CN107505906B - Fault diagnosis method and system for automatic production line of prefabricated concrete structure - Google Patents
Fault diagnosis method and system for automatic production line of prefabricated concrete structure Download PDFInfo
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- CN107505906B CN107505906B CN201710904674.8A CN201710904674A CN107505906B CN 107505906 B CN107505906 B CN 107505906B CN 201710904674 A CN201710904674 A CN 201710904674A CN 107505906 B CN107505906 B CN 107505906B
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- 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
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Abstract
The invention discloses a fault diagnosis method, namely a system, for an automatic production line of a prefabricated concrete structure, belongs to the technical field of building industrialization, and not only can realize real-time running state monitoring of the automatic production line of the prefabricated concrete structure, but also can automatically and quickly diagnose, alarm and locate faults. The method and the system comprise the following steps: setting the fault state as two levels, carrying out logic judgment on a controller for on-site fault pre-diagnosis, carrying out primary positioning on the fault phenomenon, setting a primary fault code for each fault state, and uploading data; and analyzing the primary fault code by the centralized analysis layer, and reasoning out a final fault diagnosis result. The maintenance time can be reduced, and the influence and loss caused by the production line faults are reduced.
Description
Technical Field
The invention belongs to the technical field of building industrialization, and relates to a fault diagnosis system for an automatic production line of a prefabricated concrete structure.
Background
In recent years, the country actively promotes green buildings and building materials, vigorously develops steel structures and assembly type buildings, and has unprecedented opportunity for building industrialization. Pc (prefabricated Concrete structure), i.e., a "prefabricated Concrete structure", is a Concrete structure formed by assembling, connecting and combining prefabricated Concrete members by partial cast-in-place, and is a development trend of the future construction industry.
The PC automatic production line is mainly used for factory batch production of building concrete prefabricated part series products (including prefabricated composite floor slabs, inner and outer wall plates, stairs and the like), and has extremely high requirement on system operation stability. The PC automatic production line generally produces components on the die tables, the components are large in size, dozens of die tables are recycled on line, the production line occupies a large area, has multiple stations and parameters, is oriented to multi-task production and is complex in system, so that the randomness and uncertainty of faults are increased, and the maintenance and positioning are troublesome. In order to ensure the normal operation of the system and the quality and progress of the mass production of products, once a production line fails, the failure needs to be rapidly diagnosed and positioned for maintenance.
In the prior art, a PC automatic production line is in a starting development stage, a few manufacturers engaged in the development of the PC automatic production line are involved, the major efforts are also in the development of single-machine equipment functions, a fault diagnosis system and a fault diagnosis method for the PC automatic production line are not precedent, and after the production line runs abnormally, the abnormality is usually found manually, and then the reason is checked on site and maintained, so that time and labor are wasted.
Disclosure of Invention
The technical problem solved by the invention is as follows: the method and the system for diagnosing the faults of the automatic production line of the prefabricated concrete structure not only can monitor the real-time running state of the automatic production line of the prefabricated concrete structure, but also can automatically and quickly diagnose, alarm and locate the faults, and are convenient for maintenance personnel to maintain, thereby ensuring the production progress.
The technical scheme of the invention is as follows: a fault diagnosis method for an automatic production line of a prefabricated concrete structure is characterized by comprising the following steps:
(1) constructing a fault hierarchical diagnosis system of a PC automatic production line;
the PC automatic production line fault diagnosis system is arranged into two levels, namely a field pre-diagnosis fault and a centralized analysis layer;
the on-site pre-diagnosis fault comprises a plurality of controllers and on-site detection instruments, and each single machine device on the production line is divided into a plurality of device clusters according to the process layout of the PC automatic production line, wherein each cluster adopts one controller; setting fault detection points at some parts of each station device on the PC automatic production line, collecting the device running state of the fault detection points in the administered cluster range by each controller, carrying out logic analysis and judgment, and uploading the primary fault code value and the device running data to a centralized analysis layer;
the centralized analysis layer is not directly connected with field equipment and instruments and meters, and performs data interaction with each controller of the field pre-diagnosis fault in a network communication mode; an expert knowledge base and a fault reasoning mechanism are arranged in the centralized analysis layer, all fault codes and key data states of the on-site pre-diagnosis fault are covered, the fault representation uploaded by the on-site pre-diagnosis fault can be analyzed and inferred, and finally fault reasons and parts are accurately positioned by comparing and judging according to primary fault codes uploaded by the on-site pre-diagnosis fault and data information of the operation of the prefabricated concrete structure automatic production line;
(2) the controller for on-site fault pre-diagnosis carries out logic judgment, carries out primary positioning on fault phenomena, sets a primary fault code for each fault state, and uploads data;
(3) and analyzing the primary fault code by the centralized analysis layer, and reasoning out a final fault diagnosis result.
