CN107505906A - A kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis method and system - Google Patents
A kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis method and system Download PDFInfo
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- CN107505906A CN107505906A CN201710904674.8A CN201710904674A CN107505906A CN 107505906 A CN107505906 A CN 107505906A CN 201710904674 A CN201710904674 A CN 201710904674A CN 107505906 A CN107505906 A CN 107505906A
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/05—Programmable logic controllers, e.g. simulating logic interconnections of signals according to ladder diagrams or function charts
- G05B19/058—Safety, monitoring
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/10—Plc systems
- G05B2219/14—Plc safety
- G05B2219/14006—Safety, monitoring in general
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Abstract
A kind of prefabricated assembled concrete structure automatic assembly line method for diagnosing faults of the present invention is system, belong to building industrialization technical field, can not only realize and prefabricated assembled concrete structure automatic assembly line real-time running state is monitored, and can automatic quick diagnosis, alarm and position failure.This method and system for content are：Two rank is arranged to, the controller of the pre- diagnostic horizon in scene passes through logic judgment, and Primary Location is carried out to phenomenon of the failure, every kind of malfunction is set into a primary fault code, and data are uploaded；Analysis layer parsing primary fault code is concentrated, infers final fault diagnosis result.Maintenance time can be reduced, influences and loses caused by reducing production line failure.
Description
Technical field
The invention belongs to building industrialization technical field, is related to a kind of prefabricated assembled concrete structure automatic assembly line event
Hinder diagnostic system.
Background technology
In recent years, country actively promotes green building and building materials, greatly develops steel construction and assembled architecture, building industry
Change welcomes unprecedented opportunities.PC (Prefabricated Concrete Structure) i.e. " prefabricated assembled concretes
Structure ", it is with precast concrete, through assembling, connecting, the concrete structure of the cast-in-place formation of bound fraction, is future architecture
The development trend of industry.
It is (including Prefabricated stacking floor, inside and outside that PC automatic assembly lines are mainly used in building concrete prefabricated components series of products
Wallboard, stair etc.) factory's mass production, to system run all right require it is high.PC automatic assembly lines are typically all structure
Part produces in die station, and scantling is big, and tens die station recycle on line, and production line floor space is big, and station is more, ginseng
Number is more, towards multitask production, system complex so that failure randomness, uncertain increase, is made troubles to positioning is repaired.
In order to ensure the normal operation of system, it is ensured that the quality and progress of product mass production, once production line break down, it is necessary to
Quick diagnosis and positioning maintenance are carried out to failure.
In the prior art, PC automatic assembly lines are in starting developing stage, are engaged in the producer of PC automatic assembly line developments
Seldom, its main attention is also in exploitation stand-alone device function, and fault diagnosis system and method for PC automatic assembly lines are also
Beyond example, after exception occurs in production line operation, often manually note abnormalities, then go scene investigation reason and tieed up
Repair, it is time-consuming and laborious.
The content of the invention
Present invention solves the technical problem that it is：It is proposed a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis
Method and system, it can not only realize and prefabricated assembled concrete structure automatic assembly line real-time running state is monitored, Er Qieneng
Automatic quick diagnosis, alarm simultaneously position failure, are easy to maintenance personal to repair, so as to ensure manufacturing schedule.
The technical scheme is that：A kind of prefabricated assembled concrete structure automatic assembly line method for diagnosing faults, its
It is characterised by, this method includes following content：
(1) PC automatic assembly lines failure layering diagnostic system is built；
The PC automatic assembly lines fault diagnosis system is arranged to two rank, i.e. the pre- diagnostic horizon in scene and concentration analysis layer；
The pre- diagnostic horizon in scene includes some controllers and Site Detection instrument, according to the craft cloth of PC automatic assembly lines
Office, is divided into some device clusters, each cluster uses a controller by each stand-alone device on production line；Given birth to automatically in PC
Some positions of each position equipment in producing line scene set fault detecting point, the event that each controller collection is administered in cluster wide
Hinder the equipment running status of test point, carry out logic analysis judgement and be uploaded to primary fault code value and equipment operating data
Concentrate analysis layer；
The concentration analysis layer does not contact directly with field apparatus and instrument and meter, concentrates analysis layer to pass through network service
Mode and each controller of the pre- diagnostic horizon in scene carry out data interaction；The concentration analysis layer is built-in with expert knowledge library and barrier pushes away
Reason mechanism, all malfunction codings and critical data state of the pre- diagnostic horizon in covering scene, the event that the pre- diagnostic horizon in scene can be uploaded
Hinder presentation and carry out analysis ratiocination, the primary fault code and prefabricated assembled concrete structure uploaded with reference to the pre- diagnostic horizon in scene is certainly
The data message of dynamic production line operation, by comparing and judging, is finally accurately positioned failure cause and position；
(2) controller of the pre- diagnostic horizon in scene passes through logic judgment, Primary Location is carried out to phenomenon of the failure, by every kind of failure
State sets a primary fault code, and data are uploaded；
(3) analysis layer parsing primary fault code is concentrated, infers final fault diagnosis result.
A kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system, it is characterised in that the system includes
The pre- diagnostic horizon in scene and concentration analysis layer；
The pre- diagnostic horizon in scene includes some controllers and Site Detection instrument, according to the craft cloth of PC automatic assembly lines
Office, is divided into some device clusters, each cluster uses a controller by each stand-alone device on production line；Given birth to automatically in PC
Some positions of each position equipment in producing line scene set fault detecting point, the event that each controller collection is administered in cluster wide
Hinder the equipment running status of test point, carry out logic analysis judgement and be uploaded to primary fault code value and equipment operating data
Concentrate analysis layer；
The concentration analysis layer does not contact directly with field apparatus and instrument and meter, concentrates analysis layer to pass through network service
Mode and each controller of the pre- diagnostic horizon in scene carry out data interaction；The concentration analysis layer is built-in with expert knowledge library and barrier pushes away
Reason mechanism, all malfunction codings and critical data state of the pre- diagnostic horizon in covering scene, the event that the pre- diagnostic horizon in scene can be uploaded
Hinder presentation and carry out analysis ratiocination, the primary fault code and prefabricated assembled concrete structure uploaded with reference to the pre- diagnostic horizon in scene is certainly
The data message of dynamic production line operation, by comparing and judging, is finally accurately positioned failure cause and position.
A kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system, it is characterised in that including：Monitoring meter
Calculation machine, subsystem PLC, each station executing agency and detection device；
The monitoring computer, including database point configuration module, all fronts production scheduling module, failure experts database, failure
Query analysis module；
The database point configuration module, it is to read data variable and to each subsystem from each subsystem PLC
The input/output interface module that PLC is issued an order, the data variable read with each subsystem PLC carry out one
The mode of one association carries out information exchange；
The all fronts production scheduling module, run by tracking product on prefabricated assembled concrete structure automatic assembly line
Process route track, monitor the running status of each subsystem PLC collection position equipment, while according to productive temp
Each subsystem PLC is controlled, sequentially moved so as to dispatch product between each warehouse compartment, station, completes Product Process
Processing procedure；
The failure experts database, it is that all issuable phenomena of the failure of production line are sorted out and encoded to enumerate production of being out of order
Raw position and reason, and provide the tables of data of solution；
The fault inquiry analysis module, refer in prefabricated assembled concrete structure automatic assembly line running,
The first kind malfunction coding that each subsystem PLC of scan round uploads, at the same prefabricated assembled concrete structure is automatic
The running status letter of the position equipment of each subsystem PLC feedback of the production scheduling control command of production line operation and scene
Judgements is compared in breath, draw it is live whether the second class malfunction coding corresponding to failure and failure, and according to the second class failure
Encode to transfer the corresponding content of failure experts database；
The subsystem PLC includes the controller of multiple subsystems, the state of the controller of subsystem to collection
Signal is judged to obtain the first kind fault-signal of each subsystem, and is uploaded to fault inquiry analysis module；
Subsystem PLC controls each station executing agency and detection device, gathers each station executing agency and detection
Device output state information.
The beneficial effects of the invention are as follows：
PC automatic assembly lines fault diagnosis system proposed by the present invention, the running status of PC automatic assembly lines can be carried out real-time
Monitoring, fast positioning, alarm and prompting are carried out to failure, are easy to maintenance personal to repair, so as to reduce maintenance time, reduce production
Influence and lose caused by line failure.
Brief description of the drawings
Fig. 1 is that a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system provided by the invention is specifically real
Apply mode.
Fig. 2 is a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system provided by the invention
Monitor computer each several part component relationship schematic diagram.
Embodiment
The present invention is described in further detail below.
A kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis of the present invention includes following three step：
First step structure PC automatic assembly lines failure layering diagnostic system.
PC automatic assembly lines failure layering diagnostic system includes the pre- diagnostic horizon in scene and concentrates two levels of analysis layer.
The pre- diagnostic horizon in scene is based on presentation, and collection site data simultaneously stress local station and the primary diagnosis of equipment, concentrates
Analysis layer is based on profound level, stresses overall analysis system entirety, and deduction draws final failure conclusion, and provides processing order.
During the pre- diagnostic horizon in structure scene, the support comprising hardware and software, three parts content is completed.
First, according to PC production line site technique location layouts and equipment job specification, all devices and mechanism are divided
Group, some device clusters are divided, each group of cluster sets a controller to carry out Centralized Monitoring, and controller can be PLC system
Or other functional modules, simple logical operation function can be completed, possesses digital quantity and analog input and output interface, Yi Jizong
Line communication interface.
Second, being directed to each group of device clusters, select and determine that controller carries out Centralized Monitoring (gathered data and control)
Key parameter and node, test point is set in significant points.Such as contactless contactor closure or the auxiliary signal of disconnection, motor fortune
Capable electric current and time, the temperature and humidity in maintenance storehouse, position signalling of station etc. where product on line.
Third, by cluster device running status and primary fault in the pre- each controller institute compass of competency of diagnostic horizon in scene
Phenomenon carries out digital coding, and each coding covers controller number, device number, service data, abnormal position and fault message etc..
It is necessary to have the calculating of powerful computing inference function and human-computer interaction interface during structure concentration analysis layer diagnostic system
Machine system, while it has been also required to tripartite content.
First, establishing expert knowledge library, knowledge base associates all controls of the above-mentioned pre- diagnostic horizon in scene by the form of fault tree
The critical data information that device uploads, and all malfunction coding values being pre-designed.
Second, inference mechanism or algorithm based on field data information and expert knowledge library are established, real time parsing communication collection
Whether just malfunction coding value and the equipment running status coding arrived, level are inferred to the current running status of PC automatic assembly lines
Often, it is if abnormal, analyse in depth to caused possible cause and the caused position of being out of order.
Third, design Real time dynamic display human-computer interaction interface, by PC automatic assembly lines running status with word, animation,
The diversified forms such as form are presented to user, if exception occurs in production line, give alarm, and fault reasoning diagnostic result is anti-
Feed operator, and receives the process instruction of operator.
The pre- diagnostic horizon online monitoring data in second step scene, carries out simple logic judgment, Primary Location the surface phenomenon of mal-function is simultaneously
Data are uploaded.
The controller of the pre- diagnostic horizon in scene is only responsible for cluster device operating state signal directly in the range of collection administration and set
The malfunction monitoring point information put, will actually measure obtained parameter and internal preset value be compared with simple logic judgment,
Preliminary judged result is uploaded into concentration analysis layer in the form of data encoding, wait the last diagnostic result of concentrating analysis layer and
Processing order.
3rd step concentrates analysis layer parsing primary fault code, and in-depth analysis infers final fault diagnosis result.
The concentration analysis layer does not contact directly with field apparatus and instrument and meter, only with the controller of the pre- diagnostic horizon in scene
Carry out data interaction.Concentrate analysis layer to be built with expert knowledge library, cover that all controllers in the pre- diagnostic horizon in scene set just
The critical data information of the PC automatic assembly lines operation of level failure code and controller collection.Concentrate analysis layer primary by parsing
Failure code, according to the internal reasoning mechanism of establishment, by comparison and reasoning from logic, finally it is inferred to failure cause and position,
User is fed back in the form of word, chart or data, provides fault alarm and diagnostic result, and anticipate according to the processing of operator
See that the controller of the pre- diagnostic horizon in the scene of being assigned to carries out respective handling.
A kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system of the present invention,
Two major classes are summarized as using the failure mode for being likely to occur production line operation, the first kind is to relate only to single set
The primary fault phenomenon of standby host structure, judgement is directly gathered by subsystem PLC and obtained, and malfunction coding is uploaded to monitoring and calculated
Machine；Second class is to be related to the phenomenon of the failure of multiple equipment station interaction, anti-by analyzing each subsystem PLC by monitoring computer
The field data of feedback, and compare the control command that current monitor computer is assigned, comprehensive descision obtains malfunction coding.Monitoring calculates
Machine inquires about internal prefabricated failure experts database by malfunction coding, and the content of corresponding failure experts database is shown in man-machine interface
Show to come, so as to prompt operator to be accurately positioned failure, take measures to release failure, quickly resume production.
