CN108829049B - Method for monitoring feeding speed and feeding amount in real time during manufacturing of liquid crystal glass substrate - Google Patents
Method for monitoring feeding speed and feeding amount in real time during manufacturing of liquid crystal glass substrate Download PDFInfo
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- CN108829049B CN108829049B CN201810501534.0A CN201810501534A CN108829049B CN 108829049 B CN108829049 B CN 108829049B CN 201810501534 A CN201810501534 A CN 201810501534A CN 108829049 B CN108829049 B CN 108829049B
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 32
- 238000012544 monitoring process Methods 0.000 title claims abstract description 24
- 238000000034 method Methods 0.000 title claims abstract description 22
- 239000011521 glass Substances 0.000 title claims abstract description 16
- 239000004973 liquid crystal related substance Substances 0.000 title claims abstract description 16
- 239000000758 substrate Substances 0.000 title claims abstract description 16
- 239000000463 material Substances 0.000 claims abstract description 86
- 238000013461 design Methods 0.000 claims abstract description 8
- 238000013178 mathematical model Methods 0.000 abstract description 4
- 230000000694 effects Effects 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000005816 glass manufacturing process Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 239000006060 molten glass Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 238000004886 process control Methods 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
Classifications
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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
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41885—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by modeling, simulation of the manufacturing system
-
- 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
- G05B2219/30—Nc systems
- G05B2219/33—Director till display
- G05B2219/33273—DCS distributed, decentralised controlsystem, multiprocessor
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- General Engineering & Computer Science (AREA)
- Quality & Reliability (AREA)
- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Automation & Control Theory (AREA)
- General Factory Administration (AREA)
Abstract
The invention discloses a method for monitoring the feeding speed and the feeding amount in real time in the manufacturing of a liquid crystal glass substrate, and belongs to the technical field of automatic control. Establishing a scientific and reasonable mathematical model through material weight information which can be directly acquired and a preset value, then carrying out program configuration by using a DCS (distributed control system) lower design configuration tool according to the established mathematical model, and linking corresponding data items through an upper design flow chart picture, so that the online real-time monitoring of the feeding speed, the feeding amount, the total feeding speed and the feeding amount of each bin can be realized at an upper computer operation station; and a corresponding historical trend chart can be established through system configuration according to real-time data information of the feeding speed, the feeding amount and the total feeding speed and the feeding amount of each storage bin, so that important basis is provided for analyzing quality fluctuation and improving the production process, the risk of an automatic control system is reduced, and the production operation efficiency is improved.
Description
Technical Field
the invention belongs to the technical field of automatic control, and particularly relates to a method for monitoring feeding speed and feeding amount in real time during manufacturing of a liquid crystal glass substrate.
Background
A distributed control system, DCS for short, is a new generation of instrument control system based on a microprocessor and adopting a design principle of decentralized control function, centralized display operation and consideration of both autonomous and comprehensive coordination. The real-time monitoring function generally comprises the steps of sending a 4-20 milliampere signal generated by measurement of an intelligent instrument into a DCS, establishing a corresponding model in the DCS at the stage of DCS function configuration, converting an analog signal into a digital signal and displaying the digital signal in an operation station in real time, so that real-time monitoring of various process parameters is realized.
in the existing production line of the liquid crystal glass substrate, in the process of melting → channel → molding, the real-time material weight information can be obtained only through the instruments arranged at each level of feeding bin, and the information of the feeding speed and the feeding amount cannot be directly obtained. The feeding speed and the feeding amount are important parameters in the glass manufacturing process, and are particularly important for controlling the product quality: the feeding speed and the feeding amount directly determine the stability of the liquid level, the stability of the liquid level directly influences the stability of the drawing amount of the molten glass, and the stability of the drawing amount directly determines the stability of the weight of the liquid crystal glass substrate plate. Meanwhile, the feeding speed is also an important basis for judging whether the primary spiral blanking equipment operates normally, online real-time monitoring of the feeding speed and the feeding amount is an important means for direct process control, and a historical trend chart of the feeding speed and the feeding amount is an important basis for analyzing quality fluctuation. However, in the prior art, real-time data of the feeding speed and the feeding amount cannot be intuitively observed.
