitting the glue barrel replacement time, the glue barrel capacity and the effective gluing amount to the service terminal. The service terminal is used for: receiving and storing a glue application program number from a glue application system, a glue application result, a material cylinder pressure and a motor average torque of a quantitative motor for each glue application program; receiving and storing from the robotic system a glue filling time for each glue application program; receiving and storing the replacement time of the glue barrel, the capacity of the glue barrel and the effective glue coating amount from a data box of a glue coating system; calculating effective utilization rate according to the replacement time of the rubber barrel, the effective rubber coating amount and the capacity of the rubber barrel; calculating the sizing material allowance according to the size of the rubber barrel and the effective gluing amount; generating a material cylinder pressure curve according to the material cylinder pressure, calculating a material cylinder pressure trend value, and generating a material cylinder pressure alarm signal when the material cylinder pressure trend value exceeds a material cylinder pressure trend threshold value; generating an average moment curve according to the average moment of the quantitative electromechanical machine, calculating an average moment trend value, and generating an average moment alarm signal when the average moment trend value exceeds an average moment trend threshold value; generating a filling time curve according to the filling time of the sizing material, calculating a filling time trend value, and generating a filling time alarm signal when the filling time trend value exceeds a filling time trend threshold value; obtaining a qualification rate according to the percentage of the qualified result in the gluing result to the whole result; displaying the effective utilization, the stock remaining, the material cylinder pressure curve, the average moment curve, the fill time curve, and the yield via a human-machine interface.
In a fourth aspect, embodiments of the invention provide a storage medium storing computer readable instructions which, when executed by a processor, implement a method according to any of the embodiments described above.
Compared with the problems that the manual recording and tracking mode in the prior art cannot be effectively monitored and managed, the extensive management mode is low in efficiency, high in material consumption cost and difficult to effectively control, the gluing process monitoring method, device, system and storage medium provided by the embodiment of the invention have the following advantages: the whole process monitoring of the running state of the gluing equipment can be realized, and the maintenance management of the gluing equipment is accurate, fine and preventive. The method can effectively reduce equipment shutdown, reduce spare part cost consumption, improve management efficiency, reduce gluing quality defects and reduce glue waste. The method realizes digital management and digital analysis, better and more accurate identification of risk points and early prevention.
The embodiment of the invention adopts a digital means to collect, analyze and visualize the real-time data generated by the equipment, and solves the technical problem that the traditional personnel record and tracking mode cannot be used for effectively monitoring and managing in the prior art.
The accuracy, the refinement and the preventability of the maintenance and the management of the gluing equipment can be realized by a digital monitoring technology formed by the on-site data acquisition, the data storage and the data analysis and the visual mode. The method can effectively reduce equipment shutdown, reduce spare part cost consumption, improve management efficiency, reduce gluing quality defects and reduce glue waste.
Drawings
The above, as well as additional purposes, features, and advantages of embodiments of the present invention will become apparent in the following detailed written description and claims upon reference to the accompanying drawings. Several embodiments of the present invention are illustrated by way of example, and not by way of limitation, in the figures of the accompanying drawings and in which:
fig. 1 shows a flow chart of a method of monitoring a glue application process according to an embodiment of the invention;
fig. 2 shows a schematic diagram of a gluing system to which a gluing process monitoring method according to an embodiment of the present invention is applied;
FIG. 3 shows a cylinder pressure profile of a material according to an embodiment of the invention;
FIG. 4 shows an average moment diagram according to an embodiment of the invention;
FIG. 5 shows a fill time graph according to an embodiment of the invention;
FIG. 6 shows a yield graph according to an embodiment of the invention;
fig. 7 shows a block diagram of a glue process monitoring device according to an embodiment of the invention.
In the drawings, the same or corresponding reference numerals indicate the same or corresponding parts.
Detailed Description
The principles and spirit of the present invention will be described below with reference to several exemplary embodiments. It should be understood that these embodiments are presented merely to enable those skilled in the art to better understand and practice the invention and are not intended to limit the scope of the invention in any way.
