CN102540944A - Embedded multifunctional statistical process control (SPC) device and method - Google Patents
Embedded multifunctional statistical process control (SPC) device and method Download PDFInfo
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Abstract
The invention discloses an embedded multifunctional statistical process control (SPC) device and method, wherein the device comprises a processor, an industrial control main board, an operating system, a basic information module, a data entry module, a data processing center, an SPC pattern formation module and an alarm module, wherein the data processing center is internally provided with a control limit computer and a comparator; the basic information module at least comprises hierarchy information of data and information of SPC control basis, quality control points and parameters; the control limit computer adopts an SPC technology to detect the distribution characteristics of collected data with a certain amount and in a certain time slot, calculates and stores the control limit; and the comparator compares the data and the control limit according to the judged rules of the SPC control basis. According to the invention, an SPC system is embedded in an embedded industrial control device, the seamless integration of software and hardware is realized, the system can rapidly and accurately complete quality data analysis based on the statistical principle, and adapts to the specific requirement of different manufacturing systems, and the quality control of a product process is realized.
Description
Technical field
The present invention relates to technical field of data processing, more particularly, relate to a kind of embedded type multifunctional statistical Process Control device and method.
Background technology
The development of microelectric technique and manufacturing industry application software technology makes the production equipment of mechanization on the traditional industry meaning, electrification, robotization possess the characteristic of digitizing, intellectuality, networking, and the manufacturing industry application software is information-based and industrialized fusion agent.At present, a lot of enterprises has been arranged the important component part of informationalized work as enterprise development, but because more technical development restrictions; In the middle of the informationalized process of enterprise implement; The hardware and software major part is separated, and is serious even cause the disconnection in the practical application, and application software can not play a role well; Even system does not re-use once reaching the standard grade; Even implemented the enterprise of modernized information management system, also because the characteristics of manufacturing industry itself, can only manual typing production data or need be used for the commercial production scene to common PC; Add the intrinsic factors such as instability of present Windows operating system itself, make the use of system, maintenance cost all very high.Internal pair production department in enterprise, supvr set up the underproof mechanism of prevention in order to control the production situation of product; The method of normal use statistical Process Control (Statistical Process Control, SPC), it is to be the basis with the mass data and the fact; Also analyze through collection process information, by mathematical statistics technology, situation in time notes abnormalities; Eliminate so that take measures unusual with improve operation, the method for quality control that aspires after perfection is though emerged in large numbers many softwares about SPC at present; But, on using, receive certain restriction seeing that above-mentioned informationization combines the deficiency of existence with industrialization.
Summary of the invention
The object of the invention provides a kind of embedded type multifunctional statistical Process Control device and method in order to overcome the deficiency that above-mentioned prior art exists, for the product quality management of enterprise provides good tool.
The technical scheme that the present invention adopts is: embedded type multifunctional statistical Process Control device, comprise processor, industrial control mainboard, operating system, and also comprise:
The basic data module includes the hierarchical information of data, the information that SPC controls basis, Quality Control point and parameter at least;
Data typing module comprises that manual data typing module, file or database import one or more of module, instrument and equipment data acquisition module;
Data processing centre (DPC); In be provided with control limit counter and comparer; Said control limit counter is to the some that collects and the distribution character of the data Statistical Process Control technology for detection data in the time period; Calculate control limit and storage, said comparer compares data and control limit by the different rule of declaring that SPC controls the basis;
SPC figure generation module, the control limit figure at corresponding level indicates with data;
Alarm module is reported to the police to detected unusual data cases by data processing centre (DPC).
Above-mentioned embedded type multifunctional statistical Process Control device also comprises the report output module, by data processing centre's processing collected to data and generate the statistical report form that production management is used.
Above-mentioned embedded type multifunctional statistical Process Control device; Said industrial control mainboard comprises CPU module, IDE hard disk, internal memory, display module, power module; Also comprise the Ethernet link block; The wireless network module of external WiFi, touch screen interface module, usb interface module, said Ethernet link block, wireless network module, touch screen interface module, usb interface module all are connected with CPU.