Disclosure of Invention
In order to solve the above-mentioned defects, the present invention aims to provide a method for monitoring the feeding speed and the feeding amount in real time in the manufacturing of a liquid crystal glass substrate.
The invention is realized by the following technical scheme:
A method for monitoring the feeding speed and the feeding amount in real time in the manufacturing of a liquid crystal glass substrate is realized by a DCS system and comprises the following steps:
1) setting an execution period t0 and a time counting target value N of a control module CM in the DCS; defining the duration time of one charging of the charging tank as t', a time counter as t, and increasing the total charging speed v and the total charging amount W into standard historical data acquisition items; setting an alarm value of the material weight M of the primary material bin;
2) collecting material weight information M of a first-stage storage bin, recording the material weight as an initial point material weight M1, and setting an initial value of a time counter t as 0; when the collected material weight information M of the primary material bin is smaller than or equal to an alarm value, sending an alarm signal, and starting a material filling switch F;
3) collecting information of a material filling and feeding switch F, and turning to the step 4) if the material filling and feeding switch F is closed; turning to the step 6) if the material filling switch F is turned on;
4) collecting numerical value information of a time counter t, and turning to a step 5) if the time counter t is equal to a time counting target value N; if the time counter t is not equal to the time counting target value N, the time counter t is made to be t +1, and then the step 3) is executed;
5) Collecting material weight information M of a first-level storage bin, recording the material weight at the moment as a terminal material weight MN, recovering an initial value 0 by a time counter t, calculating a total feeding speed v and a total feeding amount W according to the following formula, and storing the total feeding speed v and the total feeding amount W into a system:
the material feeding amount Wi of each first-stage bin is equal to the weight M1 of the starting point material and the weight MN of the final point material;
the total feeding speed v is equal to the feeding speed vi of each first-stage bin;
the total feeding amount W is equal to the sigma feeding amount Wi of each first-level bin;
Recording the calculated total feeding speed v and the calculated total feeding amount W in real time and sending the recorded total feeding speed v and the calculated total feeding amount W to a DCS background;
then turning to the step 2) until the production task is finished or the system is shut down;
6) At this time, the time counter t is made to be 0, after the one-time charging duration t' of the charging tank is finished, the total charging speed v and the total charging amount W are calculated according to the following method and recorded:
the feeding speed vi of each first-stage bin is the feeding speed vi' of the last execution period of the CM before the material filling switch F is started, and then:
the feeding amount Wi of each first-stage storage bin is vi 'multiplied by t';
the total feeding speed v is equal to the feeding speed vi' of each primary bin;
The total feeding amount W is equal to the sigma feeding amount Wi of each first-level bin;
Storing the calculated total feeding speed v and the calculated total feeding amount W into the system; then turning to the step 2) until the production task is finished or the system is shut down;
7) according to the total feeding speed v and the total feeding amount W recorded in the steps 5) and 6), the configuration of a lower design program of the DCS can be controlled, and the configuration of a picture surface of an upper design flow can generate a historical trend graph for monitoring the feeding speed and the feeding amount of the storage bin in real time.
Preferably, the material amount Wi and the total material amount W of each primary bunker are displayed according to the execution period t0 of the CM;
preferably, the feeding speed vi and the total feeding speed v of each primary bunker are displayed according to the time interval t0 × N.
preferably, the time count target value N is set in accordance with the following principle: the reduction in material weight in time interval t0 XN > the measuring range of the material weight measuring instrument X the accuracy of the material weight measuring instrument.
Preferably, the time count target value N is set in accordance with the following principle: the time interval t0 xn is an integer multiple of the standard historical data acquisition time interval.
Preferably, the material weight of each primary bin is less than the maximum capacity of each primary bin when the material tank is filled with the material amount of each primary bin + the last execution period before feeding.
Preferably, in step 2), the material weight information M of the primary bin is acquired by a measuring instrument arranged in the primary bin.