In one aspect, embodiments of the present invention provide a method for monitoring a glue process, referring to fig. 1-2, wherein fig. 1 shows a flowchart of a method 100 for monitoring a glue process according to an embodiment of the present invention, and fig. 2 shows a schematic diagram of a glue coating system to which the method for monitoring a glue process according to an embodiment of the present invention is applied.
As shown in fig. 2, a glue coating system to which the glue coating process monitoring method according to an embodiment of the present invention is applied mainly includes: glue pump 201, glue pump control cabinet 202, glue application system cabinet 203, glue tube 204, dosing machine drive mechanism 205, material cylinder 206, glue gun 207, and robotic system 208.
The rubber pump is used for a power mechanism for conveying rubber, namely, the rubber in the rubber barrel is pumped out and conveyed into the rubber tube, and the rubber tube is heated to ensure the flowability of the rubber.
The glue pump control cabinet mainly controls the glue pump heating function, the glue barrel replacing function and the switching function of the double-pump system.
The whole process of rubber coating is mainly controlled to rubber coating system cabinet, includes: and (3) glue filling, glue discharging driven by a quantifying machine, glue coating amount monitoring, glue coating pressure monitoring and the like.
The rubber tube is a rubber material conveying pipeline, the part needs to be heated in order to ensure the flowability of the rubber material, the inner diameter of the rubber tube is 15mm, and the rubber material is easy to accumulate and solidify under the state of long-term heating.
The drive mechanism of the quantitative machine mainly controls the quantity of the glue outlet, the drive stroke of the quantitative machine is measured through a displacement sensor, the glue outlet quantity is calculated from the inside of the system, the motor drives the screw rod to rotate, and the moment rises due to abrasion or mechanical clamping stagnation when the quantitative machine runs for a long time.
The material cylinder is a cavity for filling the sizing material, the screw rod is driven by the rotation of the quantifying machine, so that the connecting rod piston extrudes the sizing material in the cavity of the material cylinder, the sizing material is extruded, the sizing material is easy to accumulate and solidify under the state of long-term heating because the position needs to be heated and a softening agent is added for ensuring the mobility of the sizing material.
The glue gun is a terminal outlet of glue stock, and the diameters of gun nozzles of different types are different, so that the thickness requirement of the process glue stock is met, the glue gun is required to be heated in order to ensure the fluidity of the glue stock, and the glue stock is easy to accumulate and solidify under the state of long-term heating.
The gluing system is an accessory device hung in the robot system, the actions such as gluing and glue filling are controlled by the output signals of the robot, the state (whether faults exist) and the glue amount of the gluing system are automatically monitored by the gluing system and fed back to the robot, and meanwhile, the robot can calculate the glue filling time through the output to closing of the glue filling signals.
The gumming procedure is briefly described as follows: firstly, a glue pump pumps glue from a glue barrel to a glue pipe, the glue pipe is conveyed to a material cylinder in advance when a system receives a filling request, after the system receives a glue coating signal, a glue gun control valve is opened, a quantitative machine drives a screw rod to rotate, glue in the material cylinder is extruded under the rotation of the screw rod, and the glue flows out from a glue gun nozzle.
As shown in fig. 1, the glue process monitoring method 100 includes steps S101-S110. The method may be implemented on a service terminal. The service terminal may include any terminal having communication, data processing and display functions, such as a computer, a server, etc. The service terminal is communicatively connected with the glue application system, the robotic system, and the glue application system data box.
In step S101, the number of glue strokes and the glue result, cylinder pressure, and motor average torque of the dosing machine for each glue stroke are acquired and stored from the glue system. Wherein, the glue spreading sequence number is the combination of index number of a section of glue and parameters needed by glue spreading. The glue application result is generally either acceptable or unacceptable.
As an example, data may be obtained from a glue system by: activating an OPC communication interface of the gluing system; and after activation, the gluing system autonomously transmits data to the setting service terminal.
In step S102, the glue filling time for each glue application program is acquired from the robotic system and stored.