The fault diagnosis system of the automatic production line of the prefabricated concrete structure is characterized by comprising an on-site pre-diagnosis fault and a centralized analysis layer;
the on-site pre-diagnosis fault comprises a plurality of controllers and on-site detection instruments, and each single machine device on the production line is divided into a plurality of device clusters according to the process layout of the PC automatic production line, wherein each cluster adopts one controller; setting fault detection points at some parts of each station device on the PC automatic production line, collecting the device running state of the fault detection points in the administered cluster range by each controller, carrying out logic analysis and judgment, and uploading the primary fault code value and the device running data to a centralized analysis layer;
the centralized analysis layer is not directly connected with field equipment and instruments and meters, and performs data interaction with each controller of the field pre-diagnosis fault in a network communication mode; an expert knowledge base and a fault reasoning mechanism are arranged in the centralized analysis layer, all fault codes and key data states of the on-site pre-diagnosis fault are covered, the fault representation uploaded by the on-site pre-diagnosis fault can be analyzed and inferred, and the fault reason and the fault position are finally and accurately positioned by comparing and judging according to the primary fault code uploaded by the on-site pre-diagnosis fault and the data information of the operation of the prefabricated concrete structure automatic production line.
A prefabricated concrete structure automatic production line fault diagnosis system is characterized by comprising: the system comprises a monitoring computer, subsystem PLC controllers, each station actuating mechanism and a detection device;
the monitoring computer comprises a database point configuration module, a full-line production scheduling module, a fault expert database and a fault query analysis module;
the database point configuration module is an input/output interface module which reads data variables from each subsystem PLC controller and issues commands to each subsystem PLC controller, and performs information interaction in a one-to-one correlation mode of the data variables read by each subsystem PLC controller;
the whole-line production scheduling module monitors the running state of each subsystem PLC controller acquisition station device by tracking the process route track of product running on the automatic production line of the prefabricated concrete structure, and controls each subsystem PLC controller according to the production beat, so that products are scheduled to move among various warehouse positions and stations in sequence to complete the product process;
the fault expert database is a data table which classifies all possible fault phenomena of the production line, lists the positions and reasons of fault occurrence by coding, and provides solution measures;
the fault query analysis module is used for circularly scanning first-class fault codes uploaded by each subsystem PLC controller in the operation process of the automatic production line of the prefabricated concrete structure, comparing and judging production scheduling control commands of the operation of the automatic production line of the prefabricated concrete structure with operation state information of station equipment fed back by each subsystem PLC controller on site to obtain whether the site has faults and second-class fault codes corresponding to the faults, and calling corresponding contents of a fault expert library according to the second-class fault codes;
the subsystem PLC controller comprises a plurality of subsystems, and the subsystems judge the acquired state signals to obtain first-class fault signals of each subsystem and upload the first-class fault signals to a fault query analysis module;
and the subsystem PLC controller controls each station actuating mechanism and the detection device and collects the output state information of each station actuating mechanism and the detection device.
The invention has the beneficial effects that:
the fault diagnosis system for the PC automatic production line can monitor the running state of the PC automatic production line in real time, quickly position, alarm and prompt faults, and is convenient for maintenance personnel to maintain, thereby reducing maintenance time and reducing influence and loss caused by production line faults.
Drawings
Fig. 1 is a specific embodiment of a fault diagnosis system for an automatic production line of a prefabricated concrete structure according to the present invention.
Fig. 2 is a schematic diagram showing the composition relationship of each part of a monitoring computer of an automatic production line fault diagnosis system for a prefabricated concrete structure provided by the invention.
Detailed Description
The present invention is described in further detail below.
The fault diagnosis of the automatic production line of the prefabricated concrete structure comprises the following three steps:
the first step is to construct a fault hierarchical diagnosis system of the PC automatic production line.
The fault layering diagnosis system of the PC automatic production line comprises two levels of a field pre-diagnosis fault and a centralized analysis layer.
The on-site pre-diagnosis fault is based on the appearance, acquires on-site data and emphasizes primary diagnosis of local stations and equipment, the centralized analysis layer is based on the deep level, emphasizes the whole comprehensive analysis system, deduces to obtain a final fault conclusion, and gives a processing command.