Compared with the prior art, the invention has the following beneficial technical effects:
The invention discloses a method for monitoring the feeding speed and the feeding amount in real time in the manufacturing of a liquid crystal glass substrate, which comprises the steps of establishing a scientific and reasonable mathematical model through directly-collected material weight information and preset values, then carrying out program configuration by using a DCS (distributed control system) lower-level design configuration tool according to the established mathematical model, linking corresponding data items through upper-level design flow chart pictures, and realizing the online real-time monitoring of the feeding speed, the feeding amount, the total feeding speed and the feeding amount of each bin at an upper computer operation station; and a corresponding historical trend chart can be established through system configuration according to real-time data information of the feeding speed, the feeding amount, the total feeding speed and the feeding amount of each bin, so that important basis is provided for analyzing quality fluctuation and improving the production process. The configuration in the DCS system can monitor and control automated processes and equipment, collect various information from the automated processes and equipment, display the information in a more understandable manner such as graphics, transmit important information to relevant personnel in various ways, perform necessary analysis and processing on the information, and store the information to issue control commands. The invention can reduce the risk of the automatic control system and improve the production operation efficiency.
Drawings
FIG. 1 is a flow chart of the DCS system of the present invention.
Detailed Description
the present invention will now be described in further detail with reference to fig. 1, which is illustrative, but not limiting, of the present invention.
fig. 1 shows a flow chart of the DCS system of the present invention, which includes the following steps:
1) In the initial state of the system, according to actual production experience, setting an execution period t0 and a time counting target value N of a control module CM in a DCS, according to the requirement of object measurement and control, a plurality of control modules CM are required to be created, each CM is a control scheme, and functional blocks for realizing certain functions are placed in the control modules CM;
defining the duration time of one-time feeding of the material tank as t', increasing the total feeding speed v and the total feeding amount W into a standard historical data acquisition item, and automatically recording by the system after the total feeding speed v and the total feeding amount W are calculated; setting an alarm value of the material weight M of the primary material bin; making a time counter t equal to 0; then step 2) follows.
In this step, to prevent data distortion, the time count target value N is set according to the following principle: firstly, the reduction of material weight in a time interval t0 multiplied by N is larger than the measuring range of a material weight measuring instrument multiplied by the precision of the material weight measuring instrument; time interval t0 × N is an integer multiple of the standard historical data acquisition time interval. In order to prevent the raw materials in the first-level bins from overflowing, the material filling amount of each first-level bin and the material weight of each first-level bin in the last execution period before feeding are less than the maximum capacity of each first-level bin.
2) collecting material weight information M of the primary bin in real time by a measuring instrument arranged in the primary bin, wherein a weight sensor, an electronic scale and the like can be adopted, the material weight M is taken as an initial point material weight M1, the initial value of a time counter t is 0, and then carrying out step 3);
when the collected material weight information M of the primary material bin is smaller than or equal to an alarm value, an alarm signal is sent out, and a material filling switch F is turned on.
3) collecting information of a material filling switch F, if the material filling switch F is closed, turning to the step 4); and if the material filling switch F is turned on, turning to the step 6).
4) collecting numerical value information of a time counter t, and turning to a step 5) if the time counter t is equal to a time counting target value N; if the time counter t is not equal to the time counting target value N, the time counter t is made to be t +1, and then the step 3) is executed;
5) collecting material weight information M of a first-level storage bin, taking the material weight at the moment as a terminal material weight MN, recovering an initial value 0 by a time counter t, calculating a total feeding speed v and a total feeding amount W according to the following formula, and storing the total feeding speed v and the total feeding amount W into a system:
the material feeding amount Wi of each first-stage bin is equal to the weight M1 of the starting point material and the weight MN of the final point material;
the total feeding speed v is equal to the feeding speed vi of each first-stage bin;
The total feeding amount W is equal to the sigma feeding amount Wi of each first-level bin;
Recording the calculated total feeding speed v and the calculated total feeding amount W in real time and sending the recorded total feeding speed v and the calculated total feeding amount W to a DCS background;
Then go to step 2) until the production task is completed or the system is shut down.
