CN104407597A - Intelligent problem handling system for automatic production line - Google Patents
Intelligent problem handling system for automatic production line Download PDFInfo
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Abstract
本发明涉及自动化生产线设备控制技术领域，尤其是指一种自动化生产线问题智能处理系统，包括与生产设备的控制系统电连接的总控系统及与总控系统电连接的报警装置，其特征在于：所述总控系统包括问题决策模块及用于监测生产设备是否出现安全问题的监测模块，该监测模块将检测信息传送至总控系统，再由问题决策模块根据检测信息判断所述安全问题的问题等级，最后由总控系统根据问题等级从问题决策模块中调用相应的处理措施。本发明缩减了安全问题排除周期，提升生产效率，降低维护工作劳动强度和生产成本，避免了维护人员的大量重复性劳动，提升生产线整体生产效率。
The present invention relates to the technical field of automatic production line equipment control, in particular to an intelligent processing system for automatic production line problems, including a master control system electrically connected to the control system of the production equipment and an alarm device electrically connected to the master control system, characterized in that: The general control system includes a problem decision-making module and a monitoring module for monitoring whether a safety problem occurs in the production equipment. The monitoring module transmits the detection information to the general control system, and then the problem decision-making module judges the problem of the safety problem according to the detection information Finally, the general control system invokes corresponding measures from the problem decision-making module according to the problem level. The invention shortens the cycle of eliminating safety problems, improves production efficiency, reduces the labor intensity and production cost of maintenance work, avoids a large amount of repetitive labor of maintenance personnel, and improves the overall production efficiency of the production line.
Description
技术领域 technical field
本发明涉及自动化生产线设备控制技术领域，尤其是指一种自动化生产线问题智能处理系统。 The invention relates to the technical field of automatic production line equipment control, in particular to an intelligent processing system for automatic production line problems.
背景技术 Background technique
近年来，随着人力成本的快速上升，生产制造企业尤其是汽车制造行业对自动化生产线的需求日益提高。在产品生产过程中，自动化生产线不需要操作人员的参与，能够完全自主地完成全部生产工序，一般情况下仅需要少量人员完成原料供应、成品收集及设备操作维护工作，自动化可以大幅度有效提升生产效率，提升产品一致性，同时明显降低操作人员劳动强度，改善劳动环境。对生产制造企业而言，可以降低生产成本，提升企业和产品竞争力。 In recent years, with the rapid rise of labor costs, manufacturing enterprises, especially the automobile manufacturing industry, have increasingly increased demand for automated production lines. In the process of product production, the automated production line does not require the participation of operators, and can complete all production processes completely autonomously. Generally, only a small number of personnel are required to complete raw material supply, finished product collection, and equipment operation and maintenance. Automation can greatly and effectively improve production. Efficiency, improve product consistency, while significantly reducing the labor intensity of operators and improving the working environment. For manufacturing enterprises, it can reduce production costs and enhance the competitiveness of enterprises and products.
尽管自动化生产线对生产效率有着巨大的提升，但其应用仍存在不少问题。自动化生产线对生产效率的提升是以生产设备的高度稳定为前提。一般情况下，生产线自动化系统完成预置的工序步骤，并循环执行。自动化生产线一旦出现安全问题造成停机，维护人员必须立即介入，排除故障，使生产线恢复生产。考量自动化生产线实际生产效率必须考虑各种原因造成的停线对生产效率的不利影响。那么，停线时间越短对实际生产越有利。本发明就着力安全问题发生阶段，提出一种智能化响应处理方法，从整体上减少自动化生产线停线时长，在整个生产周期上提升有效生产时间的比重，从而提升生产线整体生产效率。 Although automated production lines have greatly improved production efficiency, there are still many problems in its application. The improvement of production efficiency by automated production lines is based on the high stability of production equipment. In general, the production line automation system completes the preset process steps and executes them cyclically. Once a safety problem occurs in an automated production line that causes a shutdown, maintenance personnel must immediately intervene to troubleshoot and restore the production line. Considering the actual production efficiency of an automated production line, it is necessary to consider the adverse effects of line stoppages caused by various reasons on production efficiency. Then, the shorter the downtime, the better the actual production. The present invention focuses on the occurrence stage of safety problems, and proposes an intelligent response processing method, which reduces the stoppage time of the automated production line as a whole, increases the proportion of effective production time in the entire production cycle, and thus improves the overall production efficiency of the production line.