When constructing the on-site pre-diagnosis fault, the method comprises the support of hardware and software and needs to finish three contents.
Firstly, according to the on-the-spot technology position overall arrangement of PC production line and equipment working property, divide a plurality of equipment clusters with all equipment and mechanism into groups, each group cluster sets up a controller and carries out centralized monitoring, and the controller can be PLC system or other functional modules, can accomplish simple logical operation function, possesses digital quantity and analog input/output interface to and bus communication interface.
Secondly, aiming at each group of equipment clusters, selecting and determining key parameters and nodes for centralized monitoring (data acquisition and control) of the controller, and setting detection points at important positions. Such as auxiliary signals of the closing or opening of the contactor switch, the current and time of the motor operation, the temperature and humidity in the curing barn, signals of the position of the work station where the product on the line is located, etc.
And thirdly, digitally coding the operation state and the primary fault phenomenon of the cluster equipment in the range governed by each controller of the field pre-diagnosis fault, wherein each code covers the number of the controller, the number of the equipment, operation data, abnormal parts, fault information and the like.
When a centralized analysis layer diagnosis system is constructed, a computer system with a powerful operation reasoning function and a man-machine interaction interface is needed, and the contents of the three parts also need to be completed.
Firstly, an expert knowledge base is established, and the knowledge base is related to key data information uploaded by all controllers of the field pre-diagnosis fault in a fault tree mode and all fault coding values designed in advance.
And secondly, establishing an inference mechanism or algorithm based on field data information and an expert knowledge base, analyzing fault code values and equipment running state codes acquired through communication in real time, deducing whether the current running state of the PC automatic production line is normal or not according to the hierarchy, and if the current running state is not normal, deeply analyzing possible reasons and parts generated due to faults.
Thirdly, designing a human-computer interaction interface for real-time dynamic display, presenting the running state of the PC automatic production line to a user in various forms of characters, animations, tables and the like, giving an alarm prompt if the production line is abnormal, feeding a fault reasoning diagnosis result back to an operator, and receiving a processing instruction of the operator.
And secondly, on-site pre-diagnosis of fault on-line monitoring data, simple logic judgment, primary fault appearance positioning and data uploading are carried out.
The controller for on-site fault pre-diagnosis is only responsible for directly collecting cluster equipment running state signals and set fault monitoring point information in the jurisdiction range, comparing parameters obtained by actual measurement with internal preset values and carrying out simple logic judgment, uploading a preliminary judgment result to a centralized analysis layer in a data coding mode, and waiting for a final diagnosis result and a processing command of the centralized analysis layer.
And thirdly, analyzing the primary fault codes by a centralized analysis layer, and deeply analyzing and reasoning to obtain a final fault diagnosis result.
The centralized analysis layer is not directly connected with field equipment and instruments and meters, and only carries out data interaction with a controller for predicting faults on site. The centralized analysis layer is constructed with an expert knowledge base covering primary fault codes set by all controllers in the field pre-diagnosis layer and key data information of the operation of the PC automatic production line collected by the controllers. The centralized analysis layer finally deduces the fault reason and the fault position by analyzing the primary fault code and comparing and logically reasoning according to the compiled internal reasoning mechanism, feeds back the fault reason and the fault position to a user in the form of characters, charts or data, gives a fault alarm and diagnosis result, and sends the fault alarm and diagnosis result to a controller for on-site fault pre-diagnosis according to the processing suggestion of an operator for corresponding processing.
The invention relates to a fault diagnosis system for an automatic production line of a prefabricated concrete structure,
the method is characterized in that the possible fault modes of the production line operation are summarized into two categories, wherein the first category is the primary fault phenomenon only related to a single equipment mechanism, is directly acquired and judged by a subsystem PLC, and uploads a fault code to a monitoring computer; and the second type is a fault phenomenon related to interaction of a plurality of equipment stations, and a fault code is obtained by comprehensively judging through analyzing field information fed back by each subsystem PLC by the monitoring computer and comparing control commands issued by the current monitoring computer. The monitoring computer inquires an internal prefabricated fault expert database through fault codes and displays the content of the corresponding fault expert database on a human-computer interface, so that an operator is prompted to accurately position a fault, measures are taken to remove the fault, and production is quickly recovered.
The invention relates to a PC automatic production line fault diagnosis system, comprising: the system comprises a monitoring computer, a subsystem PLC, each station actuating mechanism and a detection device.
