CN109032099A - Engineering machinery assemble production line online awareness system - Google Patents
Engineering machinery assemble production line online awareness system Download PDFInfo
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- CN109032099A CN109032099A CN201811026623.0A CN201811026623A CN109032099A CN 109032099 A CN109032099 A CN 109032099A CN 201811026623 A CN201811026623 A CN 201811026623A CN 109032099 A CN109032099 A CN 109032099A
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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], computer integrated manufacturing [CIM]
- G05B19/41875—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], computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/40—Bus networks
- H04L12/40006—Architecture of a communication node
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- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L67/00—Network arrangements or protocols for supporting network services or applications
- H04L67/01—Protocols
- H04L67/12—Protocols specially adapted for proprietary or special-purpose networking environments, e.g. medical networks, sensor networks, networks in vehicles or remote metering networks
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04W—WIRELESS COMMUNICATION NETWORKS
- H04W4/00—Services specially adapted for wireless communication networks; Facilities therefor
- H04W4/30—Services specially adapted for particular environments, situations or purposes
- H04W4/38—Services specially adapted for particular environments, situations or purposes for collecting sensor information
-
- 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
- G05B2219/32—Operator till task planning
- G05B2219/32015—Optimize, process management, optimize production line
-
- H—ELECTRICITY
- H04—ELECTRIC COMMUNICATION TECHNIQUE
- H04L—TRANSMISSION OF DIGITAL INFORMATION, e.g. TELEGRAPHIC COMMUNICATION
- H04L12/00—Data switching networks
- H04L12/28—Data switching networks characterised by path configuration, e.g. LAN [Local Area Networks] or WAN [Wide Area Networks]
- H04L12/40—Bus networks
- H04L2012/40208—Bus networks characterized by the use of a particular bus standard
- H04L2012/40215—Controller Area Network CAN
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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]
Abstract
The invention discloses a kind of engineering machinery assemble production line online awareness systems, belong to intelligence manufacture field.It includes automatic production line, and automatic production line includes multiple assembly stations；Spot sensor, device sensor, information scanning terminal and station controller are provided on each assembly station, spot sensor and device sensor are connect by ZigBee communication with station controller, and information scanning terminal is communicated by RS485 and connect with station controller；All station controllers in same workshop are connect by CAN bus with an industrial control computer；All industrial control computers are connect by Ethernet with server, and server is connected with factory's monitoring center.Online acquisition of the present invention to industry spot multi-source data, based on the network interconnection, the real-time perception of production process and the quick response and processing of dynamic control, abnormal conditions can be achieved, and provide data support for wire body computable general equilibrium, system self diagnosis, product quality retrospect, flexible manufacturing etc..
Description
Technical field
The present invention relates to intelligence manufacture fields, particularly relate to a kind of engineering machinery assemble production line online awareness system.
Background technique
Currently, the whole world, which possesses in-service engineering mechanical device, exceedes 10,000,000, wherein contain the in-service equipment in China 4,000,000, point
It is distributed in the construction site of a countries and regions more than 150.The final products assembly of the types such as engineering machinery, equipment manufacturing enterprise is (total
Dress) it is one and is related to the complicated sexuality of many factors such as material, personnel, machine.
The production process perception of engineering machinery is primarily referred to as the perception of the various production process states in assembly shop, is related to producing
Execution state, quality of production management etc..In traditional production process information obtaining mode, even in equal informationizations
System, the problems such as still remaining time-consuming information collection, lag, do not rise in value: the production of such as production status, manufacturing schedule etc is held
The quality of production information of row status information and inspection result etc is all to be input to information system by way of manual to work as
In；However, with the increasingly complication of production process scale, the factor of production changeableization at random, the information in production process is in
The feature of existing multi-source and magnanimity, if using traditional mode again, the problems such as will making time-consuming, lag, error, is more prominent, together
When can also occupy working time of worker, waste resources of production.
Summary of the invention
In order to solve the above technical problems, the present invention provides a kind of engineering machinery assemble production line online awareness system, this hair
The bright online acquisition to industry spot multi-source data, based on the network interconnection, it can be achieved that the real-time perception of production process and dynamic are controlled
System, the quick response and processing of abnormal conditions, and be wire body computable general equilibrium, system self diagnosis, product quality retrospect, flexible system
It makes etc. and data to be provided supports.