A kind of PC automatic assembly lines fault diagnosis system of the present invention, including：Monitor computer, subsystem PLC, each station
Executing agency and detection device.
The monitoring computer, including database point configuration module, all fronts production scheduling module, failure experts database, failure
Query analysis module, fault diagnosis interface and operation monitoring interface.
The database con-figuration module, it is that monitoring computer reads data variable from each subsystem PLC and is to each point
The input/output interface module that system PLC issues an order, information exchange is carried out in a manner of data variable connects by database con-figuration.
The information variable read from each subsystem PLC：Including subsystem PLC current operation modes, busy-idle condition, complete tool
Code value, each sensor signal, operation button LED status and the malfunction coding of body task situation.To each subsystem PLC
The control variable issued an order includes performing specific tasks coding, task start position coding and final position coding, each equipment
Startup and stop signal.
The all fronts production scheduling module, by tracking the process route track that product is run on PC automatic assembly lines, prison
It is responsible for the running status of (control and collection) position equipment depending on each subsystem PLC, while according to productive temp pair
Each subsystem PLC is controlled, and is sequentially moved so as to dispatch all products between each warehouse compartment, station, is completed mold attaching/detaching, is taken off
Mould, feed the process treatment process such as cloth, vibration, surface treatment and maintenance.
The failure experts database, it is that all issuable phenomena of the failure of production line are refined, sorted out and encoded, with
The form of form enumerates be out of order caused position and reason, and provides the tables of data of solution.Tables of data content includes event
Barrier coding, failure are related to subsystem name, unit component locations, failure reason analysis and solution.
The fault inquiry analysis module, refer in PC automatic assembly line runnings, each subsystem PLC of scan round
The first kind malfunction coding that controller uploads, while the production scheduling control command that PC automatic assembly lines are run and each point of scene
Judgement is compared in the key message of system PLC actual feedbacks, and whether failure and corresponding second class failure are compiled at the scene of drawing
Code, and the corresponding content of failure experts database is transferred according to first kind malfunction coding and the second class malfunction coding, in fault diagnosis
Interface display comes out.
The operation monitoring interface, it is that PC automatic assembly lines real-time exhibition in a manner of graphic animations in normal operation is whole
The man-machine interface of individual production line operation, operator inputting process parameters and can control the startup of the entire production line and stop at the interface
Only.
The fault diagnosis interface, it is the man-machine interface shown when PC automatic assembly lines break down abnormal, includes failure
Alarm, fault location, failure cause and solution and failure experts database renewal part.
The fault alarm is that the subsystem PLC that failure is related to is carried out into red light to light warning.
The fault location is that equipment mechanism position caused by failure is carried out into word description.
The failure cause and solution are that the possible cause and solution that will produce the phenomenon of the failure are carried out one by one
Enumerate.
The failure experts database renewal is that occur failure experts database in actual production not having prefabricated phenomenon of the failure, warp
Field practice is carried out content by technical staff according to table content to failure experts database supplement after confirming updates.
The subsystem PLC includes maintenance storehouse pallet truck subsystem, feeds cloth vibration subsystem, plucking troweling branch
Line subsystem, demoulding branch line subsystem, traveling subsystem and the controller for moving line car subsystem, each subsystem is with one
PLC is managed (collection information and control), and each subsystem includes some stations and stand-alone device.
The controller of the maintenance storehouse pallet truck subsystem is identified with PLC1, and PLC1 controllers are responsible for conserving storehouse humiture prison
Control, the control of stacking vehicle device and the collection and judgement of the subsystem first kind fault-signal.
Humiture exception, stacking in the subsystem PLC1 collections and the first kind fault-signal judged, including maintenance storehouse
Car motion motor on tri- directions of XYZ frequency converter failure alarm, pallet truck on tri- directions of XYZ position limit signal,
The current of electric overheating fault and subsystem PLC1 switch board jerk failures of other non-frequency devices driving inside pallet truck.
The cloth vibration subsystem of feeding is identified with PLC2, is responsible for the control of feeding equipment, apparatus for distributing, vibratory equipment unit
The collection and judgement of system and the subsystem first kind fault-signal.