As an example, data may be acquired from a robotic system by: the communication between the robot and the service terminal is realized by editing a robot background program, and the background of each workpiece produced is set to automatically send gluing data to a virtual server created by a data center computer, wherein the data comprise the ID number of the robot and the filling time of sizing materials.
In step S103, the glue bucket replacement time, the glue bucket capacity and the effective glue amount are acquired and stored from the glue system data box.
As an example, data may be obtained from a gumming system data box by: by editing the Python program, the service terminal actively handshakes with the data box and obtains data from the rubberized data box. The data of the data box is obtained from a gluing system which, in general, automatically sends the relevant data into the data box each time a gluing is completed or each time a trolley is applied.
Steps S101-S103 mainly relate to data acquisition and data storage.
In step S104, the effective utilization rate is calculated according to the replacement time of the glue barrel, the effective glue coating amount and the glue barrel capacity. For example, the replacement time of the glue barrel can be directly extracted, and then the effective glue coating amount is obtained according to the time period, so that the effective utilization rate is calculated, and the formula is as follows:
effective utilization = effective glue amount/glue vat capacity 100%
The effective utilization rate of the sizing material is calculated, the replacement time of the sizing barrel is automatically monitored through equipment, the service time of each barrel of sizing material can be calculated, and the effective utilization rate of each barrel of sizing material is automatically calculated by collecting the effective gluing amount in the service time.
In step S105, the glue stock margin is calculated based on the glue barrel capacity and the effective glue amount. For example, the stock balance calculation formula is as follows:
sizing margin = barrel capacity-effective glue amount
In step S106, a material cylinder pressure curve is generated from the material cylinder pressure, and a material cylinder pressure trend value is calculated, and a material cylinder pressure warning signal is generated when the material cylinder pressure trend value exceeds a material cylinder pressure trend threshold. As an embodiment of the present invention, the method further comprises: the material cylinder pressure includes a material cylinder average pressure and/or a material cylinder maximum pressure.
In step S107, an average moment curve is generated according to the average moment of the quantitative motor, and an average moment trend value is calculated, and when the average moment trend value exceeds the average moment trend threshold, an average moment alarm signal is generated.
In step S108, a filling time curve is generated according to the filling time of the glue stock, and a filling time trend value is calculated, and when the filling time trend value exceeds a filling time trend threshold, a filling time alarm signal is generated.
In step S109, the qualification rate is obtained according to the percentage of the qualified result in the gluing result to the whole result.
Steps S104-S109 mainly involve data processing and operations. And slicing the data with fixed format sent by the gluing system and the robot system by using Python to extract useful data and information.
Referring to fig. 3-6, a material cylinder pressure profile, an average moment profile, a fill time profile, and a percent of pass profile, respectively, are shown in accordance with an embodiment of the present invention.
As shown in fig. 3, the upper and lower curves represent the maximum pressure curve and the average pressure curve of the cylinder, respectively. The cylinder pressure trend (0.0) indicates that the cylinder pressure trend value is 0.0.
The curve shown in fig. 4 is a motor average torque curve, and the motor torque trend (-0.009) indicates that the average torque trend value is-0.009.
The graph shown in fig. 5 is a graph of fill time, with a fill time trend (-0.003) indicating that the fill time trend value is-0.003.
The graph shown in fig. 6 is a daily yield graph calculated for yield over the day.
For the material cylinder pressure, the average motor torque of the quantitative motor and the glue filling time, the trend value of the material cylinder pressure, the average motor torque of the quantitative motor and the glue filling time can be calculated by using a least square method through linear relations. The calculation method may be, for example: fitting all the data values into a straight line in a rectangular coordinate system, enabling all points to be close to the straight line, finally obtaining two parameters (a and b) of a straight line equation by using a least square method, and finally obtaining a straight line equation y=a+bx, wherein the slope of the straight line is a trend value.
When the curves show sudden rise or drop, the trend value exceeds a certain upper limit and a certain lower limit of the threshold, so that abnormal conditions of each curve can be judged by monitoring the trend value, an alarm is given when the trend value exceeds the early warning value, a worker can find out the abnormality in time, and the maintenance and the replacement of the fault parts are facilitated.
