CN101561668A - Online monitoring system and monitoring method of oilless bushing sintering production line - Google Patents
Online monitoring system and monitoring method of oilless bushing sintering production line Download PDFInfo
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- 238000000034 method Methods 0.000 title claims abstract description 84
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 39
- 238000005245 sintering Methods 0.000 title claims abstract description 27
- 238000012544 monitoring process Methods 0.000 title abstract description 18
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Abstract
The invention discloses a monitoring system and a monitoring method of an oilless bushing sintering production line. By means of the thought and method of the SPC process management theory, the operation process of the sintering production line is monitored all the way; by automatic interpretation of mean value-range chart, the vibration of the process is prewarned and warned, ensuring that the process capability executed by the system conforms to requirements and ensuring the quality conformity of final machined parts as well. The monitoring system of the oilless bushing sintering production line comprises a PLC 1, a server 2, a workstation computer 3, a client computer 4 and a sensor-based system 5. The monitoring system of the oilless bushing sintering production line mainly comprises the following steps: reading data; calculating the mean value and range value of all data; respectively calculating the centerlines, upper control lines and lower control lines of mean value chart and range chart; drawing mean value chart and range chart; calculating process capability indexes Cpk and Ppk; judging the process; returning to data reading to carry out dynamic update of continuous fetching.
Description
Technical field
The present invention relates to a kind of continuously acting production lines supervisory system and method for supervising, relate in particular to a kind of oilless bushing sintering production line supervisory system and method, belong to the process control technology field.
Background technology
The a lot of products of manufacturing need to carry out production processes such as hot-working, thermal treatment in process, and these operations are generally as the important procedure in the production process, because product can't be checked adding man-hour, and do not have the suitable method of inspection that the batch machining result is checked, perhaps can't take comparatively economical and easy measuring means is verified.Therefore the parameter control of process seems extremely important, such as forging, thermal treatment, metal sintering or the like industry, temperature is often as most important machined parameters, be the important quality that the accuracy of equipment processing temperature and stability can the decision products, and product quality require highly more then then to require higher to the accuracy and the stability of equipment.
Present robotization control can realize by industrial computer equipment being controlled and operating and setting, but accurately whether the result of equipment execution actually, process whether add up by controlled having no idea, and can only the product of final completion be detected.If therefore process does not obtain monitoring, in case meeting out of control brings great refining losses.
In the sintered production line of Nonlubricated bearing, package cold-rolled steel sheet or steel band pass through at the certain thickness copper alloy powder of its surface sediment, through after the heat-agglomerating with the steel backing strong bond, produce copper powder sheet material, again through cutting out, punching press, shaping, surface treatment etc. are a series of is processed into final no oily boundary lubrication bearing.Wherein sintering circuit is one of operation that the oilless bearing quality is risen crucial influence, and its sintering temperature has determined the bonding strength of copper alloy layer.Therefore be necessary each operation of the production line especially parameters such as sintering temperature of sintering circuit is carried out whole process supervision.
Summary of the invention
The object of the present invention is to provide a kind of method of oilless bushing sintering production line monitoring, use the thinking and the method for SPC process management theory, the operational process of complete monitoring sintered production line, automatic interpretation by average-extreme difference figure, early warning and warning are carried out in variation to process, the process capability that the assurance system carries out meets the requirements, and guarantees the qualified of final workpiece quality.
Purpose of the present invention is achieved by the following technical programs:
A kind of oilless bushing sintering production line online monitoring system comprises PLC1, server 2, workstation computer 3, client computer 4, sensor-based system 5.Described server 2, client computer 4 are connected communication by Ethernet with workstation computer 3; Described server 2 is responsible for the authority of the daily process data of record, process program data, system operators and information log etc.; The order that described client computer 4 will be operated passes to workstation computer 3, operates production line with the client form; Sensor-based system 5 is made up of sensor 6 and converter 7, and 6 pairs of temperature of sensor, speed, humidity etc. detect, and by converter 7 analog quantity is converted to numerical information and passes to workstation computer 3; Described PLC1, converter 7 are connected communication with workstation computer 3 by the RS232 interface, after workstation computer 3 obtains sensing data, data recording in server 2, are carried out data operation simultaneously, and parameter is carried out process analysis procedure analysis.