Subsystem PLC2 collection and the first kind fault-signal judged, including feeding movable motor and upset motor
Frequency converter failure alarm, frequency converter failure alarm, the frequency conversion of apparatus for distributing material extrusion motor of apparatus for distributing XY directions motion motor
Device fault alarm, vibrate the hydraulic station fault alarm of unit, the thermal overload protection failure of vibrating motor, and walk in feeding,
Position limit signal and subsystem PLC2 switch board jerk failures on apparatus for distributing direction of travel.
The plucking troweling branch line subsystem is identified with PLC3, is responsible for troweling unit, plucking unit, plucking troweling branch line and is driven
The control of driving wheel and the subsystem first kind fault-signal judge.The driving wheel of the plucking troweling branch line be used to control product
Movement on plucking troweling branch line between each station.
First kind fault-signal responsible the subsystem PLC3, including troweling XY directions mobile motor frequency converter failure report
Police, the movement of troweling electric rotating machine thermal overload failure, plucking lifting motor thermal overload failure, troweling and the event of the plucking lifting position limit
Barrier, the alarm of plucking troweling branch line driving wheel frequency converter failure, plucking troweling branch line travel limit sensor fault and drawing
Hair troweling branch line push-button station jerk failure.
The demoulding branch line subsystem is identified with PLC4, is responsible for edge-on demoulding unit, is cleaned unit, demoulding branch line driving wheel
Control and the subsystem first kind fault-signal judge.The demoulding branch line driving wheel be used to control product in demoulding branch line
Movement between upper each station.
First kind fault-signal responsible the subsystem PLC4, including edge-on hydraulic station fault alarm, cleaning motor heat
Overload fault, the alarm of demoulding branch line driving wheel frequency converter failure, demoulding branch line limit position sensor failure and demoulding branch line
Push-button station jerk failure.
The traveling subsystem is identified with PLC5, is responsible for pouring the location equipment on branch line, is poured branch line traveling driving wheel
Control and the subsystem first kind fault-signal judge.The branch line traveling driving wheel that pours be used to control product pouring
Build the movement between each station on branch line.
First kind fault-signal responsible the subsystem PLC5, including location equipment frequency converter failure alarm, pour branch
The alarm of line driving wheel frequency converter failure, pour branch line limit position sensor failure and pour push-button station jerk event on branch line
Barrier.
The shifting line car subsystem is identified with PLC6, is responsible for demoulding branch line and is poured shifting line equipment between traveling branch line, rises
The control of descending mechanism and the subsystem first kind fault-signal judge.
First kind fault-signal responsible the subsystem PLC6, including move the alarm of line equipment walking frequency converter failure, move
Line equipment lifting motor thermal overload failure, limit position sensor failure and subsystem PLC6 switch board jerk failures.
There is a situation where between each subsystem PLC product interaction when, it is understood that there may be the second class failure by monitoring
Computer monitoring simultaneously judges to draw.
Each subsystem PLC has that product interaction includes：Product is coming out to demoulding branch line from maintenance storehouse, relates to
And interacted between subsystem PLC1 and PLC4；Product moves line to traveling branch line is poured from demoulding branch line, is related to subsystem
PLC4, PLC6 and PLC5；Product comes out to plucking troweling branch line from maintenance storehouse or enters to conserve storehouse from plucking troweling branch line, is related to
Interacting between subsystem PLC1 and PLC3；Product enters to conserve storehouse from traveling branch line is poured, and is related between PLC1 and PLC5
Coordinate；When die station is transplanted on hello cloth vibration station manipulation by advance system, it is related to PLC2 and PLC5 cooperation.
Production scheduling control command described in the fault inquiry analysis module, refer to each subsystem PLC it
Between there is a situation where product interaction when, automatic assembly line operation production scheduling control command.
Second class failure also includes communication failure, each detection sensor sheet of following situations monitoring computer and each subsystem
Body goes wrong, mechanism bite or causes situations such as live foreign matter product movement abnormal, and each subsystem PLC can not judge to learn
Phenomenon of the failure, by monitoring computer judge provide result.
Each station executing agency and detection device, are included in maintenance storehouse and set temperature and moisture sensors, every
Individual product station is positioned proximate to switch, in the direction set location sensor of each mechanism operation.Motor is entered using frequency converter
Row packet driving, PLC are acquired to the malfunction of frequency converter, and monitor the auxiliary contact letter of every group of motor contactor break-make
Number.The motor being directly connected to using contactor and three phase mains, is monitored to electric current.Pass through the electricity of the one-to-one driving of frequency converter
Machine, directly gather frequency converter running status and obtain fault message.
