CN108490864B - Intelligent production flexible routing control system - Google Patents
Intelligent production flexible routing control system Download PDFInfo
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- CN108490864B CN108490864B CN201810324767.8A CN201810324767A CN108490864B CN 108490864 B CN108490864 B CN 108490864B CN 201810324767 A CN201810324767 A CN 201810324767A CN 108490864 B CN108490864 B CN 108490864B
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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
- G05B19/054—Input/output
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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
- G05B2219/11—Plc I-O input output
- G05B2219/1103—Special, intelligent I-O processor, also plc can only access via processor
Abstract
The utility model provides a flexible route control system of intelligence production, relate to route control system technical field, it includes draws the unit, the vacuum concentration unit, the alcohol precipitation unit, the resin column unit, the ceramic membrane unit, the milipore filter unit, receive filter membrane unit and concentrate blending unit, draw the unit respectively with vacuum concentration unit and ceramic membrane unit connection, the vacuum concentration unit is connected with alcohol precipitation unit and concentrate blending unit respectively, the alcohol precipitation unit is connected with vacuum concentration unit and resin column unit respectively, the resin column unit is connected with the vacuum concentration unit, the ceramic membrane unit is connected with the milipore filter unit, the milipore filter unit respectively with the vacuum concentration unit, resin column unit and receive filter membrane unit connection, receive filter membrane unit and concentrate blending unit connection. The intelligent production flexible routing control system is economical and reliable, enables the system to have flexible routing control capability, provides a simple and visual production process routing editor, and is convenient for production personnel to edit the production requirement of a new product at a low threshold.
Description
The technical field is as follows:
the invention relates to the technical field of routing control systems, in particular to an intelligent production flexible routing control system.
Background art:
in the development process of production and manufacturing control technology, intelligent control and flexible control attract more and more attention of people, but a plurality of domestic manufacturers of traditional Chinese medicine extraction, dairy products, health-care wine and the like still keep the traditional production control system. Although the traditional production control system can keep good reliability and work efficiency on the premise of single product and fixed production process, with the increasing improvement of living standard of people, the single product of the production enterprise can not meet the continuous pursuit of the public for new things, so that the production enterprise is forced to update the existing product line, adjust the production process and produce new products by combining different production units. However, the problem also arises that the conventional control system must change the existing control program when performing the process adjustment, which must be performed by a professional software engineer, and requires much manpower and material resources, and also consumes a long debugging time. Or the production units are arranged step by step in a manual intervention mode without changing the control program, and the new product is produced in a semi-automatic mode. The result of this is that not only the production efficiency is reduced a lot, but also the manual intervention is easy to cause misoperation, which brings about no small loss.
According to the solutions provided by the existing large industrial control product enterprises (Siemens, Roxwell and the like), the existing control system needs to be upgraded to have intelligent control and flexible routing control capability, the existing system needs to be overturned to be re-done, the cost is high, the production is stopped for a long time for installation and debugging, few enterprises can do the same under the balance of advantages and disadvantages, and thus, the flexible routing control method based on the control system programming language shows practicability and necessity.
The invention content is as follows:
the invention aims to overcome the defects of the prior art and provide an intelligent production flexible routing control system which is economical and reliable, upgrades the traditional production control system, enables the system to have flexible routing control capability, provides a simple and visual production process routing editor and is convenient for production personnel to edit the production requirements of new products at low threshold.
The technical scheme adopted by the invention is as follows: flexible route control system of intelligence production, including drawing unit, vacuum concentration unit, alcohol precipitation unit, resin column unit, ceramic membrane unit, milipore filter unit, receive filter membrane unit and concentrate allotment unit, draw the unit respectively with vacuum concentration unit and ceramic membrane unit connection, vacuum concentration unit respectively with alcohol precipitation unit and concentrate allotment unit connection, alcohol precipitation unit respectively with vacuum concentration unit and resin column unit connection, resin column unit and vacuum concentration unit connection, ceramic membrane unit and milipore filter unit connection, the milipore filter unit respectively with vacuum concentration unit, resin column unit and receive filter membrane unit connection, receive filter membrane unit and concentrate allotment unit connection.