In step S110, the effective utilization, the stock allowance, the cylinder pressure profile, the average moment profile, the filling time profile and the yield are displayed via a human-machine interface.
The gluing process monitoring method provided by the embodiment of the invention is beneficial to finding equipment problems in time and provides powerful assistance for equipment overhaul and component replacement. For example, if the driving mechanism is subjected to resistance, the motor moment can rise, the trend of the resistance of the driving mechanism can be monitored by presenting and monitoring the motor moment value of the gluing process of the quantitative machine, and when the motor moment value is monitored to be abnormal, the problem of the driving mechanism can be judged, and the fault detection is required. If the sizing material does not flow for a long time, the sizing material can be solidified in the material cylinder, the sizing material outlet resistance can be increased, the sizing material outlet pressure value is subjected to comparative analysis, and the solidification degree trend of the material cylinder can be monitored through an algorithm. In addition, when the rubber pipeline is in response to the flowability of the rubber due to the reasons of rubber pipe blockage, rubber hardening, rubber impurities and the like, the flow of the rubber is resistant, so that the filling time is prolonged, the flow resistance of the rubber in the pipeline can be analyzed by monitoring the time of each rubber filling of the equipment, and the curing condition and trend of the pipeline can be monitored.
And the motor moment value and the glue outlet pressure value in the gluing process of the quantitative machine are compared and analyzed, and the relation between the moment change trend and the pressure change trend is calculated through an algorithm, so that whether a driving mechanism has a problem or not and whether a material cylinder has solidification or not can be analyzed.
The gluing process monitoring method provided by the embodiment of the invention can effectively monitor the stability of the gluing quality of the equipment through the proportion of the qualified gluing number to the unqualified gluing number.
As an embodiment of the present invention, the method may further include: generating a glue coating amount alarm signal according to the effective glue coating amount and the upper and lower limit thresholds of the glue coating amount if the effective glue coating amount exceeds the upper and lower limit thresholds of the glue coating amount; and displaying a comparison graph of the effective glue coating amount and upper and lower limit thresholds of the glue coating amount through a human-computer interface.
As an embodiment of the present invention, the method further comprises: acquiring and storing a set capacity, a gluing capacity and a capacity deviation from a gluing system; the set capacity, glue capacity and capacity deviation are displayed via a human-machine interface. The set capacity is the technological requirement of coating one section of glue, the glue coating capacity can be the total glue coating amount of one trolley, and the capacity deviation is the difference between the set capacity and the glue coating capacity of one trolley. Optionally, the glue spreading amount statistical comparison chart can be further displayed according to the set capacity, the glue spreading capacity and the capacity deviation.
According to the embodiment, the problem of gluing quality can be solved, the gluing quantity of each piece is displayed and compared with the set capacity (monitoring value), whether the gluing quantity of the workpiece has a problem or not can be monitored in real time, the upper limit and the lower limit of the gluing quantity can be set, and an alarm can be sent out when the gluing quantity exceeds the upper limit and the lower limit.
As an embodiment of the present invention, the method may further include: acquiring a glue stock validity period associated with the glue bucket replacement time from a glue spreading system data box; displaying the replacement time of the rubber barrel and the effective period of the rubber material through a man-machine interface; and when the current time exceeds the valid period of the rubber, generating and displaying a replacement prompt message of the rubber barrel. The validity period of the sizing material can be obtained by scanning the bar code on the sizing barrel through a logistics code scanning gun when the sizing barrel is replaced, and then the logistics code scanning gun uploads data to a data box of the sizing system.
According to the embodiment, the problem of effective utilization rate of the sizing material can be solved, and personnel can be timely reminded of replacing the sizing barrel by displaying the sizing material replacement time and expiration time, so that the expiration sizing material cannot be used, and quality accidents are caused.
As an embodiment of the present invention, the method further comprises: determining the waste amount of the glue stock according to the replacement time of the glue stock, the effective glue coating amount and the capacity of the glue stock; the amount of gum waste is displayed via a human-machine interface.