Above-mentioned embedded type multifunctional statistical Process Control device; Comprise CPU module, IDE hard disk, internal memory, display module, power module; It is characterized in that: also comprise the Ethernet link block; The wireless network module of external WiFi, touch screen interface module, usb interface module, said Ethernet link block, wireless network module, touch screen interface module, usb interface module all are connected with CPU.
Above-mentioned embedded type multifunctional statistical Process Control device, said CPU module also is connected with infrared remote control module, camera link block, audio-frequency module.
The control method of above-mentioned embedded type multifunctional statistical Process Control device may further comprise the steps:
1) analytic product manufacture process is confirmed Quality Control point and parameter thereof;
2) product variety, operation, Quality Control point, parameter, bad code information layering are provided with;
3) press level and select the appropriate control graph type;
4) basic data acquisition and analysis, data are declared surely;
The stable data calculation control limit that 5) will collect;
6) daily process data collection and declare surely if process stabilization then continues monitoring, then triggers warning if the data shakiness occurs.
Above-mentioned multi-functional statistical process control method, basic data acquisition, analyze and declare steady step after confirm the processing procedure process capability.
Compared with prior art, the present invention has the following advantages:
1) the present invention has set up the software application system that a cover has certain practicality; The SPC statistical process control system is embedded in the built-in industrial opertaing device; Realize that software and hardware is seamless integrated, system applies be framework on the integrated basis of software and hardware height, possess the advantage of PC power and embedded system simultaneously; Be applied on the manufacturing equipment of manufacturing industry; It can accomplish the various qualitative data analysises based on Statistics quickly and accurately, adapts to the particular requirement of different manufacturing systems, has realized the quality control to the product process.
2) the present invention is with the intelligent industrial control mainboard of characteristics such as function is strong, low in energy consumption, performance is high, interface is many, the resolution height support member as the industrial control equipment whole system bottom; Embedded Windows CE operating system; Simultaneously SPC technology and production quality control are organically combined; To the practical application of SPC, adopt the c# high-level programming language that the design of its simulation softward is analyzed, set up controlling models.
3) the present invention has multilingual support, the customization arbitrarily of system layer information, product and qualifying point infinite expanding, many type of alarms, judges that unusual rule can be adjusted, rights management mechanism and support function such as ERP system, the powerful practicality of systemic-function comprehensively.
Description of drawings
Fig. 1 is the industrial control mainboard structural representation of embedded type multifunctional statistical Process Control device of the present invention;
Fig. 2 is an embedded type multifunctional statistical Process Control apparatus structure frame diagram of the present invention;
Fig. 3 is an embedded type multifunctional statistical Process Control device workflow diagram of the present invention.
Embodiment
Below pass through embodiment, and combine accompanying drawing that the present invention is described further.
Referring to Fig. 1-3; The SPC statistical process control technology is applied to use multidimensional data to be expressed as the business indicators of a value; System can detect process capability potential in the enterprise production process and rule; And can monitor the variation of its essence, and therefore can notify the potential variation trend of certain Quality Control point to the production manager of enterprise through reporting to the police, through correction, preventive measure the quality of product is got a promotion.Embedded type multifunctional statistical Process Control device of the present invention is SPC control technology and Computer Control Technology perfect adaptation, for the product quality management of enterprise provides good tool.