发明内容 Contents of the invention
本发明要解决的技术问题是提供一种优化生产线安全问题处理流程和故障响应流程的自动化生产线问题智能处理系统，减少自动化生产线停线时长，大大提升了整体生产效率。 The technical problem to be solved by the present invention is to provide an automatic production line problem intelligent processing system that optimizes the production line safety problem processing process and fault response process, reduces the stoppage time of the automatic production line, and greatly improves the overall production efficiency.
为了解决上述技术问题，本发明采用如下技术方案：一种自动化生产线问题智能处理系统，包括与生产设备的控制系统电连接的总控系统及与总控系统电连接的报警装置，所述总控系统包括问题决策模块及用于监测生产设备是否出现安全问题的监测模块，该监测模块将检测信息传送至总控系统，再由问题决策模块根据检测信息判断所述安全问题的问题等级，最后由总控系统根据问题等级从问题决策模块中调用相应的处理措施。 In order to solve the above technical problems, the present invention adopts the following technical solutions: an intelligent processing system for automatic production line problems, including a master control system electrically connected to the control system of the production equipment and an alarm device electrically connected to the master control system, the master controller The system includes a problem decision-making module and a monitoring module for monitoring whether there is a safety problem in the production equipment. The monitoring module transmits the detection information to the general control system, and then the problem decision-making module judges the problem level of the safety problem according to the detection information. Finally, the The master control system invokes corresponding processing measures from the problem decision-making module according to the problem level. the
优选的，所述安全问题包括设备级安全问题、生产系统未知安全问题和生产系统已知安全问题； Preferably, the security issues include device-level security issues, unknown security issues of the production system, and known security issues of the production system;
若问题决策模块判断为设备级安全问题，则处理措施为紧急按钮启动，所有设备立即停止； If the problem decision-making module determines that it is a device-level safety problem, the handling measure is to activate the emergency button and stop all devices immediately;
若问题决策模块判断为总控系统未知安全问题或已知安全问题，则处理措施为故障设备的控制系统停止接受指令，自动停机或执行必要动作后停机，由报警装置发出警报。 If the problem decision-making module judges that the general control system has an unknown safety problem or a known safety problem, the treatment measures are that the control system of the faulty equipment stops accepting instructions, automatically stops or stops after performing necessary actions, and the alarm device sends out an alarm.
优选的，所述生产设备的控制系统为分布式系统，各设备系统松耦合独立运行，设备端控制系统仅执行有限的合法指令。 Preferably, the control system of the production equipment is a distributed system, each equipment system is loosely coupled and operates independently, and the equipment-side control system only executes limited legal instructions.
优选的，所述问题决策模块判断为总控系统未知安全问题时，总控系统获取故障信息后，向相关的非故障设备发出恢复指令，指示相关设备以安全速度执行恢复动作，到达准备运行状态，并等待运行指令。 Preferably, when the problem decision-making module determines that the general control system has an unknown safety problem, the general control system sends a recovery command to the relevant non-faulty equipment after obtaining the fault information, instructing the relevant equipment to perform recovery actions at a safe speed and reach the ready-to-run state , and wait for the execution command.
优选的，所述问题决策模块判断为总控系统已知安全问题时，总控系统获取故障信息后，根据设备关联关系和设备当前运行状态，向相关的非故障设备发出慢速指令。 Preferably, when the problem decision-making module determines that the master control system has a known safety problem, the master control system sends slow instructions to related non-faulty devices according to the device association relationship and the current operating status of the devices after obtaining the fault information.