According to the embodiment, the waste amount of the sizing material is calculated, so that the waste condition of the sizing material can be found in time, workers can check on site in time, a waste point is found, and the loss of the sizing material is avoided.
Compared with the problems that the manual recording and tracking mode in the prior art cannot be effectively monitored and managed, the extensive management mode is low in efficiency, high in material consumption cost, difficult to effectively control and the like, the gluing process monitoring method provided by the embodiment of the invention has the following advantages: the whole process monitoring of the running state of the gluing equipment can be realized, and the maintenance management of the gluing equipment is accurate, fine and preventive. The method can effectively reduce equipment shutdown, reduce spare part cost consumption, improve management efficiency, reduce gluing quality defects and reduce glue waste. The method realizes digital management and digital analysis, better and more accurate identification of risk points and early prevention.
In another aspect, an embodiment of the present invention provides a glue process monitoring device. Referring to fig. 7, a block diagram of a gumming process monitoring device in accordance with an embodiment of the present invention is shown. As shown in fig. 7, the apparatus includes modules 701-710.
A gluing system data acquisition module 701 configured to acquire and store a gluing process number from the gluing system and a gluing result, a material cylinder pressure, a quantitative motor average torque for each gluing process;
a robotic system data acquisition module 702 configured to acquire and store, from the robotic system, a glue fill time for each glue application program;
a data box data acquisition module 703 configured to acquire and store a glue bucket replacement time, a glue bucket capacity, and an effective glue amount from a glue system data box;
the effective utilization rate calculating module 704 is configured to calculate an effective utilization rate according to the replacement time of the glue barrel, the effective glue coating amount and the glue barrel capacity;
the sizing material allowance calculation module 705 is configured to calculate sizing material allowance according to the capacity of the rubber barrel and the effective gluing amount;
a pressure trend determination module 706 configured to generate a material cylinder pressure curve from the material cylinder pressure and calculate a material cylinder pressure trend value, and generate a material cylinder pressure alarm signal when the material cylinder pressure trend value exceeds a material cylinder pressure trend threshold;
the average moment trend determining module 707 is configured to generate an average moment curve according to the average moment of the quantitative motor, calculate an average moment trend value, and generate an average moment alarm signal when the average moment trend value exceeds an average moment trend threshold value;
a filling time trend determination module 708 configured to generate a filling time curve according to the filling time of the glue stock, and calculate a filling time trend value, and generate a filling time alarm signal when the filling time trend value exceeds a filling time trend threshold;
a qualification rate determining module 709 configured to obtain a qualification rate according to the percentage of the qualified result in the gluing result to the whole result;
the display module 710 is configured to display, via a human-machine interface, the effective utilization, the stock remaining, the cylinder pressure profile, the average moment profile, the fill time profile, and the percent of pass.
In yet another aspect, the embodiment of the invention further provides a gluing process monitoring system, which comprises a gluing system, a robot system, a gluing system data box and a service terminal.
The gluing system is used for transmitting a gluing program number, a gluing result, a material cylinder pressure and a motor average moment of the quantifying motor for each gluing program to the service terminal.
The robotic system is configured to transmit the glue filling time for each glue application program to the service terminal.
The gluing system data box is used for transmitting the glue barrel replacement time, the glue barrel capacity and the effective gluing amount to the service terminal.
The service terminal is used for executing the following operations:
receiving and storing a glue application program number from a glue application system, a glue application result, a material cylinder pressure and a motor average torque of a quantitative motor for each glue application program;
receiving and storing from the robotic system a glue filling time for each glue application program;
receiving and storing the replacement time of the glue barrel, the capacity of the glue barrel and the effective glue coating amount from a data box of a glue coating system;
calculating the effective utilization rate according to the replacement time of the rubber barrel, the effective gluing amount and the capacity of the rubber barrel;
calculating the sizing material allowance according to the capacity of the sizing barrel and the effective sizing amount;
generating a material cylinder pressure curve according to the material cylinder pressure, calculating a material cylinder pressure trend value, and generating a material cylinder pressure alarm signal when the material cylinder pressure trend value exceeds a material cylinder pressure trend threshold value;
generating an average moment curve according to the average moment of the quantitative motor, calculating an average moment trend value, and generating an average moment alarm signal when the average moment trend value exceeds an average moment trend threshold value;
generating a filling time curve according to the filling time of the sizing material, calculating a filling time trend value, and generating a filling time alarm signal when the filling time trend value exceeds a filling time trend threshold value;
obtaining the qualification rate according to the percentage of the qualified result in the gluing result to the whole result;
the effective utilization, the sizing material allowance, the material cylinder pressure curve, the average moment curve, the filling time curve and the qualification rate are displayed through a human-computer interface.