A kind of oilless bushing sintering production line method for supervising comprises the following step:
1) Network Check;
2) if step 1) failure, then system alarm and end;
3) if the database connection is then carried out in the step 1) success;
4) systematic parameter initialization;
5) port data initialization;
6) carrying out hardware connects;
7) if step 6) failure, then system alarm and end;
8) execution in step 9 if step 6) is successful);
9) data read;
10) data computation;
11) carry out control chart and draw and be back to step 9);
12) data storage;
13) finish.
Purpose of the present invention can also further realize by following technical measures:
The step 10) of above-mentioned oilless bushing sintering production line method for supervising, 11) specifically be divided into the following step:
1) calculates average and the extreme difference value of respectively organizing data;
2) CL (center line), UCL (upper control line), the LCL (following control line) of difference computation of mean values figure and range chart;
3) draw average figure and range chart;
4) computation process Capability index Cpk and Ppk;
5) process is judged;
6) be back to data read, continue peek and dynamically update.
Compared with prior art, the invention has the beneficial effects as follows: by running on the watchdog routine among the production line online monitoring system, use the thinking and the method for SPC process management theory, the operational process of complete monitoring sintered production line, automatic interpretation by average-extreme difference figure, early warning and warning are carried out in variation to process, and the process capability that the assurance system carries out meets the requirements, and guarantees the qualified of final workpiece quality.
Description of drawings
Fig. 1 is a system construction drawing of the present invention.
Fig. 2 is a program flow diagram of the present invention.
Fig. 3 is the program flow diagram of embodiment.
Fig. 4 is the average figure of embodiment.
Fig. 5 is the range chart of embodiment.
Fig. 6 is typical nonrandom figure.
Embodiment
The invention will be further described below in conjunction with the drawings and specific embodiments.
As shown in Figure 1, a kind of oilless bushing sintering production line online monitoring system comprises PLC1, server 2, workstation computer 3, client computer 4, sensor-based system 5.Described server 2, client computer 4 are connected communication by Ethernet with workstation computer 3; Described server 2 is responsible for the authority of the daily process data of record, process program data, system operators and information log etc.; The order that described client computer 4 will be operated passes to workstation computer 3, operates production line with the client form; Sensor-based system 5 is made up of sensor 6 and converter 7, and 6 pairs of temperature of sensor, speed, humidity etc. detect, and by converter 7 analog quantity is converted to numerical information and passes to workstation computer 3; Described PLC1, converter 7 are connected communication with workstation computer 3 by the RS232 interface, after workstation computer 3 obtains sensing data, data recording in server 2, are carried out data operation simultaneously, and parameter is carried out process analysis procedure analysis.
As Fig. 2, shown in Figure 3, the oilless bushing sintering production line method for supervising comprises the following step:
1) Network Check;
2) if step 1) failure, then system alarm and end;
3) if the database connection is then carried out in the step 1) success;
4) systematic parameter initialization;
5) port data initialization;
6) carrying out hardware connects;
7) if step 6) failure, then system alarm and end;
8) execution in step 9 if step 6) is successful);
9) data read;
10) calculate average and the extreme difference value of respectively organizing data;
11) CL (center line), UCL (upper control line), the LCL (following control line) of difference computation of mean values figure and range chart;
12) draw average figure and range chart;
13) computation process Capability index Cpk and Ppk;
14) process is judged.
15) be back to step 9) continue the peek dynamically update;
12) data storage;
13) finish.
In the sintered production line of oilless bushing, package cold-rolled steel sheet or steel band pass through at the certain thickness copper alloy powder of its surface sediment, through after the heat-agglomerating with the steel backing strong bond, produce copper powder sheet material, again through cutting out, punching press, shaping, surface treatment etc. are a series of is processed into final no oily boundary lubrication bearing.The typical process route of this production line is: mud (shop self-lubricating material PTFE) → oven dry → roughing → PTFE plasticizing → finish rolling → cut apart (cutting out) → rolling is smoothed → is contained in cold-rolled steel sheet/steel band → uncoiling → smoothing → butt welding (during the stub bar seam) → smoothing → cleaning → oven dry → polishing → shop powder (copper powder) → sintering → traction.Wherein the oilless bearing quality is played two operations that have of crucial influence, one is shop powder (copper powder), and its shop powder thickness and homogeneity have determined the dimensional accuracy of products level; Another is a sintering circuit, and its sintering temperature has determined the bonding strength of copper alloy layer.For sintering circuit, generally need the temperature value of 10 heating zone of monitoring, the center that is chosen in the heating furnace Entry Interface is placed 10 pieces of temperature sensors successively and is obtained temperature data.