优选的，若生产设备当前执行的动作是时间敏感的，则指示该设备执行故障响应动作；若生产设备当前执行的动作不是时间敏感的，则指示该设备以安全速度继续执行当前动作。 Preferably, if the action currently performed by the production equipment is time-sensitive, the equipment is instructed to perform a fault response action; if the action currently performed by the production equipment is not time-sensitive, the equipment is instructed to continue to perform the current action at a safe speed.
优选的，所述总控系统通过通信链路与生产设备的控制系统通信。 Preferably, the general control system communicates with the control system of the production equipment through a communication link.
优选的，所述问题决策模块对发现的安全问题进行分析后自主生成处理措施，并将处理措施分发到相关设备，由控制系统控制生产设备执行处理措施。 Preferably, the problem decision-making module automatically generates processing measures after analyzing the discovered security problems, and distributes the processing measures to related equipment, and the control system controls the production equipment to execute the processing measures.
本发明的有益效果在于：本发明提供了一种自动化生产线问题智能处理系统，本发明通过引入自动化生产线安全问题智能化响应处理方法，实现对安全问题响应处理过程的智能优化，缩减安全问题排除周期，提升生产效率，降低维护工作劳动强度和生产成本。相对于传统的安全问题处理办法，本发明利用自动化系统的通信链路和指令执行系统，精细优化安全问题处理流程，避免了复杂设备关联条件下认为操作出错的缺陷，避免了维护人员的大量重复性劳动，明显缩减生产线恢复周期，提升生产线整体生产效率。 The beneficial effect of the present invention is that: the present invention provides an intelligent processing system for problems in an automated production line. By introducing an intelligent response processing method for safety problems in an automated production line, the present invention realizes intelligent optimization of the process of responding to safety problems and reduces the cycle of eliminating safety problems. , Improve production efficiency, reduce maintenance labor intensity and production costs. Compared with the traditional security problem handling method, the present invention uses the communication link of the automation system and the command execution system to finely optimize the security problem processing flow, avoiding the defect that the operation error is considered under complex equipment related conditions, and avoiding a large number of repetitions by maintenance personnel Sexual labor, significantly shorten the recovery cycle of the production line, and improve the overall production efficiency of the production line.
附图说明 Description of drawings
图1为本发明所涉及安全问题检测系统结构图。 FIG. 1 is a structural diagram of a safety problem detection system involved in the present invention.
图2为本发明所涉及的生产线系统安全问题响应处理流程图。 Fig. 2 is a flow chart of the production line system safety problem response processing involved in the present invention.
图3为本发明所涉及的设备故障响应和处理流程图。 Fig. 3 is a flow chart of equipment fault response and processing involved in the present invention.
具体实施方式 Detailed ways
为了便于本领域技术人员的理解，下面结合实施例与附图对本发明作进一步的说明，实施方式提及的内容并非对本发明的限定。 In order to facilitate the understanding of those skilled in the art, the present invention will be further described below in conjunction with the embodiments and accompanying drawings, and the contents mentioned in the embodiments are not intended to limit the present invention.
如附图1至图3所示，自动化生产线问题智能处理系统，包括与生产设备的控制系统电连接的总控系统及与总控系统电连接的报警装置，所述总控系统包括问题决策模块及用于监测生产设备是否出现安全问题的监测模块，该监测模块将检测信息传送至总控系统，再由问题决策模块根据检测信息判断所述安全问题的问题等级，最后由总控系统根据问题等级从问题决策模块中调用相应的处理措施。 As shown in accompanying drawings 1 to 3, the automatic production line problem intelligent processing system includes a master control system electrically connected to the control system of the production equipment and an alarm device electrically connected to the master control system, and the master control system includes a problem decision-making module And a monitoring module for monitoring whether there is a safety problem in the production equipment. The monitoring module transmits the detection information to the general control system, and then the problem decision module judges the problem level of the safety problem according to the detection information, and finally the general control system according to the problem The class invokes the corresponding actions from the problem decision module.