Subsystem PLC controls each station executing agency and detection device, gathers each station executing agency and detection
Device output state information.
A kind of as shown in figure 1, PC automatic assembly lines fault diagnosis system Organization Chart for the present invention.Calculated including monitoring
Machine, maintenance storehouse pallet truck subsystem PLC1, feed cloth vibration subsystem PLC2, plucking troweling branch line subsystem PLC3, demoulding branch
Line subsystem PLC4, traveling subsystem PLC5 and shifting line car subsystem PLC6.Wherein, PLC1 is responsible for conserving storehouse and pallet truck is set
Standby control and signal acquisition；PLC2 is responsible for control and the signal acquisition of feeding equipment, apparatus for distributing and vibratory equipment；PLC3
It is responsible for control and the signal acquisition of troweling unit, plucking unit and plucking troweling branch line driving wheel；PLC4 is responsible for the edge-on demoulding
Unit, clean unit and be stripped control and the signal acquisition of branch line driving wheel；PLC5 be responsible for pouring location equipment on branch line,
Pour control and the signal acquisition of branch line traveling driving wheel；PLC6 is responsible for the control of shifting the line equipment, elevating mechanism between each branch line
And signal acquisition.
Configuration software is installed on the monitoring computer, carried out by industrial ethernet switch and each subsystem PLC
TCP/IP network services.
The monitoring computer is associated one by one in a manner of database con-figuration with each subsystem PLC variables, so as to
Know production line presence states and assign action command.
Without information exchange between each subsystem PLC.
As shown in Fig. 2 be each several part component relationship schematic diagram of monitoring computer, including it is database point configuration module, complete
Line production scheduling module, failure experts database, fault inquiry analysis module, fault diagnosis interface and operation monitoring interface.
The database point configuration module is the bridge of connection monitoring computer and each subsystem PLC variables.
On the one hand all fronts production scheduling module is entered under line command by database point configuration module to each subsystem PLC
Put and analyzed with on-site data gathering, on the other hand simultaneously running the real-time dynamic information at scene in the form of chart, animation
Monitoring interface is fed back.Completely production is adjusted also by the write-in of operation monitoring interface for production line process parameter and all fronts start-up and shut-down control
Spend in module.
The fault inquiry analysis module, on the one hand read the first of each subsystem PLC by database point configuration module
Key sensor information on class malfunction coding, the current action state for reading each PLC feedbacks and production line, on the other hand by complete
Line production scheduling module obtains the action command that current monitor computer is assigned to each subsystem PLC, and comprehensive analysis obtains second
Class malfunction coding.After obtaining malfunction coding, then inquiry obtains all fault messages of corresponding malfunction coding from failure experts database,
Come out including failure subsystem PLC, unit position, reason and solution etc., and in fault diagnosis interface display.
The fault diagnosis interface shows except carrying out fault message when PC automatic assembly lines break down, can also be
During PC automatic assembly line off-duties, operator updates position in failure experts database, is related to subsystem according to malfunction coding, failure
The order of name, failure unit component locations, causation analysis and solution is added to the content of failure expert's table.
As it was previously stated, first kind malfunction coding is voluntarily gathered by each subsystem PLC and judges to obtain, mainly by setting
Standby key position sets detection sensor directly to monitor obtained fault message；Second class malfunction coding is by monitoring computer
Analysis judgement obtains, the fault message that each subsystem PLC can not voluntarily perceive.Second class fault message content mainly includes monitoring
The failure feelings that computer and each subsystem PLC communication failure and product may occur when being shifted between each subsystem PLC
Condition.
Failure situation when the product needs to shift between each subsystem PLC, including pallet truck take production from maintenance storehouse
Product are related to the cooperation between subsystem PLC1 and subsystem PLC4 when being sent to demoulding branch line；Die station is from demoulding branch line by moving line
Car is transferred to when pouring branch line, the cooperation being related between PLC4, PLC5 and PLC6 three；Pallet truck from maintenance storehouse modulus platform to
Plucking troweling branch line, the cooperation being related between PLC1 and PLC3；Pallet truck is related to when connecing die station to maintenance storehouse from advance system
Cooperation between PLC1 and PLC5；Die station by advance system be transplanted on feed cloth vibrate station manipulation when, be related to PLC2 with
PLC5 cooperation.