The present invention selects SPC, and (Statistial Process Control: statistical Process Control) this statistical method because SPC emphasizes the control to process, obtains qualified processing result by the control to process as monitoring means.SPC serves as decision means according to the calculating by a series of quantifications and figure with the normal distribution probability theory, tell the supvr whether this is taken measures in process of production with quantitative determination methods, rather than by the time just make a response afterwards, promptly need not wait until to finish production to learn just that by check production run occurs unusual, SPC process statistics method statistic be the result that " people, machine, material, method, ring, survey " produces six key element combined actions.
The most frequently used monitoring pattern is exactly average-range chart (Xbar-R Chart) among the SPC, and present embodiment is selected this figure for use.Be example with the sintering circuit monitoring temperature below, specifically introduce step 9) in the oilless bushing sintering production line method for supervising to the computation process of step 15):
1, at first obtains measured temperature by sensor
Per second is got a temperature value and record at set intervals or after certain processing quantity, gets 1 to 10 (present embodiment is got 5) continuously.System calculates every group average and extreme difference value automatically.Computing formula is as follows:
| | Group | 1 | |
|
|
…… |
| x1 | 550.572 | 550.572 | 550.772 | 551.002 | …… | |
| x2 | 550.796 | 550.906 | 550.616 | 550.796 | …… | |
| x3 | 550.192 | 550.372 | 550.072 | 549.962 | …… | |
| x4 | 550.254 | 550.384 | 550.754 | 550.434 | …… | |
| x5 | 550.432 | 550.532 | 550.402 | 550.662 | …… |
Class mean
 |
550.4492 | 550.5532 | 550.5232 | 550.5712 | …… |
| Group extreme difference R | 0.604 | 0.534 | 0.7 | 1.04 | …… |
2, the value sum reaches after 100, respectively CL (Center Line center line), UCL (Upper C0ntrol Limit upper control line), the LCL (control line under the Lower C0ntrol Limit) of computation of mean values figure and range chart
A wherein
2, D
3, D
4Be coefficient, relevant with n, can obtain by the inquiry following table:
Annotate: n representative group is held, i.e. every group data number (5);
As calculated:
UCLx＝551.029 UCLr＝1.749
LCLx＝550.074 LCLr＝0
3, Automatic Program is drawn control chart, and promptly average figure and range chart are seen Fig. 4,5;
Among Fig. 4, each data point on the Xbar figure is represented the mean value of each group data
Each data point on Fig. 5 is represented the extreme difference value R of each group data;
4, computation process Capability index Cpk and Ppk
Process capability is meant that qualitative factors such as personnel, equipment, material, method, environment, measurement fully standardize, the ability of the assurance procedure quality that is under the state of a control to be showed.This is intrinsic repeatability of a kind of process or conforming ability, is a kind of comprehensive assurance ability.Process capability is the basis and the important symbol of procedure quality control.
Since process capability is a kind of ability, it can be measured in fact.Facts have proved that process capability is strong more, the fluctuation of quality characteristic value is also just more little; Process capability is poor more, and the fluctuation of quality characteristic value is also just big more.
Cpk computation process is as follows:
As calculated: Cpk=4.1649
Ppk computation process is as follows:
As calculated: Ppk=4.7607
Annotate:＜1〉Ppk value is mainly used in considering of erratic processes such as trial production, short run, and usage is with the Cpk value.
＜2〉d
2Be coefficient, relevant with n, can obtain by the inquiry following table:
| |
2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 |
| d 2 | 1.12 8 | 1.69 3 | 2.05 9 | 2.32 6 | 2.53 4 | 2.70 4 | 2.84 7 | 2.97 0 | 3.07 8 |
The big more declarative procedure of Cpk value is stable more in theory, and the qualification rate of its processing result is also high more.But in the actual production, the Cpk value is not to be the bigger the better, and pursues too high Cpk value and drops into more handling cost in often meaning, chooses appropriate C pk desired value, is the important process of SPC management yet.Following table is the reference of choosing of Cpk desired value.