The coding method comprises the following steps:
1) firstly, selecting a product name needing to edit a new route by a manufacturer;
2) sequentially clicking the selectable process units in sequence, displaying the selected process flow in the selected process unit every time clicking is performed, and prompting to reselect the process unit which is not displayed with errors when the selected process does not meet the existing process flow conditions;
3) after the process flow is selected, a producer clicks a 'generating process code' button, a program automatically generates a process route code of the product, and the code is a binary 32-bit long integer number (DINT type);
4) a series of codes are generated by the upper computer, process routes of production units less than or equal to 15 steps are supported, and the codes are stored in the server and can be called at any time;
5) before production, the upper computer calls a routing code in the server and transmits the routing code to the PLC;
6) the PLC decodes the received codes to obtain routing instructions of the first-step production unit and transmits the routing instructions and the routing codes to the first-step production unit;
7) the production unit starts production after receiving the instruction, transmits the product to the second step unit according to the routing instruction after the production is finished, simultaneously re-edits the routing code, writes the result of the first step finished production into the code and transmits the code back to the PLC controller;
8) the PLC re-decodes the returned codes to obtain a second-step production routing instruction, and transmits the second-step production routing instruction together with the returned codes to a second-step production unit;
9) repeating the above two steps until the production is finished.
The decoding method comprises the following steps:
1) production unit A converts the 32-bit code to WORD type for the next bit operation;
2) taking out the 5 th and 6 th bits of WORD type data;
3) converting the 5 th digit and the 6 th digit which are taken out into decimal numbers, obtaining a number of 0-3 and outputting the number to a 'CODE' port, wherein the number of 0-3 is a routing result of the step, and the controller receives the result from the 'CODE' port and conveys the material to a corresponding next-step production unit B;
4) the 32-bit CODE is shifted to the left by 2 bits, and the obtained newly generated 32-bit CODE is output to an 'R _ NEXT' port, and the new 32-bit CODE is transmitted to a production unit B together with the 'CODE' in the previous step;
5) the production unit B repeats the above 4 steps to obtain a routing result 'CODE' of the production unit B, and transmits 'R _ NEXT' to the NEXT production unit again until the production is finished.
The process routing codes of each step in the step 3) occupy two bits, the expressed results are '00', '01', '10' and '11', more than or equal to 4 outgoing directions are generated after the process of each step is finished, the codes support 15 steps of processes, and symbols are marked as a 1 st step route and a 2 nd step route.
The invention has the beneficial effects that:
1) the flexibility of the control system is improved, and the production process of a new product can be adjusted at any time;
2) the upgrading is simple, the debugging is convenient, and production enterprises do not need to stop production;
3) the operation is visual and convenient, and the enterprise self-editing production process is realized at a low threshold;
4) high reliability, eliminating manual intervention and realizing full-automatic production routing control.
Description of the drawings:
FIG. 1 is a diagram of the connection of production units according to the present invention;
FIG. 2 is a diagram of a host process routing panel of the present invention;
FIG. 3 is a diagram of the encoding process of the present invention;
fig. 4 is a diagram of the decoding process of the present invention.
The specific implementation mode is as follows:
referring to the figures, the intelligent production flexible routing control system comprises an extraction unit, a vacuum concentration unit, an alcohol precipitation unit, a resin column unit, a ceramic membrane unit, an ultrafiltration membrane unit, a nanofiltration membrane unit and a concentrated solution blending unit, wherein the extraction unit is respectively connected with the vacuum concentration unit and the ceramic membrane unit, the vacuum concentration unit is respectively connected with the alcohol precipitation unit and the concentrated solution blending unit, the alcohol precipitation unit is respectively connected with the vacuum concentration unit and the resin column unit, the resin column unit is connected with the vacuum concentration unit, the ceramic membrane unit is connected with the ultrafiltration membrane unit, the ultrafiltration membrane unit is respectively connected with the vacuum concentration unit, the resin column unit and the nanofiltration membrane unit, and the nanofiltration membrane unit is connected with the concentrated solution blending unit.
The coding method comprises the following steps:
1) firstly, selecting a product name needing to edit a new route by a manufacturer;
2) sequentially clicking the selectable process units in sequence, displaying the selected process flow in the selected process unit every time clicking is performed, and prompting to reselect the process unit which is not displayed with errors when the selected process does not meet the existing process flow conditions;
3) after the process flow is selected, a producer clicks a 'generating process code' button, a program automatically generates a process route code of the product, and the code is a binary 32-bit long integer number (DINT type);
4) a series of codes are generated by the upper computer, process routes of production units less than or equal to 15 steps are supported, and the codes are stored in the server and can be called at any time;
5) before production, the upper computer calls a routing code in the server and transmits the routing code to the PLC;
6) the PLC decodes the received codes to obtain routing instructions of the first-step production unit and transmits the routing instructions and the routing codes to the first-step production unit;
7) the production unit starts production after receiving the instruction, transmits the product to the second step unit according to the routing instruction after the production is finished, simultaneously re-edits the routing code, writes the result of the first step finished production into the code and transmits the code back to the PLC controller;
8) the PLC re-decodes the returned codes to obtain a second-step production routing instruction, and transmits the second-step production routing instruction together with the returned codes to a second-step production unit;
9) repeating the above two steps until the production is finished.