The industrial control unit (ICU) mainboard comprises CPU module 1, IDE hard disk, internal memory 9, display module 2, power module; Also comprise Ethernet link block 3; The wireless network module 4 of external WiFi; Touch screen interface module 12, usb interface module 5, infrared remote control module 7, camera link block 6, audio-frequency module 11, external memory 8, sound card 10, above-mentioned module or peripheral hardware all are connected with CPU.Be embedded with Windows CE operating system at the IDE hard disk.Mainboard adopts the AU1250 of RMI Corp. processor; With the support member of 3.5 inches (146mm x 102mm) mainboards as the industrial control unit (ICU) whole system bottom; Embedded Windows CE operating system can be carried out types of applications procedure development and use, is applied to all trades and professions.The Alchemy Au1250 series processors of RMI Corp.; Be a low-power consumption, high performance SOC(system on a chip) solution; Towards portable multifunctional media player (mPMP), mobile message amusement equipment, family digital media filter (DMA), navigator, medical electronics and commercial Application; The Au1250 processor is supported MPEG-1, MPEG-2,4wmv9, DivX and the full D1 of Xvid (720x480) video 30fps smooth playing, and processor interface is abundant, and is powerful; Support maximum 1280x1024 resolution; Be particularly suitable for the performance application that general arm processor can't satisfy, its SoC framework has been integrated most of peripherals, thereby has greatly reduced material cost.Integrated following hardware on the industrial control mainboard mainboard: power supply, CPU, RTC, FLASH, DDR2 SDRAM, Ethernet, WiFi, USB2.0, RS232/RS485 serial ports, CF/SDHC/MMC/xD/MS card, IDE hard disk, sound card, power amplifier, touch screen controller, 8x8 keyboard, infrared remote control, VGA, LCD driving, backlight control, Camera etc.The Windows CE embedded OS that operating system adopts Microsoft company to produce, this system is a kind of compactness, efficient, telescopic 32 operating system, can do the function cutting according to actual needs, mainly towards various embedded systems and product.The multithreading that it had, multitask, the characteristics of preemptive type are to aim at variously to have the hardware system of very strict resource limit to design fully.Can reach following technical indicator by above-mentioned scientific allocation, for the SPC control system provides strong support:
(1) supports hand-written touch screen more than 7 to 15 inches;
(2) the preventable disease poison is invaded, and is easy to maintenance;
(3) low-power consumption is approximately 1/10 of common PC, saves energy greatly, and general relatively PC, can be about 2000 Renminbi of enterprise's saves energy every every year;
(4) the hardware volume is little, can be placed in the worktable, also can be installed in the equipment, practices thrift space, factory place;
(5) stability is high, has higher class of safety protection than common PC;
(6) compare with common PC, maintenance cost is cheap, and there is self-protective mechanism in system;
(7) can insert a plurality of equipment simultaneously through expansion, support USB interface, Ethernet interface, RS232/RS485, and wireless transmission function.
In order scientifically data to be carried out statistical study, seek the quality influence key element of CCP, the prophylaxis of undesired article produce, and to reach the purpose that reduces quality cost, improves the quality of products, total system is by constituting with lower module:
(1) data typing module comprises that manual data typing, file or database import, the instrument and equipment data acquisition, accomplishes the data acquisition and the typing at each reference mark of product that enterprise produces.
(2) basic data module comprises:
The hierarchical information typing---accomplish the hierarchical information in the production run, can carry out multi-faceted control by different level when making process control, such as batch, information such as equipment, personnel, order of classes or grades at school, client.
Quality Control point and parameter typing---accomplish the typing of each product key control parameter information.
User information data typing---completion system uses the typing of user basic information, comprises the operating right of system etc.
The typing of SPC control basic data---accomplish typing, comprise control chart essential information (specification limit, control limit, sample size, process capability criterion etc.), declare the typing of information such as different rule SPC theoretical direction information.
(3) the SPC figure generates---and comprise the operation map generalization and check module, accomplish checking and analyzing operation trend figure; Control chart generates and checks module, accomplishes checking and analyzing control chart; The process capability analysis chart generates and checks module, accomplishes checking and analyzing the process capability analysis chart.
(4) form and policy paper output module---accomplish through gathering, result behind the statistics and analysis, and guide production.
(5) Realtime Alerts module---accomplish instant warning, the generation of prevention quality accident to production data in the production run.Alarm module contrast control limit parameter value comparison typing or equipment obtain data, to determine whether to exist the situation of break bounds limit, if break bounds, then trigger and report to the police.The mode of reporting to the police is selected by the user, and is preset in system, as sending warning Email, short message service, bright alarm lamp or the like.
Also be provided with maintenance module in the system, be used to accomplish maintenance, such as initialization, data backup and data recovery etc. system data.