The monitoring computer comprises a database point configuration module, a full-line production scheduling module, a fault expert database, a fault query analysis module, a fault diagnosis interface and an operation monitoring interface.
The database configuration module is an input/output interface module for reading data variables from each subsystem PLC and issuing commands to each subsystem PLC by the monitoring computer, and performs information interaction in a data variable connection mode by using the database configuration.
Information variables read from each subsystem PLC: the system comprises a current working mode, a busy-idle state, a code value for completing specific task conditions, signals of each sensor, states of operating button indicator lights and fault codes of a subsystem PLC. The control variables for issuing commands to each subsystem PLC include the specific task code, the start position code and the end position code of the task, and the start and stop signals of each device.
The whole-line production scheduling module monitors the running state of station equipment which is responsible for (controls and collects) by tracking the process route track of product running on the PC automatic production line, and controls each subsystem PLC according to the production beat, so that all products are scheduled to move between each warehouse location and each station location in sequence, and the process treatment processes of die disassembly, demolding, material feeding, vibration, surface treatment, maintenance and the like are completed.
The fault expert database is a data table which is used for extracting, classifying and coding all possible fault phenomena of the production line, listing the positions and reasons of fault generation in a table form and providing solving measures. The data table content comprises fault codes, fault related subsystem names, single machine component positions, fault reason analysis and solutions.
The fault query analysis module is used for circularly scanning first-class fault codes uploaded by PLC controllers of all subsystems in the running process of the PC automatic production line, comparing and judging production scheduling control commands of the running of the PC automatic production line with key information actually fed back by the PLCs of all subsystems on site to obtain whether the site has faults and corresponding second-class fault codes, calling corresponding contents of a fault expert library according to the first-class fault codes and the second-class fault codes, and displaying the contents on a fault diagnosis interface.
The operation monitoring interface is a human-computer interface for displaying the operation of the whole production line in real time in a graphic animation mode when the PC automatic production line operates normally, and an operator can input process parameters on the human-computer interface and control the starting and stopping of the whole production line.
The fault diagnosis interface is a human-computer interface displayed when the fault abnormality occurs in the PC automatic production line, and comprises a fault alarm part, a fault positioning part, a fault reason and solution part and a fault expert database updating part.
And the fault alarm is to light the red light of the PLC of the subsystem involved in the fault for warning.
The fault location is to describe the position of the equipment mechanism generated by the fault in a text mode.
The failure causes and the solving measures are listed one by one to the possible causes and the solving measures of the failure phenomenon.
And the updating of the fault expert database is that no prefabricated fault phenomenon of the fault expert database occurs in actual production, and after confirmation of field practice, a technician performs content supplementary updating on the fault expert database according to the table content.
The branch system PLC controller comprises a maintenance warehouse pallet truck branch system, a feeding and distributing vibration branch system, a napping and polishing branch system, a demolding branch system, a traveling branch system and a controller of a line shifting truck branch system, each branch system is managed (information acquisition and control) by one PLC, and each branch system comprises a plurality of stations and single-machine equipment.
The controller of the maintenance warehouse pallet truck sub-system is identified by a PLC1, and a PLC1 controller is responsible for temperature and humidity monitoring of the maintenance warehouse, control of pallet truck equipment and acquisition and judgment of a first type fault signal of the sub-system.
The first fault signals collected and judged by the subsystem PLC1 comprise temperature and humidity abnormality in the maintenance warehouse, frequency converter fault alarm of a motor for moving the pallet truck in the three directions of XYZ, position limit signals of the pallet truck in the three directions of XYZ, motor current overheating faults driven by other non-frequency converters in the pallet truck and emergency stop faults of a subsystem PLC1 control cabinet.
The feeding and distributing vibration subsystem is identified by a PLC2 and is responsible for controlling the feeding equipment, the distributing equipment and the single vibrating equipment and collecting and judging a first type of fault signals of the subsystem.
The first fault signals collected and judged by the subsystem PLC2 comprise frequency converter fault alarms of a feeding walking motor and a turnover motor, frequency converter fault alarms of an XY direction movement motor of a distributing device, frequency converter fault alarms of a material extruding motor of the distributing device, hydraulic station fault alarms of a vibration single machine, thermal overload protection faults of the vibration motor, position limit signals in the feeding walking and distributing device walking directions and emergency stop faults of a subsystem PLC2 control cabinet.