Illustrated when being coordinated between PLC1 and PLC4 exemplified by issuable phenomenon of the failure and trouble location.
When the action command that PLC1 receives monitoring computer is to be transferred to demoulding branch line buffer station from certain warehouse compartment modulus platform
When, reached after PLC1 can reach certain warehouse compartment in pallet truck, product is taken out from certain warehouse compartment, pallet truck takes out product and demoulding branch line is handed over
Mutual these key point moment of position give monitoring computer feedback completion status, are uploaded when monitoring computer receives PLC1
Product is taken out when being stripped the feedback information of branch line mouth wait transfer, if checking that PLC4 current state is adapted to receive pallet truck
The product to come over, then computer is monitored to the signal for selling PLC4 control demoulding branch line buffer station driving wheel rotations, to selling
The signal of transfer driving wheel rotation on PLC1 control pallet trucks.
The sensor that product has been removed on detection pallet truck in this time-division system PLC1 misses if there is failure, pallet truck
To think product to have been moved off finishing and stop the rotation transfer of driving wheel, product actually is not transferred also on pallet truck, and
The subsystem PLC4 of responsible demoulding branch line buffer station driving wheel can rotate to receive always after receiving the order of monitoring computer
Product, until there is product to reach the station, without the failure for finding PLC1.And first kind failure prefabricated PLC1 itself does not have yet
Have including this type of self-sensor device failure.
Above-mentioned this second class failure situation is just completed by monitoring computer to monitor.Computer is monitored to subsystem
After PLC1 and PLC4 assigns instruction, monitored by timing, when delay time refers to more than that should be normally received PLC4 feedback completions
Without receiving, delay time inquires about corresponding subsystem again earlier than when should be normally received the corresponding feedbacks of PLC1 and completing instruction for order
Communication it is normal, so that it may analysis obtain the second class malfunction coding of pallet truck transmitting place sensor fault, by recall correspondingly
Failure experts database content is fed back at fault diagnosis interface.
Claims (10)
1. a kind of prefabricated assembled concrete structure automatic assembly line method for diagnosing faults, it is characterised in that this method is included such as
Lower content：
(1) PC automatic assembly lines failure layering diagnostic system is built；
The PC automatic assembly lines fault diagnosis system is arranged to two rank, i.e. the pre- diagnostic horizon in scene and concentration analysis layer；
The pre- diagnostic horizon in scene includes some controllers and Site Detection instrument, according to the process layout of PC automatic assembly lines,
Each stand-alone device on production line is divided into some device clusters, each cluster uses a controller；Produced automatically in PC
Some positions of each position equipment in line scene set fault detecting point, the failure that each controller collection is administered in cluster wide
The equipment running status of test point, carry out logic analysis judgement and primary fault code value and equipment operating data are uploaded to collection
Middle analysis layer；
The concentration analysis layer does not contact directly with field apparatus and instrument and meter, concentrates analysis layer by way of network service
Data interaction is carried out with each controller of the pre- diagnostic horizon in scene；The concentration analysis layer is built-in with expert knowledge library and barrier inference machine
System, all malfunction codings and critical data state of the pre- diagnostic horizon in covering scene, the bug list that the pre- diagnostic horizon in scene can be uploaded
As carrying out analysis ratiocination, given birth to automatically with reference to the primary fault code and prefabricated assembled concrete structure that the pre- diagnostic horizon in scene uploads
The data message of producing line operation, by comparing and judging, is finally accurately positioned failure cause and position；
(2) controller of the pre- diagnostic horizon in scene passes through logic judgment, Primary Location is carried out to phenomenon of the failure, by every kind of malfunction
One primary fault code is set, and data are uploaded；
(3) analysis layer parsing primary fault code is concentrated, infers final fault diagnosis result.