It should be noted that, the operations of each module in the monitoring device for a gluing process and each device in the monitoring system for a gluing process according to the embodiments of the present invention are in one-to-one correspondence with each step of the monitoring method for a gluing process described above, and the detailed description, examples and beneficial effects of the monitoring method for a gluing process are referred to in the description of the monitoring method for a gluing process and are not repeated herein.
In yet another aspect, embodiments of the present invention provide a storage medium storing computer readable instructions that, when executed by a processor, implement the method of monitoring a glue application process described in any of the above embodiments.
Compared with the problems that the manual recording and tracking mode in the prior art cannot be effectively monitored and managed, the extensive management mode is low in efficiency, high in material consumption cost and difficult to effectively control, the gluing process monitoring method, device, system and storage medium provided by the embodiment of the invention have the following advantages: the whole process monitoring of the running state of the gluing equipment can be realized, and the maintenance management of the gluing equipment is accurate, fine and preventive. The method can effectively reduce equipment shutdown, reduce spare part cost consumption, improve management efficiency, reduce gluing quality defects and reduce glue waste. The method realizes digital management and digital analysis, better and more accurate identification of risk points and early prevention.
The embodiment of the invention adopts a digital means to collect, analyze and visualize the real-time data generated by the equipment, and solves the technical problem that the traditional personnel record and tracking mode cannot be used for effectively monitoring and managing in the prior art.
The accuracy, the refinement and the preventability of the maintenance and the management of the gluing equipment can be realized by a digital monitoring technology formed by the on-site data acquisition, the data storage and the data analysis and the visual mode. The method can effectively reduce equipment shutdown, reduce spare part cost consumption, improve management efficiency, reduce gluing quality defects and reduce glue waste.
The foregoing description of embodiments of the invention have been presented for the purpose of illustration and is not intended to be exhaustive or to limit the invention to the precise form disclosed. It will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.
Claims (9)
1. A method for monitoring a glue application process, the method comprising:
acquiring and storing a gluing process number from a gluing system, and for each gluing process, gluing results, material cylinder pressure and a motor average torque of a quantitative motor;
acquiring and storing the glue filling time for each glue application program from the robotic system;
acquiring and storing glue barrel replacement time, glue barrel capacity and effective glue coating amount from a glue coating system data box;
calculating effective utilization rate according to the replacement time of the rubber barrel, the effective rubber coating amount and the capacity of the rubber barrel;
calculating the sizing material allowance according to the size of the rubber barrel and the effective gluing amount;
generating a material cylinder pressure curve according to the material cylinder pressure, calculating a material cylinder pressure trend value, and generating a material cylinder pressure alarm signal when the material cylinder pressure trend value exceeds a material cylinder pressure trend threshold value;
generating an average moment curve according to the average moment of the quantitative electromechanical machine, calculating an average moment trend value, and generating an average moment alarm signal when the average moment trend value exceeds an average moment trend threshold value;
generating a filling time curve according to the filling time of the sizing material, calculating a filling time trend value, and generating a filling time alarm signal when the filling time trend value exceeds a filling time trend threshold value;
obtaining a qualification rate according to the percentage of the qualified result in the gluing result to the whole result;
displaying the effective utilization, the stock remaining, the material cylinder pressure curve, the average moment curve, the fill time curve, and the yield via a human-machine interface.