The galling and plastering branch subsystem is identified by a PLC3 and is responsible for the control of a plastering single machine, a galling single machine and a galling and plastering branch driving wheel and the judgment of a first-class fault signal of the subsystem. And the driving wheels of the napping and finishing branch are used for controlling the movement of the product among all stations on the napping and finishing branch.
The first type of fault signals responsible for the subsystem PLC3 comprise a frequency converter fault alarm of a moving motor in the smearing XY direction, a heat overload fault of a smearing rotating motor, a heat overload fault of a galling lifting motor, a limit fault of a smearing moving and galling lifting position, a frequency converter fault alarm of a driving wheel of a galling smearing branch line, a sensor fault of an advancing limit position of the galling smearing branch line and an emergency stop fault of a galling smearing branch line button station.
The demolding branch subsystem is identified by a PLC4 and is responsible for controlling the side-standing demolding single machine, the cleaning single machine and the demolding branch driving wheel and judging the first-class fault signal of the subsystem. The stripper spur drive wheel is used to control movement of the product between stations on the stripper spur.
The first type of fault signals which are responsible for the subsystem PLC4 comprise a side-standing hydraulic station fault alarm, a cleaning motor thermal overload fault, a demoulding branch driving wheel frequency converter fault alarm, a demoulding branch limit position sensor fault and a demoulding branch button station emergency stop fault.
The advancing subsystem is identified by a PLC5 and is responsible for the control of positioning equipment on the pouring branch line and the advancing driving wheel of the pouring branch line and the judgment of a first-class fault signal of the subsystem. The pouring spur travel drive wheels are used to control movement of the product between stations on the pouring spur.
The first type of fault signals responsible for the branch system PLC5 comprise a positioning device frequency converter fault alarm, a pouring branch driving wheel frequency converter fault alarm, a pouring branch limit position sensor fault and a pouring branch on-line button station emergency stop fault.
The branch system of the wire moving vehicle is identified by a PLC6 and is responsible for controlling a wire moving device and a lifting mechanism between a demolding branch wire and a pouring advancing branch wire and judging a first-class fault signal of the branch system.
The first type of fault signals responsible for the subsystem PLC6 comprise a fault alarm of a walking frequency converter of the line moving equipment, a thermal overload fault of a lifting motor of the line moving equipment, a fault of a limit position sensor and an emergency stop fault of a subsystem PLC6 control cabinet.
When product interaction exists among the PLC controllers of the subsystems, the possible second type of faults are monitored and judged by the monitoring computer.
The condition that product interaction exists in each subsystem PLC comprises the following steps: products come out from a curing warehouse to a demolding branch line, and interaction between a subsystem PLC1 and a subsystem PLC4 is involved; the product moves from a demolding branch line to a pouring advancing branch line, and relates to a subsystem PLC4, a subsystem PLC6 and a subsystem PLC 5; products come out from the curing warehouse to the galling and smearing branch line or enter the curing warehouse from the galling and smearing branch line, and interaction between the subsystem PLC1 and the subsystem PLC3 is involved; products enter a curing warehouse from a pouring advancing branch line, and the cooperation between the PLC1 and the PLC5 is involved; when the die table is moved to the feeding cloth vibration station through the traveling system for operation, the PLC2 is matched with the PLC 5.
The production scheduling control command in the fault query analysis module is a production scheduling control command for the operation of an automatic production line when product interaction exists among the PLC controllers of the subsystems.
The second type of fault also comprises communication faults of the monitoring computer and each subsystem, abnormal product movement caused by the conditions that each detection sensor has problems, the mechanism is jammed or foreign matters on site and the like, and the fault phenomenon that each subsystem PLC cannot judge can be judged by the monitoring computer, and the result is given by the judgment of the monitoring computer.
The station actuating mechanism and the detecting device comprise a temperature sensor and a humidity sensor arranged in the curing warehouse, a proximity switch arranged at each product station, and a position sensor arranged in the running direction of each mechanism. The frequency converters are adopted to drive the motors in groups, the PLC collects the fault states of the frequency converters and monitors the auxiliary contact signals of the on-off of each group of motor contactors. The current is monitored by adopting a motor with a contactor directly connected with a three-phase power supply. The running state of the frequency converter is directly collected through the motor driven by the frequency converter one to obtain fault information.
And the subsystem PLC controller controls each station actuating mechanism and the detection device and collects the output state information of each station actuating mechanism and the detection device.