| Grade | Cpk | The process capability evaluation | Disposal route |
| Superfine | Cp＞1.67 | Too abundant | Only be used for production valuable, sophisticated product.For the production of common product, can consider to reduce production cost.As adopt precision lower, and the equipment that efficient is higher, reduced inspection requires or the process control requirement. |
| One-level | 1.33≤Cp＜1.67 | Ability is abundant | If not significant process, suitably reduced inspection and process control requirement. |
| Secondary | 1≤Cp＜1.33 | Ability still can | Process should be controlled, can not reduced inspection, otherwise will produce more unacceptable product |
| Three grades | 0.67≤Cp＜1 | Scarce capacity | The process capability of must taking measures to improve will be strengthened check to the product of producing, and needs full inspection in case of necessity |
| Level Four | Cp＜0.67 | The ability wretched insufficiency | Must suspend processing, trace reason immediately, formulate improvement plan, take innovative approach.To strengthen check to the product of producing, preferably inspection entirely |
For present embodiment, it is too abundant that Cpk=4.1649 just belongs to process capability, though be the critical process characterisitic parameter of bearing, considering to carry out suitable adjustment under the cost situation, and Cpk is controlled at about 1.67 for good.
5, process is judged
The carrying out of declaring different foundation " small probability event " of control chart.Under following situation, the SPC supervisory system proposes report to the police (optional):
When a) the Cpk value is lower than setting value (be defaulted as 1.330, can revise);
B) in average figure and the range chart, data point is outside control limit or just on control limit;
C) in average figure and the range chart, the data point in the control limit is arranged (Fig. 6 has exemplified the typical nonrandom figure of part) not at random, comprising:
I. continuous 7 risings of numerical point descend, continuous 7 in center line one side;
Ii. numerical point continuous 7 in center line one side;
Iii. in continuous 3 points, have at least at 2 near control limit;
Iv. in continuous 7 points, have at least at 3 near control limit;
V. in continuous 10 points, have at least at 4 near control limit;
Vi. in continuous 11 points, have at least at 10 in center line one side;
Vii. in continuous 14 points, have at least at 12 in center line one side;
Viii. in continuous 17 points, have at least at 14 in center line one side;
Ix. in continuous 20 points, have at least at 16 in center line one side.
6, continue peek, dynamically update.
Along with producing constantly operation, data volume increases gradually, and control chart upgrades automatically, and lower control limit in the revision calculates Cpk and Ppk (process capability index) simultaneously, sums up up-to-date process condition.
In addition to the implementation, the present invention can also have other embodiments, and all employings are equal to the technical scheme of replacement or equivalent transformation formation, all drop in the protection domain of requirement of the present invention.
Claims (3)
1, a kind of oilless bushing sintering production line supervisory system comprises PLC (1), server (2), workstation computer (3), client computer (4), sensor-based system (5), it is characterized in that described server (2), client computer (4) are connected communication by Ethernet with workstation computer (3); Described server (2) is responsible for the authority of the daily process data of record, process program data, system operators and information log etc.; The order that described client computer (4) will be operated passes to workstation computer (3), operates production line with the client form; Sensor-based system (5) is made up of sensor (6) and converter (7), and sensor (6) detects temperature, speed, humidity etc., and by converter (7) analog quantity is converted to numerical information and passes to workstation computer (3); Described PLC (1), converter (7) are connected communication with workstation computer (3) by the RS232 interface, after workstation computer (3) obtains sensing data, data recording in server (2), are carried out data operation simultaneously, and parameter is carried out process analysis procedure analysis.
2, a kind of oilless bushing sintering production line method for supervising is characterized in that, this method comprises the following step:
1) Network Check;
2) if step 1) failure, then system alarm and end;
3) if the database connection is then carried out in the step 1) success;
4) systematic parameter initialization;
5) port data initialization;
6) carrying out hardware connects;
7) if step 6) failure, then system alarm and end;
8) execution in step 9 if step 6) is successful);
9) data read;
10) data computation;
11) carry out control chart and draw and be back to step 9);
12) data storage;
13) finish.
3, a kind of oilless bushing sintering production line method for supervising as claimed in claim 2 is characterized in that described step 10), 11) specifically be divided into the following step:
1) calculates average and the extreme difference value of respectively organizing data;
2) CL (center line), UCL (upper control line), the LCL (following control line) of difference computation of mean values figure and range chart;
3) draw average figure and range chart;
4) computation process Capability index Cpk and Ppk;
5) process is judged;
6) be back to data read, continue peek and dynamically update.
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