2. The method according to claim 1, wherein the method further comprises:
generating a glue spreading amount alarm signal according to the effective glue spreading amount and the upper and lower glue spreading amount threshold values, if the effective glue spreading amount exceeds the upper and lower glue spreading amount threshold values;
and displaying a comparison graph of the effective glue coating amount and upper and lower limit thresholds of the glue coating amount through the man-machine interface.
3. The method according to claim 1, wherein the method further comprises: the material cylinder pressure comprises a material cylinder average pressure and/or a material cylinder maximum pressure.
4. The method according to claim 1, wherein the method further comprises:
acquiring and storing a set capacity, a gluing capacity and a capacity deviation from the gluing system;
displaying the set capacity, the glue application capacity and the capacity deviation via the human-machine interface.
5. The method according to claim 1, wherein the method further comprises:
acquiring a sizing material valid period associated with the replacement time of the sizing barrel from the data box of the gluing system;
displaying the replacement time of the rubber barrel and the effective period of the rubber material through the man-machine interface;
and when the current time exceeds the valid period of the sizing material, generating and displaying a sizing barrel replacement prompt message.
6. The method according to claim 1, wherein the method further comprises:
determining the waste amount of the sizing material according to the replacement time of the sizing barrel, the effective sizing amount and the capacity of the sizing barrel;
displaying the amount of wasted gum material via the human-machine interface.
7. A glue process monitoring device, the device comprising:
the gluing system data acquisition module is configured to acquire and store a gluing process number from the gluing system, and gluing results, material cylinder pressure and motor average torque of the quantitative motor for each gluing process;
the system comprises a robot system data acquisition module, a glue filling module and a glue filling module, wherein the robot system data acquisition module is configured to acquire and store glue filling time for each glue coating program from a robot system;
the data box data acquisition module is configured to acquire and store glue barrel replacement time, glue barrel capacity and effective glue coating amount from a glue coating system data box;
the effective utilization rate calculating module is configured to calculate the effective utilization rate according to the replacement time of the rubber bucket, the effective rubber coating amount and the capacity of the rubber bucket;
the sizing material allowance calculation module is configured to calculate sizing material allowance according to the size of the rubber barrel and the effective gluing amount;
the pressure trend determining module is configured to generate a material cylinder pressure curve according to the material cylinder pressure, calculate a material cylinder pressure trend value and generate a material cylinder pressure alarm signal when the material cylinder pressure trend value exceeds a material cylinder pressure trend threshold;
the average moment trend determining module is configured to generate an average moment curve according to the average moment of the quantitative motor, calculate an average moment trend value and generate an average moment alarm signal when the average moment trend value exceeds an average moment trend threshold value;
the filling time trend determining module is configured to generate a filling time curve according to the filling time of the sizing material, calculate a filling time trend value and generate a filling time alarm signal when the filling time trend value exceeds a filling time trend threshold;
the qualification rate determining module is configured to obtain qualification rate according to the percentage of qualified results in the gluing results to the whole results;
the display module is configured to display the effective utilization, the sizing material allowance, the material cylinder pressure curve, the average moment curve, the filling time curve and the qualification rate via a human-machine interface.