Fig. 1 is a diagram showing the architecture of a PC automatic production line fault diagnosis system according to the present invention. The automatic line feeding and smoothing system comprises a monitoring computer, a maintenance warehouse pallet truck branch system PLC1, a feeding and distributing vibration branch system PLC2, a napping and smoothing branch system PLC3, a demolding branch system PLC4, a traveling branch system PLC5 and a line shifting truck branch system PLC 6. The PLC1 is responsible for control and signal acquisition of a maintenance warehouse and pallet truck equipment; the PLC2 is responsible for the control and signal acquisition of feeding equipment, distributing equipment and vibrating equipment; the PLC3 is responsible for the control and signal acquisition of the single polishing machine, the single napping machine and the driving wheels of the napping and polishing branch lines; the PLC4 is responsible for controlling and acquiring signals of the side stand single demolding machine, the single cleaning machine and the driving wheel of the demolding branch line; the PLC5 is responsible for the control and signal acquisition of positioning equipment on the pouring branch line and a pouring branch line travelling driving wheel; the PLC6 is responsible for the control of the wire moving equipment and the lifting mechanism among all branch wires and the signal acquisition.
Configuration software is installed on the monitoring computer, and TCP/IP network communication is carried out between the monitoring computer and each subsystem PLC through an industrial Ethernet switch.
The monitoring computer is in one-to-one association with each subsystem PLC variable in a database configuration mode, so that the field state of the production line is obtained, and an action command is issued.
And information interaction is not carried out among the branch systems PLC.
As shown in fig. 2, a schematic diagram of the relationship between the components of the monitoring computer includes a database point configuration module, a full-line production scheduling module, a fault expert database, a fault query and analysis module, a fault diagnosis interface, and an operation monitoring interface.
And the database point configuration module is a bridge for connecting the monitoring computer and the PLC variables of each subsystem.
The whole-line production scheduling module carries out command setting and field data acquisition and analysis on the PLCs of all subsystems through the database point configuration module on one hand, and simultaneously feeds back real-time dynamic information of a field in the form of charts and animations on an operation monitoring interface on the other hand. The production line process parameters and the full-line start-stop control are also written into the full-line production scheduling module through the operation monitoring interface.
The fault query analysis module reads the first type of fault codes of the PLCs of each subsystem and reads the current action state fed back by each PLC and key sensor information on a production line through the database point configuration module on one hand, and obtains action commands sent to the PLCs of each subsystem by the current monitoring computer through the whole-line production scheduling module on the other hand, and comprehensively analyzes to obtain the second type of fault codes. After the fault codes are obtained, all fault information corresponding to the fault codes, including fault sub-system PLC, single machine parts, reasons, solving measures and the like, are inquired from the fault expert database and displayed on a fault diagnosis interface.
The fault diagnosis interface can not only display fault information when the PC automatic production line has faults, but also add the contents of the fault expert table according to the sequence of fault codes, fault related subsystem names, fault single-machine component positions, phenomenon reason analysis and solutions when an operator updates the fault expert database when the PC automatic production line does not run.
As mentioned above, the first type of fault codes are acquired and judged by each subsystem PLC, and mainly fault information is obtained by setting a detection sensor at a key part of the equipment to directly monitor; the second type of fault codes are obtained by analyzing and judging through a monitoring computer, and fault information which cannot be detected by each subsystem PLC. The second type of fault information content mainly comprises communication faults of the monitoring computer and each subsystem PLC and fault conditions which can occur when products are transferred among the subsystems PLC.
The fault condition of the product needing to be transferred among the subsystems PLC comprises the matching between the subsystem PLC1 and the subsystem PLC4 when the pallet truck takes the product from the curing warehouse and sends the product to the demolding branch line; when the die table is transferred to a pouring branch line from a demolding branch line through a line transfer vehicle, the cooperation among the PLC4, the PLC5 and the PLC6 is involved; the pallet truck takes a mould platform from a curing warehouse to a napping and polishing branch line, and the cooperation between a PLC1 and a PLC3 is involved; the pallet truck relates to the matching between the PLC1 and the PLC5 when moving from the die receiving platform of the system to the curing warehouse; when the die table is moved to the feeding cloth vibration station through the traveling system for operation, the PLC2 is matched with the PLC 5.
The description will be made by taking as an example a trouble phenomenon and a trouble portion which may occur when PLC1 and PLC4 are mated.