The decoding method comprises the following steps:
1) production unit A converts the 32-bit code to WORD type for the next bit operation;
2) taking out the 5 th and 6 th bits of WORD type data;
3) converting the 5 th digit and the 6 th digit which are taken out into decimal numbers, obtaining a number of 0-3 and outputting the number to a 'CODE' port, wherein the number of 0-3 is a routing result of the step, and the controller receives the result from the 'CODE' port and conveys the material to a corresponding next-step production unit B;
4) the 32-bit CODE is shifted to the left by 2 bits, and the obtained newly generated 32-bit CODE is output to an 'R _ NEXT' port, and the new 32-bit CODE is transmitted to a production unit B together with the 'CODE' in the previous step;
5) the production unit B repeats the above 4 steps to obtain a routing result 'CODE' of the production unit B, and transmits 'R _ NEXT' to the NEXT production unit again until the production is finished.
The process routing codes of each step in the step 3) occupy two bits, the expressed results are '00', '01', '10' and '11', more than or equal to 4 outgoing directions are generated after the process of each step is finished, the codes support 15 steps of processes, and symbols are marked as a 1 st step route and a 2 nd step route.
Referring to fig. 1, it can be seen that the whole production process comprises 8 production units of extraction, vacuum concentration, alcohol precipitation, resin column, ceramic membrane, ultrafiltration membrane, nanofiltration membrane, and concentrated solution preparation. As can be seen in the figure, extraction is the first step of the process, routed through several production units and finally into the concentrate formulation unit. If the process is limited to within 15 steps, there will be as many as tens of routes going from the first step to the last step. According to the traditional control system scheme, a full-automatic control program is compiled according to several routes of the existing product varieties, or production personnel select the next place to go after the production unit finishes working in each step. The result of this is that the former can not satisfy the full-automatic production requirement of new product new technology, and the latter can not full-automatic production, and even more because the manual intervention easily produces the maloperation. The flexible routing control coding and decoding method is optimized for the production flow pair, the production routing codes of the products are called before production, and full-automatic routing production is realized after decoding.
Referring to fig. 2, the upper computer is shown to edit the panel of the production process, and the operation process is as follows:
1) firstly, selecting a product name needing to edit a new route by a manufacturer;
2) sequentially clicking the selectable process units in sequence, displaying the selected process flow in the selected process unit every time clicking is performed, and prompting to reselect the process unit which is not displayed with errors when the selected process does not meet the existing process flow conditions;
3) after the process flow is selected, a producer clicks a 'generate process code' button, and the program automatically generates the process routing code of the product, wherein the code is a binary 32-bit long integer number (DINT type). The process routing codes of each step occupy two bits, the expressed results are '00', '01', '10' and '11', namely, the number of the process routing codes of each step is no more than 4 at most, two-bit sign bits of 32-bit data are abandoned, the codes support 15 steps of processes at most, and the codes are stored in a database of a server for facilitating future retrieval. Briefly, the encoded 32-bit data structure is: sign flag bit, route of step 1, route of step 2.
Referring to fig. 3, the delivery process of the routing code can be seen as follows:
1) a series of codes are generated by the upper computer, process routes of production units less than or equal to 15 steps are supported, and the codes are stored in the server and can be called at any time;
2) before production, the upper computer calls a routing code in the server and transmits the routing code to the PLC;
3) the PLC decodes the received codes to obtain routing instructions of the first-step production unit and transmits the routing instructions and the routing codes to the first-step production unit;
4) the production unit starts production after receiving the instruction, transmits the product to the second step unit according to the routing instruction after the production is finished, simultaneously re-edits the routing code, writes the result of the first step finished production into the code and transmits the code back to the PLC controller;
5) the PLC re-decodes the returned codes to obtain a second-step production routing instruction, and transmits the second-step production routing instruction together with the returned codes to a second-step production unit;
6) repeating the above two steps until the production is finished.