6) at this time, the time counter t is made to be 0, and after the one-time charging duration t' of the charging tank is finished, the total charging speed v and the total charging amount W are calculated and recorded according to the following method:
at this time, the actual feeding speed cannot be calculated, and the feeding speed vi of each primary bin is defined as the feeding speed vi' of the last execution cycle of CM before the material filling switch F is turned on so as to maintain the continuity of data, and then:
the feeding amount Wi of each first-stage storage bin is vi 'multiplied by t';
the total feeding speed v is equal to the feeding speed vi' of each primary bin;
The total feeding amount W is equal to the feeding amount Wi of each first-level bin,
storing the calculated total feeding speed v and the calculated total feeding amount W into the system; then turning to the step 2) until the production task is finished or the system is shut down;
Turning to the step 2) until the production task is completed or the system is stopped.
7) according to the total feeding speed v and the total feeding amount W recorded in the steps 5) and 6), the configuration of a lower design program of the DCS can be controlled, and the configuration of a picture surface of an upper design flow can generate a historical trend graph for monitoring the feeding speed and the feeding amount of the storage bin in real time.
for convenient real-time monitoring, the material feeding amount Wi and the total material feeding amount W of each primary bin can be set to be displayed according to the execution period t0 of the CM, and the material feeding speed vi and the total material feeding speed v of each primary bin are displayed according to the time interval t0 multiplied by N. And a corresponding historical trend graph can be established through system configuration according to the real-time data information of the feeding speed vi, the total feeding speed v, the feeding amount Wi and the total feeding amount W of each primary bin. Provides important basis for analyzing quality fluctuation and improving production process.
in the following, the effect of the present invention is described visually with reference to a set of data, for example, table 1 shows the partial values of a time period of a certain primary bunker derived in the DCS system using the method of the present invention, the standard historical data acquisition time interval is 60S, t0 is set to 1S, N is 600, and t0 × N is 600S. In order to facilitate production statistics, the feeding amount is displayed in the form of accumulated feeding amount.
in the time period of 7:22: 00-7: 41:00, feeding in a first-level storage bin, closing a material filling switch F, and calculating a feeding speed vi every 600 seconds by the system; and starting the material charging switch in a time period of 7:44: 00-7: 45:00, charging, wherein the charging speed vi is equal to the charging speed of the last execution period of the CM before the material charging switch F is started, stopping the material charging switch after charging is finished in a time period of 7:46: 00-7: 47:00, t is 0 at 7:47:00, and continuously calculating the charging speed vi every 600 seconds by the system. Meanwhile, the historical data of the material weight of the storage bin and the accumulated material feeding amount are stored in the system and used as references for analyzing and improving production and quality.
TABLE 1
As can be seen from the data in the table 1, the invention can realize the real-time monitoring of the feeding speed and the feeding amount, has important guiding function on production management and quality improvement, reduces the risk of an automatic control system and improves the production operation efficiency.
Claims (7)
1. the method for monitoring the feeding speed and the feeding amount in real time in the manufacturing of the liquid crystal glass substrate is characterized by being realized through a DCS (distributed control system), and comprises the following steps of:
1) setting an execution period t0 and a time counting target value N of a control module CM in the DCS; defining the duration time of one charging of the charging tank as t', a time counter as t, and increasing the total charging speed v and the total charging amount W into standard historical data acquisition items; setting an alarm value of the material weight M of the primary material bin;
2) Collecting material weight information M of a first-stage storage bin, recording the material weight as an initial point material weight M1, and setting an initial value of a time counter t as 0;
When the collected material weight information M of the primary material bin is smaller than or equal to an alarm value, sending an alarm signal, and starting a material filling switch F;
3) collecting information of a material filling and feeding switch F, and turning to the step 4) if the material filling and feeding switch F is closed; turning to the step 6) if the material filling switch F is turned on;
4) Collecting numerical value information of a time counter t, and turning to a step 5) if the time counter t is equal to a time counting target value N; if the time counter t is not equal to the time counting target value N, the time counter t is made to be t +1, and then the step 3) is executed;