本发明通过引入自动化生产线安全问题智能化响应处理方法，实现对安全问题响应处理过程的智能优化，缩减安全问题排除周期，提升生产效率，降低维护工作劳动强度和生产成本。相对于传统的安全问题处理办法，本发明利用自动化系统的通信链路和指令执行系统，精细优化安全问题处理流程，避免了复杂设备关联条件下认为操作出错的缺陷，避免了维护人员的大量重复性劳动，明显缩减生产线恢复周期，提升生产线整体生产效率。 The present invention realizes the intelligent optimization of the safety problem response processing process by introducing the intelligent response processing method of the safety problem in the automated production line, shortens the safety problem elimination cycle, improves the production efficiency, and reduces the maintenance work labor intensity and production cost. Compared with the traditional security problem handling method, the present invention uses the communication link of the automation system and the command execution system to finely optimize the security problem processing flow, avoiding the defect that the operation error is considered under complex equipment related conditions, and avoiding a large number of repetitions by maintenance personnel Sexual labor, significantly shorten the recovery cycle of the production line, and improve the overall production efficiency of the production line.
本实施例中，所述生产设备的控制系统为分布式系统，各设备系统松耦合独立运行，设备端控制系统仅执行有限的合法指令；所述安全问题包括设备级安全问题、生产系统未知安全问题和生产系统已知安全问题； In this embodiment, the control system of the production equipment is a distributed system, each equipment system is loosely coupled and operates independently, and the equipment-side control system only executes limited legal instructions; the security issues include equipment-level security issues, unknown security issues of the production system, etc. Issues and production system known security issues;
若问题决策模块判断为设备级安全问题，则处理措施为紧急按钮启动，所有设备立即停止，保障现场人员、设备安全。 If the problem decision-making module judges that it is a safety problem at the equipment level, the treatment measure is to activate the emergency button, and all equipment will be stopped immediately to ensure the safety of on-site personnel and equipment.
若问题决策模块判断为总控系统未知安全问题或已知安全问题，则处理措施为故障设备的控制系统停止接受指令，自动停机或执行必要动作后停机，由报警装置发出警报，提醒现场人员介入，便于现场人员进行人工处理。 If the problem decision-making module judges that the general control system has an unknown safety problem or a known safety problem, the treatment measures are that the control system of the faulty equipment stops accepting instructions, automatically stops or stops after performing necessary actions, and the alarm device sends out an alarm to remind on-site personnel to intervene , which is convenient for on-site personnel to perform manual processing.
具体的，所述问题决策模块判断为总控系统未知安全问题时，总控系统获取故障信息后，向相关的非故障设备发出恢复指令，指示相关设备以安全速度执行恢复动作，到达准备运行状态，并等待运行指令。 Specifically, when the problem decision-making module judges that the general control system has an unknown safety problem, the general control system sends a recovery command to the relevant non-faulty equipment after obtaining the fault information, instructing the relevant equipment to perform recovery actions at a safe speed and reach the ready-to-run state , and wait for the execution command.
本实施例中，所述问题决策模块判断为总控系统已知安全问题时，总控系统获取故障信息后，根据设备关联关系和设备当前运行状态，向相关的非故障设备发出慢速指令。 In this embodiment, when the problem decision-making module determines that the general control system has a known safety problem, the general control system sends a slow command to the relevant non-faulty equipment according to the equipment association relationship and the current operating status of the equipment after obtaining the fault information.
总控系统获取故障信息后，根据设备关联关系和设备当前运行状态，向相关的非故障设备发出慢速指令。具体的，若系统设备当前执行的动作是时间敏感的，则指示该设备执行故障响应动作；若系统设备当前执行的动作不是时间敏感的，则指示该设备以安全速度继续执行当前动作。 After the master control system obtains the fault information, it sends a slow speed command to the relevant non-faulty equipment according to the equipment association relationship and the current operating status of the equipment. Specifically, if the action currently performed by the system device is time-sensitive, instruct the device to perform a fault response action; if the action currently performed by the system device is not time-sensitive, instruct the device to continue to perform the current action at a safe speed.