When the PLC1 receives an action command of the monitoring computer and transfers the action command from a certain warehouse position to a branch demoulding line buffering station, the PLC1 feeds back a completion state to the monitoring computer at the moment when the pallet truck reaches a certain warehouse position, takes out a product from the certain warehouse position and reaches a key point of the interaction position with a branch demoulding line after the pallet truck takes out the product, and when the monitoring computer receives feedback information that the pallet truck waits for transferring at a branch demoulding line port and is uploaded by the PLC1, the monitoring computer checks the current state of the PLC4 and if the current state is suitable for receiving the product coming from the pallet truck, the monitoring computer sends a signal for the PLC4 to control the branch demoulding line buffering station driving wheel to rotate and sends a signal for the PLC1 to control the transferring driving wheel on the pallet truck to rotate.
At this time, if a sensor for detecting that the product on the pallet truck has been removed in the subsystem PLC1 fails, the pallet truck mistakenly considers that the product has left and stops the rotary transfer of the driving wheel, the product is not actually transferred on the pallet truck, and the subsystem PLC4 which is responsible for the driving wheel of the demoulding branch line buffering station rotates to receive the product after receiving the command of the monitoring computer until the product reaches the station, but the fault of the PLC1 cannot be found. And the first type of failure that PLC1 prefabricates itself does not include the type of self-sensor failure.
This second type of fault condition is monitored by the monitoring computer. After the monitoring computer gives instructions to the subsystems PLC1 and PLC4, the monitoring computer monitors the system by timing, when the delay time exceeds the time when the PLC4 feedback completion instruction is normally received but not received, and the delay time is earlier than the time when the PLC1 corresponding feedback completion instruction is normally received, the monitoring computer inquires that the communication of the corresponding subsystem is normal, so that the second type fault code of the fault of the pallet truck transfer position sensor can be analyzed and obtained, and the content of the corresponding fault expert database is called out to feed back the fault code on a fault diagnosis interface.
Claims (1)
1. A fault diagnosis system for an automatic production line of a prefabricated concrete structure is characterized by comprising a fault layered diagnosis system of a PC automatic production line;
the PC automatic production line fault diagnosis system is arranged into two levels, namely a field pre-diagnosis fault and a centralized analysis layer;
the on-site pre-diagnosis fault comprises a plurality of controllers and on-site detection instruments, and each single machine device on the production line is divided into a plurality of device clusters according to the process layout of the PC automatic production line, wherein each cluster adopts one controller; setting fault detection points at some parts of each station device on the PC automatic production line, collecting the device running state of the fault detection points in the administered cluster range by each controller, carrying out logic analysis and judgment, and uploading the primary fault code value and the device running data to a centralized analysis layer;
the controller for on-site fault pre-diagnosis carries out logic judgment, carries out primary positioning on fault phenomena, sets a primary fault code for each fault state, and uploads data;
the controller for on-site fault pre-diagnosis is only responsible for directly collecting cluster equipment running state signals and set fault monitoring point information in the jurisdiction range, comparing parameters obtained by actual measurement with an internal preset value and carrying out simple logic judgment, uploading a preliminary judgment result to a centralized analysis layer in a data coding mode, and waiting for a final diagnosis result and a processing command of the centralized analysis layer;
the centralized analysis layer analyzes the primary fault codes and deduces a final fault diagnosis result;
the centralized analysis layer is not directly connected with field equipment and instruments and meters, and performs data interaction with each controller of the field pre-diagnosis fault in a network communication mode; an expert knowledge base and a fault reasoning mechanism are arranged in the centralized analysis layer, primary fault codes set by all controllers in the field pre-diagnosis fault and key data information of the operation of the PC automatic production line collected by the controllers are covered, the fault representation uploaded by the field pre-diagnosis fault can be analyzed and reasoned, and the fault reasons and the fault positions are finally and accurately positioned by comparing and judging the primary fault codes uploaded by the field pre-diagnosis fault and the data information of the operation of the prefabricated concrete structure automatic production line;
when a centralized analysis layer is constructed, the method specifically comprises the following three parts:
firstly, establishing an expert knowledge base: the expert knowledge base associates data information uploaded by all controllers of the on-site pre-diagnosis fault with all fault coding values designed in advance in a fault tree mode;
establishing an inference mechanism or algorithm based on field data information and an expert knowledge base: analyzing fault code values and equipment running state codes acquired through communication in real time, judging whether the current running state of the PC automatic production line is normal or not according to the hierarchy, and if not, deeply analyzing possible reasons for fault generation and generated parts;