5) collecting material weight information M of a first-level storage bin, recording the material weight at the moment as a terminal material weight MN, recovering an initial value 0 by a time counter t, calculating a total feeding speed v and a total feeding amount W according to formulas (1) to (4), and storing the total feeding speed v and the total feeding amount W into a system:
feeding speed of each first-level storage bin
The material feeding amount Wi of each first-stage bin is equal to the weight M1 of the starting point material and the weight MN of the final point material; (2)
The total feeding speed v is equal to the feeding speed vi of each first-stage bin; (3)
the total feeding amount W is equal to the sigma feeding amount Wi of each first-level bin; (4)
Recording the calculated total feeding speed v and the calculated total feeding amount W in real time and sending the recorded total feeding speed v and the calculated total feeding amount W to a DCS background; then turning to the step 2) until the production task is finished or the system is shut down;
6) at this time, the time counter t is made to be 0, and after the one-time charging duration time t' of the charging tank is finished, the total charging speed v and the total charging amount W are calculated according to the following method and recorded:
the feeding speed vi of each first-stage bin is the feeding speed vi' of the last execution period of the CM before the material filling switch F is started, and then:
The feeding amount Wi of each first-stage storage bin is vi 'multiplied by t';
the total feeding speed v is equal to the feeding speed vi' of each primary bin;
the total feeding amount W is equal to the sigma feeding amount Wi of each first-level bin;
Storing the calculated total feeding speed v and the calculated total feeding amount W into the system; then turning to the step 2) until the production task is finished or the system is shut down;
7) According to the total feeding speed v and the total feeding amount W recorded in the steps 5) and 6), the configuration of a lower design program of the DCS can be controlled, and the configuration of a picture surface of an upper design flow can generate a historical trend graph for monitoring the feeding speed and the feeding amount of the storage bin in real time.
2. the method for real-time monitoring of the feeding speed and the feeding amount in the manufacture of liquid crystal glass substrates as claimed in claim 1, wherein the feeding amount Wi and the total feeding amount W of each primary silo are displayed according to the execution period t0 of CM.
3. The method for real-time monitoring of feeding speed and feeding amount in manufacturing of liquid crystal glass substrates as claimed in claim 1, wherein the feeding speed vi and the total feeding speed v of each primary silo are displayed according to the time interval t0 XN.
4. the method for real-time monitoring of feeding speed and feeding amount in liquid crystal glass substrate manufacturing according to claim 1, wherein the time count target value N is set according to the following principle: the reduction in material weight in time interval t0 XN > the measuring range of the material weight measuring instrument X the accuracy of the material weight measuring instrument.
5. The method for real-time monitoring of feeding speed and feeding amount in liquid crystal glass substrate manufacturing according to claim 1 or 4, wherein the time count target value N is set according to the following principle: the time interval t0 xn is an integer multiple of the standard historical data acquisition time interval.
6. the method for real-time monitoring of feeding speed and feeding amount in liquid crystal glass substrate manufacturing according to claim 1, wherein the feeding amount to each primary hopper in the feeding tank + the weight of each primary hopper during the last execution cycle before feeding < the maximum capacity of each primary hopper.
7. The method for monitoring the feeding speed and the feeding amount in real time in the manufacturing of the liquid crystal glass substrate as claimed in claim 1, wherein in the step 2), the material weight information M of the primary silo is collected by a measuring instrument arranged in the primary silo.
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CN111624957A (en) * | 2020-04-10 | 2020-09-04 | 彩虹集团有限公司 | Online data acquisition and extraction system and method for G8.5 liquid crystal glass substrate MES system |
CN111580473B (en) * | 2020-04-10 | 2021-05-28 | 彩虹集团有限公司 | Method for automatically controlling glass extraction amount of liquid crystal substrate |
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CN107632583A (en) * | 2017-10-16 | 2018-01-26 | 四川虹禾晶科技有限公司 | A kind of automatic control system of glass production flow |
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JPH10177163A (en) * | 1990-04-11 | 1998-06-30 | Seiko Epson Corp | Liquid crystal display panel and its manufacture |
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Application publication date: 20181116 Assignee: Hunan Shaohong special glass Co.,Ltd. Assignor: CAIHONG GROUP Co.,Ltd. Contract record no.: X2023980042112 Denomination of invention: A Method for Real Time Monitoring of Feeding Speed and Quantity in the Manufacturing of Liquid Crystal Glass Substrates Granted publication date: 20191206 License type: Common License Record date: 20230922 |