2. a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system, it is characterised in that the system includes existing
The pre- diagnostic horizon in field and concentration analysis layer；
The pre- diagnostic horizon in scene includes some controllers and Site Detection instrument, according to the process layout of PC automatic assembly lines,
Each stand-alone device on production line is divided into some device clusters, each cluster uses a controller；Produced automatically in PC
Some positions of each position equipment in line scene set fault detecting point, the failure that each controller collection is administered in cluster wide
The equipment running status of test point, carry out logic analysis judgement and primary fault code value and equipment operating data are uploaded to collection
Middle analysis layer；
The concentration analysis layer does not contact directly with field apparatus and instrument and meter, concentrates analysis layer by way of network service
Data interaction is carried out with each controller of the pre- diagnostic horizon in scene；The concentration analysis layer is built-in with expert knowledge library and barrier inference machine
System, all malfunction codings and critical data state of the pre- diagnostic horizon in covering scene, the bug list that the pre- diagnostic horizon in scene can be uploaded
As carrying out analysis ratiocination, given birth to automatically with reference to the primary fault code and prefabricated assembled concrete structure that the pre- diagnostic horizon in scene uploads
The data message of producing line operation, by comparing and judging, is finally accurately positioned failure cause and position.
3. a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system according to claim 2, it is special
Sign is that the concentration analysis layer has human-computer interaction interface, and DTC is converted into the shape of word, chart or data
Formula is fed back, and provides fault alarm and diagnostic result, and proposes corresponding treatment measures.
A kind of 4. prefabricated assembled concrete structure automatic assembly line fault diagnosis system, it is characterised in that including：Monitoring calculates
Machine, subsystem PLC, each station executing agency and detection device；
The monitoring computer, including database point configuration module, all fronts production scheduling module, failure experts database, fault inquiry
Analysis module；
The database point configuration module, it is to read data variable from each subsystem PLC and each subsystem PLC is controlled
The input/output interface module that device processed is issued an order, closed one by one with the data variable that each subsystem PLC is read
The mode of connection carries out information exchange；
The all fronts production scheduling module, by tracking the work that product is run on prefabricated assembled concrete structure automatic assembly line
Skill route track, the running status of each subsystem PLC collection position equipment is monitored, while according to productive temp to each
Subsystem PLC is controlled, and is sequentially moved so as to dispatch product between each warehouse compartment, station, completes Product Process processing
Process；
The failure experts database, sorted out all issuable phenomena of the failure of production line and caused by coding enumerates and be out of order
Position and reason, and provide the tables of data of solution；
The fault inquiry analysis module, refer in prefabricated assembled concrete structure automatic assembly line running, circulate
The first kind malfunction coding that each subsystem PLC uploads is scanned, while prefabricated assembled concrete structure is produced automatically
The running state information of the position equipment of each subsystem PLC feedback of the production scheduling control command of line operation and scene is entered
Row contrast judgement, the scene of drawing whether the second class malfunction coding corresponding to failure and failure, and according to the second class malfunction coding
To transfer the corresponding content of failure experts database；
The subsystem PLC includes the controller of multiple subsystems, the status signal of the controller of subsystem to collection
Judged to obtain the first kind fault-signal of each subsystem, and be uploaded to fault inquiry analysis module；
Subsystem PLC controls each station executing agency and detection device, gathers each station executing agency and detection device
Output state information.
5. a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system according to claim 4, it is special
Sign is that the monitoring computer also includes operation monitoring interface；The operation monitoring interface is PC automatic assembly lines normal
The man-machine interface that real-time exhibition the entire production line is run in a manner of graphic animations during operation.
6. a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system according to claim 4, it is special
Sign is that the monitoring computer also includes fault diagnosis interface；The fault diagnosis interface, it is that PC automatic assembly lines event occur
The man-machine interface shown when hindering abnormal.
7. a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system according to claim 4, it is special
Sign is, the production scheduling control command described in the fault inquiry analysis module, refers between each subsystem PLC
When product interaction be present, the production scheduling control command of automatic assembly line operation.
8. a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system according to claim 4, it is special
Sign is that the subsystem PLC includes maintenance storehouse pallet truck subsystem, feeds cloth vibration subsystem, plucking troweling branch
Line subsystem, demoulding branch line subsystem, traveling subsystem and the controller for moving line car subsystem, i.e., each subsystem is with one
PLC is controlled.
9. a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system according to claim 4, it is special
Sign is, each station executing agency and detection device, is included in maintenance storehouse and sets temperature and moisture sensors, each
Product station is positioned proximate to switch, direction set location sensor in the operation of each mechanism, frequency converter, one-to-one with frequency converter
The motor of driving.
10. a kind of prefabricated assembled concrete structure automatic assembly line fault diagnosis system according to claim 4, it is special
Sign is, installs configuration software on the monitoring computer, is carried out by industrial ethernet switch and each subsystem PLC
TCP/IP network services.
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