thirdly, a real-time dynamically displayed human-computer interaction interface presents the running state of the PC automatic production line to a user in various forms of characters, animations and tables, gives an alarm prompt if the production line is abnormal, feeds a fault reasoning diagnosis result back to an operator, and receives a processing instruction of the operator;
the centralized analysis layer is provided with a human-computer interaction interface, converts the fault diagnosis codes into characters, graphs or data for feedback, gives fault alarm and diagnosis results, and provides corresponding processing measures;
this prefabricated concrete structure automatic production line fault diagnosis system includes: the system comprises a monitoring computer, subsystem PLC controllers, each station actuating mechanism and a detection device;
the monitoring computer comprises a database point configuration module, a full-line production scheduling module, a fault expert database and a fault query analysis module;
the database point configuration module is an input/output interface module which reads data variables from each subsystem PLC controller and issues commands to each subsystem PLC controller, and performs information interaction in a one-to-one correlation mode of the data variables read by each subsystem PLC controller;
the whole-line production scheduling module monitors the running state of each subsystem PLC controller acquisition station device by tracking the process route track of product running on the automatic production line of the prefabricated concrete structure, and controls each subsystem PLC controller according to the production beat, so that products are scheduled to move among various warehouse positions and stations in sequence to complete the product process;
the subsystem PLC controller comprises a plurality of subsystems, and the subsystems judge the acquired state signals to obtain first-class fault signals of each subsystem and upload the first-class fault signals to a fault query analysis module;
the fault query analysis module is used for circularly scanning first-class fault codes corresponding to first-class fault signals uploaded by each subsystem PLC controller, namely primary fault codes of pre-diagnosis faults, in the operation process of the automatic production line of the prefabricated concrete structure, comparing and judging production scheduling control commands of the operation of the automatic production line of the prefabricated concrete structure with operation state information of station equipment fed back by each subsystem PLC controller on site to obtain whether the site has faults and second-class fault codes corresponding to the faults, and calling corresponding contents of a fault expert library according to the second-class fault codes;
the possible failure modes of the production line operation are summarized into two main categories:
the first type is a primary fault phenomenon only related to a single equipment mechanism, and is obtained by directly acquiring and judging by a subsystem PLC (programmable logic controller), and a first type fault code is uploaded to a monitoring computer;
the second type is a fault phenomenon related to interaction of a plurality of equipment stations, and a second type fault code is obtained by comprehensively judging through analyzing field information fed back by each subsystem PLC by the monitoring computer and comparing control commands issued by the current monitoring computer;
the second category of failures also includes the following cases: communication faults between the monitoring computer and each subsystem, problems of each detection sensor, jamming of a mechanism or field foreign matter conditions cause abnormal product movement, and the fault phenomenon which cannot be judged by each subsystem PLC is judged by the monitoring computer, so that the result is given out by the judgment of the monitoring computer;
when product interaction exists among the PLC controllers of the subsystems, a second type of fault which possibly exists is monitored and judged by the monitoring computer;
the fault expert database is a data table which classifies all possible fault phenomena of the production line, lists the positions and reasons of fault occurrence by coding, and provides solution measures;
the subsystem PLC controller controls each station actuating mechanism and the detection device, collects the output state information of each station actuating mechanism and the detection device,
the monitoring computer also comprises an operation monitoring interface; the operation monitoring interface is a human-computer interface for displaying the operation of the whole production line in real time in a graphic animation mode when the PC automatic production line is in normal operation;
the monitoring computer also comprises a fault diagnosis interface; the fault diagnosis interface is a human-computer interface displayed when the fault abnormality occurs in the PC automatic production line,
the production scheduling control command in the fault query analysis module is a production scheduling control command for the operation of an automatic production line when product interaction exists among the PLC controllers of all subsystems,
the subsystem PLC controller comprises a maintenance warehouse pallet truck subsystem, a feeding and distributing vibration subsystem, a napping and polishing subsystem, a demoulding subsystem, a traveling subsystem and a controller of a line shifting truck subsystem, namely each subsystem is controlled by one PLC,
the actuating mechanism and the detecting device of each station comprise a temperature sensor and a humidity sensor arranged in the curing warehouse, a proximity switch arranged at each product station, a position sensor, a frequency converter and a motor which is driven by the frequency converter in a one-to-one way manner in the running direction of each mechanism,
configuration software is installed on the monitoring computer, and TCP/IP network communication is carried out between the monitoring computer and each subsystem PLC through an industrial Ethernet switch.
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