The present invention uses c# as programming language, and Visual Studio 2008 is a development environment, and Microsoft SQL Server 2000 is a background data base.Because the WinCE exploitation all is the VC++ environment of well known; Fast convenient, the powerful technical support of Microsoft, its development difficulty is far below built-in Linux; With the property of the same clan of WindowXP, Win2000, but the program increased ease of implantation thereof that has guaranteed originally on PC, to develop is in embedded system; Up-to-date Visual Studio 2008 has supported the exploitation based on the Windows CE application program under the Compact Framework; Add that Windows CE can be come by the convenient migration of Win32 application program; Can be transplanted in the middle of the application of Windows CE through the exploitation of Visual Studio 2008 based on SPC basic framework program under the Windows and foundation class etc. what found out; Actual requirement according to application program under the Windows CE remakes necessary adjustment and improvement again, adds that the expansion of function is able to form.Realize the embedding in the SPC statistical process control system built-in industrial opertaing device through above scheme, reach the seamless integrated application of software and hardware.In addition, after program development was accomplished, with some assemblies and Windows CE operating system and the associated components that need, the compiling packing was integrated together, in the disposable burned built-in industrial opertaing device with programming system.Make system maintenance easy like this, avoid extraneous factor such as virus and disturb, thus steady operation.
Software design of the present invention is through setting up mathematical model, after system receives the data from various load modules, and by SPC data processing centre (DPC) deal with data, generate the SPC control chart, thereby for the supvr provides accurately, the means of quality management and control intuitively.Introduce native system SPC control map generalization below in detail and declare different criterion.The SPC control chart mainly is divided into variable (Variable chart) figure and attribute (Attribute chart) figure and prognostic chart (Capability chart).Three control lines are all arranged in the control chart, i.e. UCL USL, control central line SL and lower control limit LSL, adopt following computing formula:
Thereby system utilizes the SPC technology to come calculation control to limit to be estimated, the variation of analytic process.Usually; Use control limit counter to accomplish this function, at first, system is with at least 100 data points of the use in a period of time scope; Through SPC technique computes UCL and lower control limit, mean value; And the generation control chart, demonstrate UCL, lower control limit, three horizontal lines of center line (mean value) on the control chart usually, and on figure, mark each data point position.The chart that the SPC control chart of default is commonly used has: fraction defective control chart, control chart for number of defects, mean chart, standard deviation control chart, range chart etc.
Wherein, control chart for number of defects can be kept watch on " defective " quantity of equivalent sample easily based on Poisson process, is applicable to illustrate bad report counting takes place.Average and range chart then are usually used in daily production run control.
The data of getting certain interval earlier are as preliminary date, and the data number N preferably has more than 100.By the time be divided into N n=4 is whenever arranged, 5 k=20～25 group and tabulating, Xmax is the maximal value in the data set, Xmin is the minimum value in the data set, and data are carried out computing by following formula:
The design unification of data structure with 5 measured values as one group of data set.For make draw and last calculating more convenient, need all data set content stores be got off.Use container can dynamically add object.In addition; Draw for ease and hotspot query (data point on the click coordinate axle shows the details of the residing data set of this data point) is provided; Write a data class (DetailData); Be used for preserving the details of data set, comprise the description of 5 master data values, data set average (promptly being in the value of the data point of this data set), data set extreme difference value, collection date and time and abnormal conditions in the data set.Write an Attribute class (Pointer) again, this class description be the data point attribute, comprise the object of abscissa value x, ordinate value y, abnormal conditions, whether up to specification, data set specifying information.
When one group of data is measured in success, at first generate an object of data class, the information of record data group comprises average and extreme difference, collection date and time and the abnormal conditions (if do not have, then being normal) of 5 master datas, data set.Mean value computation according to data set goes out corresponding coordinate figure then, and situation up to specification then generates the object of an Attribute class, joins in the container.If abnormal conditions occur, generate an object of data class equally, it all is 0 that the essential information of data set is set at 5 master datas, average and extreme differences, sets and gathers date and time and corresponding abnormal conditions.Ordinate value is the minimum value of axis of ordinates, sets it and falls short of specifications, and generates the object of an Attribute class equally, joins in the container.Like this, can fairly simplely carry out drawing and statistical computation afterwards easily.