It is as follows that the present invention provides technical solution:
A kind of engineering machinery assemble production line online awareness system, including automatic production line, the automatic production line
Including multiple assembly stations；Spot sensor, device sensor, information scanning terminal and station are provided on each assembly station
Controller, the spot sensor and device sensor are connect by ZigBee communication with the station controller, the information
End of scan is communicated by RS485 and is connect with the station controller；All station controllers in same workshop are total by CAN
Line is connect with an industrial control computer；All industrial control computers are connect by Ethernet with server, the service
Device is connected with factory's monitoring center.
Further, the spot sensor includes torque sensor, oil pressure sensor and/or workpiece alignment sensor.
Further, the torque sensor includes torque detection module, data processing module, communication module and power supply mould
The torque value is converted to digital signal by block, the torque detection module real-time detection torque value, the data processing module,
The communication module is transmitted the digital signal with industrial communication format by ZigBee communication.
Further, the oil pressure sensor includes pressure sensing cell, signal processing unit, data processing unit, leads to
The pressure change of detected portion is transformed into the variation of resistance value, institute by letter unit and power supply unit, the pressure sensing cell
It states signal processing unit and the variation of the resistance value is converted into analog signal, the data processing unit is by the analog signal
Handle and treated data conversion at digital signal, the communication unit is believed the number by ZigBee communication
It number is transmitted with industrial communication format.
Further, the workpiece alignment sensor includes photoelectric proximity switch, single-chip microcontroller, communication device and power supply dress
It sets.
Further, the device sensor includes the switch sensor of collector's operating state data, acquires equipment
The temperature sensor of operating temperature and environment temperature acquires the acceleration transducer of equipment operational vibration situation, detection device work
Make the voltage sensor of state, acquire the Hall sensor of station material quantity data, the weighing of acquisition weight of material data passes
Sensor detects the dust sensor of manufacturing shop working environment.
Further, the spot sensor and device sensor include fault queue's counter, work as measurand
When continuing to exceed the upper limit or reaching pre-determined number lower than the number of lower limit, triggering is interrupted.
Further, the engineering machinery assemble production line online awareness system further includes ZigBee coordinator node, institute
Stating ZigBee coordinator node includes microprocessor module, RS232 interface, antenna, FLASH, control panel and power supply, described
RS232 interface is connect by conditioning circuit with the UART unit of the microprocessor module, and the antenna improves electricity by radio frequency
Road is connect with the 2.4G transceiver of the microprocessor module, and the SPI unit of the FLASH and the microprocessor module connects
It connects, the control panel is connect with the man-machine interaction unit of the microprocessor module.
Further, the industrial control computer includes:
Data fusion module, for extracting characteristic from the data that spot sensor and device sensor obtain；
Fusion Features module obtains believable fault diagnosis letter for the comprehensive feature obtained from data fusion module
Breath；
Information Fusion Module finally determines failure for integrating historical experience information and failure diagnosis information.
Further, the information scanning terminal includes worker's identity reader, RFID card reader and/or bar code scan
Device.
The invention has the following advantages:
The present invention is communicated by ZigBee, RS485 the sensor of each station and work microcontroller connecting into a net
Network, all station controllers in workshop connect into a network by CAN bus and industrial control computer, all workshops
Industrial control computer connects into a network by Ethernet and server.Based on fieldbus, Industrial Ethernet, wireless biography
The technologies such as sensor network, RFID, bar code construct the large-scale engineering machinery assembling line on-line monitoring system of multibus, complete
The online acquisition of pairs of industry spot multi-source data, is based on the network interconnection, the present invention can be achieved the real-time perception of production process with
It dynamically controls, the quick response and processing of abnormal conditions, and traced for wire body computable general equilibrium, system self diagnosis, product quality,
Flexible manufacturing etc. provides data and supports.