8. A monitoring system for a gluing process is characterized by comprising a gluing system, a robot system, a data box of the gluing system and a service terminal,
the gluing system is used for transmitting a gluing program number to the service terminal, and the gluing result, the material cylinder pressure and the motor average moment of the quantitative motor for each gluing program;
the robot system is used for transmitting the glue filling time for each glue spreading procedure to the service terminal;
the gluing system data box is used for transmitting the glue barrel replacement time, the glue barrel capacity and the effective gluing amount to the service terminal;
the service terminal is used for:
receiving and storing a glue application program number from a glue application system, a glue application result, a material cylinder pressure and a motor average torque of a quantitative motor for each glue application program;
receiving and storing from the robotic system a glue filling time for each glue application program;
receiving and storing the replacement time of the glue barrel, the capacity of the glue barrel and the effective glue coating amount from a data box of a glue coating system;
calculating effective utilization rate according to the replacement time of the rubber barrel, the effective rubber coating amount and the capacity of the rubber barrel;
calculating the sizing material allowance according to the size of the rubber barrel and the effective gluing amount;
generating a material cylinder pressure curve according to the material cylinder pressure, calculating a material cylinder pressure trend value, and generating a material cylinder pressure alarm signal when the material cylinder pressure trend value exceeds a material cylinder pressure trend threshold value;
generating an average moment curve according to the average moment of the quantitative electromechanical machine, calculating an average moment trend value, and generating an average moment alarm signal when the average moment trend value exceeds an average moment trend threshold value;
generating a filling time curve according to the filling time of the sizing material, calculating a filling time trend value, and generating a filling time alarm signal when the filling time trend value exceeds a filling time trend threshold value;
obtaining a qualification rate according to the percentage of the qualified result in the gluing result to the whole result;
displaying the effective utilization, the stock remaining, the material cylinder pressure curve, the average moment curve, the fill time curve, and the yield via a human-machine interface.
9. A storage medium storing computer readable instructions which, when executed by a processor, implement the method of any one of claims 1-6.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210597615.1A CN117217723A (en) | 2022-05-30 | 2022-05-30 | Method, device, system and storage medium for monitoring gluing process |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202210597615.1A CN117217723A (en) | 2022-05-30 | 2022-05-30 | Method, device, system and storage medium for monitoring gluing process |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117217723A true CN117217723A (en) | 2023-12-12 |
Family
ID=89037579
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202210597615.1A Pending CN117217723A (en) | 2022-05-30 | 2022-05-30 | Method, device, system and storage medium for monitoring gluing process |
Country Status (1)
| Country | Link |
|---|---|
| CN (1) | CN117217723A (en) |
-
2022
- 2022-05-30 CN CN202210597615.1A patent/CN117217723A/en active Pending
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CN102672932B (en) | preventative maintenance system | |
| US20070293977A1 (en) | Preventative Maintenance Indicator System | |
| WO2007143856A1 (en) | Preventative maintenance update system | |
| CN110701137B (en) | Intelligent online detection and diagnosis device and method for hydraulic system of heading machine | |
| CN108006017A (en) | Hot continuous rolling skin pass mill group hydraulic station real-time level tracking and controlling method | |
| CN103226651A (en) | Wind turbine state evaluation and early-warning method and system based on similarity statistics | |
| CN111531830A (en) | State determination device and state determination method | |
| CN116275755A (en) | Intelligent control system of welding production line | |
| CN108748936A (en) | A kind of injection workshop Intelligent Production Management System and its method | |
| CN117217723A (en) | Method, device, system and storage medium for monitoring gluing process | |
| EP3749501A1 (en) | Method for operating an extruder, and extruder | |
| WO2020038666A1 (en) | Device for outputting a future state of a lubrication system | |
| CN213579938U (en) | Displacement pump leakproofness detecting system and fracturing system | |
| CN110962315B (en) | State determination device and state determination method | |
| DE102006032648B4 (en) | Diagnostic system and method for condition monitoring and detection of malfunctions and failures to compressing and rotating machines | |
| US20220347906A1 (en) | Method for monitoring the hydraulic supply system of a plastic processing machine | |
| CN112213038A (en) | Detection system and detection method for sealing performance of displacement pump and fracturing system | |
| CN115222076A (en) | Intelligent management system for maintenance of rail transit vehicle frame | |
| WO2023222160A1 (en) | Method and device for detecting measurement data of a machine, and tire heating press having a device for detecting measurement data | |
| CN210219260U (en) | Intelligent centralized lubricating device of oil pumping unit | |
| EP4181027A1 (en) | System and method of monitoring a cyclically operating manufacturing device | |
| WO2020188462A1 (en) | A performance monitoring system of a cnc machine | |
| CN114442564A (en) | Injection molding machine production data acquisition monitoring system and working method thereof | |
| CN110727253A (en) | Construction method of energy metering instrument data quality early warning mechanism | |
| CN114876782A (en) | Hydraulic pump fault detection method and device and working machine |
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 |