Before the simulation actual measurement; By the mathematical expectation (mu) of elder generation of system according to the data area computational data; Import standard deviation (sig) by the user; Have the data of standardized normal distribution with the functional based method generation, generating corresponding off-gauge obedience mathematical expectation by system again is that mu, variance are the data of sig square normal distribution.
After having measured 100 data that are normal distribution, corresponding statistics such as the mean value of the automatic computational data of system, standard deviation and performance index also show.This step card program correctness.Data are afterwards just generated by system at random.The scope of measured value adds that at numerical value difference and numerical value subtract between the allowance below nominal size; Have functional based method to produce random number among the C#, adopt during design be produce greater than 0, less than the random value of last difference, and produce greater than allowance below nominal size, random value less than 0; With numerical value and the two addition, draw measured value.Design can as often as possible produce the numerical value of intermediate range like this, accomplishes to make the data normal distribution as far as possible.
Also must set in the SPC control basic module and declare different rule and control limit regulation rule.Control limit counter needs in existing data, to search trend, if following situation:
● individual point is on the UCL or under the lower control limit
● continuous 9 in center line the same side
● there are six data points that rise or descend continuously continuously
● continuous 14 consecutive point alternatively up and down
● seven points all are higher or lower than mean value
● datacycle or other nonrandom pattern appear
Above-mentioned situation need recomputate the control limit; For example, indivedual break bounds occur in limited time, earlier suspicious points is rejected; If after recomputating back new control limit and mean value; Distribution of data points better (the roughly data point of equivalent is arranged in the mean value both sides) can think that then new control limit is more suitable, has higher confidence level.If there are seven data points that rise or descend continuously continuously, can think usually that then significant variation has appearred in data, need the enterprise administrator more concern.
Claims (7)
1. embedded type multifunctional statistical Process Control device comprises processor, industrial control mainboard, operating system, it is characterized in that: also comprise:
The basic data module includes the hierarchical information of data, the information that SPC controls basis, Quality Control point and parameter at least;
Data typing module comprises that manual data typing module, file or database import one or more of module, instrument and equipment data acquisition module;
Data processing centre (DPC); In be provided with control limit counter and comparer; Said control limit counter is to the some that collects and the distribution character of the data Statistical Process Control technology for detection data in the time period; Calculate control limit and storage, said comparer compares data and control limit by the different rule of declaring that SPC controls the basis;
SPC figure generation module, the control limit figure at corresponding level indicates with data;
Alarm module is reported to the police to detected unusual data cases by data processing centre (DPC).
2. embedded type multifunctional statistical Process Control device according to claim 1 is characterized in that: also comprise the report output module, by data processing centre's processing collected to data and generate the statistical report form that production management is used.
3. embedded type multifunctional statistical Process Control device according to claim 2; It is characterized in that: said industrial control mainboard comprises CPU module, IDE hard disk, internal memory, display module, power module; Also comprise the Ethernet link block; The wireless network module of external WiFi, touch screen interface module, usb interface module, said Ethernet link block, wireless network module, touch screen interface module, usb interface module all are connected with CPU.
4. embedded type multifunctional statistical Process Control device according to claim 3; It is characterized in that: comprise CPU module, IDE hard disk, internal memory, display module, power module; It is characterized in that: also comprise the Ethernet link block; The wireless network module of external WiFi, touch screen interface module, usb interface module, said Ethernet link block, wireless network module, touch screen interface module, usb interface module all are connected with CPU.
5. embedded type multifunctional statistical Process Control device according to claim 4 is characterized in that: said CPU module also is connected with infrared remote control module, camera link block, audio-frequency module.
6. embedded type multifunctional statistical process control method is characterized in that may further comprise the steps:
1) analytic product manufacture process is confirmed Quality Control point and parameter thereof;
2) product variety, operation, Quality Control point, parameter, bad code information layering are provided with;
3) press level and select the appropriate control graph type;
4) basic data acquisition and analysis, data are declared surely;
The stable data calculation control limit that 5) will collect;
6) daily process data collection and declare surely if process stabilization then continues monitoring, then triggers warning if the data shakiness occurs.
7. embedded type multifunctional statistical process control method according to claim 6 is characterized in that: basic data acquisition, analyze and declare steady step after confirm the processing procedure process capability.
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