本实施例中，所述总控系统通过通信链路与生产设备的控制系统通信,用于设备控制系统和总控系统双向的信息通信 In this embodiment, the master control system communicates with the control system of the production equipment through a communication link, which is used for two-way information communication between the equipment control system and the master control system
本实施例中，所述问题决策模块对发现的安全问题进行分析后自主生成处理措施，并将处理措施分发到相关设备，由控制系统控制生产设备执行处理措施。 In this embodiment, the problem decision-making module independently generates processing measures after analyzing the discovered security problems, and distributes the processing measures to related equipment, and the control system controls the production equipment to execute the processing measures.
在实际的生产应用中，总控系统通过通信链路获知设备是否出现安全问题以及安全问题具体描述。总控系统能够同时获取一台或多台设备的安全问题，并根据生产线所有设备安全问题出现情况作出决策。 In actual production applications, the master control system learns whether there is a safety problem in the equipment and the specific description of the safety problem through the communication link. The master control system can obtain the safety issues of one or more equipment at the same time, and make decisions based on the occurrence of safety issues of all equipment in the production line.
结合图2所示的系统安全问题处理流程模型，实际应用中，总控系统获知一台或多台设备出现安全问题后，首先发出警报，告知操作人员生产线出现故障，然后区分判别该安全问题是已知还是未知。若为未知安全问题，则系统决策安全问题处理流程，然后将相关指令分发到安全问题相关设备。相关设备收到故障处理指令后根据指令，执行安全问题处理动作。设备执行完成这些动作后，维护人员才介入，人工处理故障问题。故障处理完成后，维护人员恢复生产线自动化运行。若为已知安全问题，则系统决策安全问题处理流程，然后将相关指令分发到问题相关设备。相关设备收到故障处理指令后根据指令，执行安全问题处理动作。一般情况下，该类安全问题可由生产线自动化系统自主处理完成。设备执行完成这些动作后，总控系统自主恢复生产线自动化运行。 Combined with the system safety problem processing process model shown in Figure 2, in practical applications, after the master control system learns that one or more devices have a safety problem, it first sends out an alarm to inform the operator that the production line is faulty, and then distinguishes whether the safety problem is Known or unknown. If it is an unknown security problem, the system decides on the security problem processing procedure, and then distributes relevant instructions to devices related to the security problem. After the relevant equipment receives the fault handling instruction, it executes the safety problem handling action according to the instruction. After the equipment completes these actions, the maintenance personnel will intervene to manually solve the fault problem. After the troubleshooting is completed, maintenance personnel resume the automatic operation of the production line. If it is a known security problem, the system decides on the security problem handling process, and then distributes relevant instructions to the devices related to the problem. After the relevant equipment receives the fault handling instruction, it executes the safety problem handling action according to the instruction. In general, such safety issues can be handled by the production line automation system autonomously. After the equipment executes these actions, the master control system automatically resumes the automatic operation of the production line.
如图3所示为本发明所涉及设备安全问题处理流程。该流程一般出现在生产设备调试阶段，在设备能够稳定运行之前，操作人员一般在设备操作面板前进行操作。生产设备应安装紧急停止按钮。操作人员一旦发现设备出现安全问题，则立即按下紧急停止按钮，设备立即停机，保障设备和现场人员安全。 As shown in FIG. 3 , the processing flow of the device security problem involved in the present invention is shown. This process generally occurs in the debugging stage of production equipment. Before the equipment can run stably, the operator usually operates in front of the equipment operation panel. Production equipment should be equipped with emergency stop buttons. Once the operator finds that there is a safety problem with the equipment, he will immediately press the emergency stop button, and the equipment will stop immediately to ensure the safety of the equipment and on-site personnel.
说明书未作详细描述的内容属于本领域专业技术人员公知的现有技术。 The content not described in detail in the specification belongs to the prior art known to those skilled in the art.
上述实施例为本发明较佳的实现方案，除此之外，本发明还可以其它方式实现，在不脱离本技术方案构思的前提下任何显而易见的替换均在本发明的保护范围之内。 The above-mentioned embodiments are preferred implementation solutions of the present invention. In addition, the present invention can also be realized in other ways, and any obvious replacements are within the scope of protection of the present invention without departing from the concept of the technical solution.
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