Referring to fig. 4, there is shown an encoding and decoding module edited in a PLC programming language. It can be seen from the figure that the left end of the module is a code input port "R", and the 32-bit routing code transmitted from the upper computer or the production unit enters the module through the input port. Then, the decoding module performs encoding and decoding, and the specific steps are as follows (explained by production units a and B):
1) production unit A converts the 32-bit code to WORD type for the next bit operation;
2) taking out the 5 th and 6 th bits of WORD type data;
3) converting the 5 th digit and the 6 th digit which are taken out into decimal numbers, obtaining a number of 0-3 and outputting the number to a 'CODE' port, wherein the number of 0-3 is a routing result of the step, and the controller receives the result from the 'CODE' port and conveys the material to a corresponding next-step production unit B;
4) the 32-bit CODE is shifted to the left by 2 bits, and the obtained newly generated 32-bit CODE is output to an 'R _ NEXT' port, and the new 32-bit CODE is transmitted to a production unit B together with the 'CODE' in the previous step;
5) the production unit B repeats the above 4 steps to obtain a routing result 'CODE' of the production unit B, and transmits 'R _ NEXT' to the NEXT production unit again until the production is finished.
In summary, the intelligent production flexible routing control system improves the flexibility of the control system, and can be adjusted to adapt to the production process of new products at any time; the upgrading is simple, the debugging is convenient, and production enterprises do not need to stop production; the operation is visual and convenient, and the enterprise self-editing production process is realized at a low threshold; high reliability, eliminating manual intervention and realizing full-automatic production routing control.
Claims (2)
1. An intelligent production flexible routing control system, wherein an encoding method of the intelligent production flexible routing control system is applied to the following systems, and is characterized in that: the system comprises an extraction unit, a vacuum concentration unit, an alcohol precipitation unit, a resin column unit, a ceramic membrane unit, an ultrafiltration membrane unit, a nanofiltration membrane unit and a concentrated solution blending unit, wherein the extraction unit is respectively connected with the vacuum concentration unit and the ceramic membrane unit; the coding method of the system is as follows:
1) firstly, selecting a product name needing to edit a new route by a manufacturer;
2) sequentially clicking the selectable process units in sequence, displaying the selected process flow in the selected process unit every time clicking is performed, and prompting to reselect the process unit which is not displayed with errors when the selected process does not meet the existing process flow conditions;
3) after a process flow is selected, a producer clicks a 'process code generation' button, a program automatically generates a process route code of the product, the code is a binary 32-bit long integer number (DINT type), the process route code of each step occupies two bits, the expressed result is '00', '01', '10' and '11', more than or equal to 4 outgoing directions are generated after the process of each step is finished, the code supports 15 steps of processes, and the symbol marks are a 1 st step route and a 2 nd step route.
4) A series of codes are generated by the upper computer, process routes of production units less than or equal to 15 steps are supported, and the codes are stored in the server and can be called at any time;
5) before production, the upper computer calls a routing code in the server and transmits the routing code to the PLC;
6) the PLC decodes the received codes to obtain routing instructions of the first-step production unit and transmits the routing instructions and the routing codes to the first-step production unit;
7) the production unit starts production after receiving the instruction, transmits the product to the second step unit according to the routing instruction after the production is finished, simultaneously re-edits the routing code, writes the result of the first step finished production into the code and transmits the code back to the PLC controller;
8) the PLC re-decodes the returned codes to obtain a second-step production routing instruction, and transmits the second-step production routing instruction together with the returned codes to a second-step production unit;
and (4) repeating the steps 7) and 8) till the production is finished.
2. An intelligent production flexible routing control system according to claim 1, wherein: the method for applying the decoding method of the intelligent production flexible routing control system to the system comprises the following steps:
1) production unit A converts the 32-bit code to WORD type for the next bit operation;
2) taking out the 5 th and 6 th bits of WORD type data;
3) converting the 5 th digit and the 6 th digit which are taken out into decimal numbers, obtaining a number of 0-3 and outputting the number to a 'CODE' port, wherein the number of 0-3 is a routing result of the step, and the controller receives the result from the 'CODE' port and conveys the material to a corresponding next-step production unit B;
4) the 32-bit CODE is shifted to the left by 2 bits, and the obtained newly generated 32-bit CODE is output to an 'R _ NEXT' port, and the new 32-bit CODE is transmitted to a production unit B together with the 'CODE' in the previous step;
the production unit B repeats the above 4 steps to obtain a routing result 'CODE' of the production unit B, and transmits 'R _ NEXT' to the NEXT production unit again until the production is finished.
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