Detailed description of the invention
Fig. 1 is the schematic diagram of one specific example of automatic production line of the invention；
Fig. 2 is the schematic diagram of engineering machinery assemble production line online awareness system of the invention；
Fig. 3 is single station network system schematic diagram；
Fig. 4 is server schematic diagram；
Fig. 5 is torque sensor schematic diagram；
Fig. 6 is oil pressure sensor schematic diagram；
Fig. 7 is workpiece alignment sensor schematic diagram；
Fig. 8 is ZigBee coordinator node schematic diagram；
Fig. 9 is embedded intelligence gateway schematic diagram.
Specific embodiment
To keep the technical problem to be solved in the present invention, technical solution and advantage clearer, below in conjunction with attached drawing and tool
Body embodiment is described in detail.
The present invention provides a kind of engineering machinery assemble production line online awareness system, as shown in Figs. 1-2, including automatic metaplasia
Producing line 1, the automatic production line 1 include multiple assembly stations 2；Spot sensor 3, equipment are provided on each assembly station 2
Sensor 4, information scanning terminal 5 and station controller 6, spot sensor 3 and device sensor 4 pass through ZigBee communication and work
Level controller 6 connects, and information scanning terminal 5 is communicated by RS485 and connect with station controller 6；All works in same workshop
Level controller 6 is connect by CAN bus with an industrial control computer 7；All industrial control computers 7 by Ethernet with
Server 8 connects, and server 8 is connected with factory's monitoring center 9.Spot sensor preferably includes torque sensor 100, oil pressure passes
Sensor 200, workpiece alignment sensor 300 and/or force snesor 400 etc., information scanning terminal include worker's identity reader
500, RFID card reader 600 and/or barcode scanner 700.
It is assembled as the production activity of manufacturing process final stage, is by various technical process by different components by suitable
Sequence is assembled into a kind of production process with specific function product.Engineering machinery is smaller with respect to outputs such as car, trucies, although
There is very fast development in recent years, but the degree of automation is not still high.The assembly of large-scale engineering machinery complete machine, past use always
The mode of platform position formula is determined in dispersion, and this assembly method quality randomness is big, and labor intensity is high, and is not easily controlled.In order to gram
These disadvantages are taken, realize the requirement of production mass.The present invention carries out automatic improving to engineering machinery production line, and construction is large-scale
Engineering machinery automatic production line, production line are equipped with automatic assembling apparatus, workpiece positioning check device, work handling device etc..
What Fig. 1 was provided is the assembling line of bull-dozer, for including 23 assembly stations, be merely given as one of Fig. 1
Example, automatic production line of the invention are not limited to the form that Fig. 1 is provided, and can also be other forms.
In engineering machinery assembling process, multiple working procedure needs to detect the physical quantitys such as torque, hydraulic, liquid level, displacement, the present invention
Each assembly station on the spot sensors such as torque, oil pressure, the workpiece positioning be furnished with according to process difference.In addition equipment itself
The states such as temperature, vibration be also required to detect, set on automatic production line of the invention or in the equipment of automatic production line
It is equipped with the device sensor of detection device oneself state, these sensors are made up of wireless ZigBee communication and station controller
Sensor network.
All it is to be detected using non-electrical class instrument or analog signal instrument on production line at present, cannot achieve the intelligence of sensor
Change and networking.The application using intelligentized spot sensor and device sensor, high reliablity, low-power consumption, environment are suitable
It should be with strong antijamming capability.
It,, can while being produced although there is the automation equipment of screwing machine etc at Assembling Production scene
Corresponding data is generated, still, as production information " isolated island ", data can only be stored locally, and what can be played acts on
It is real limited.Hand-kept or manual data transfer in tradition application, it is time-consuming and laborious, do not have real-time, and error probability
It is high.In consideration of it, the application improves production equipment using device sensor, it is allowed to carry out device data acquisition automatically, for production letter
Breath management provides basic data, reaches and carries out comprehensive tracking, analysis, optimization and control to production process, and realization produced
Journey more accurately and timely monitors and actively perceive, pushes the improvement of Assembling Production mode, to be assembling manufacturing implementation procedure
Create good efficient, healthy running environment.
Also, all devices in each workshop are connected into a unified network by the present invention, and the data between workshop are whole again
Report is closed, the wisdom factory of workshop cooperation management more than one is formed.Various spot sensors on each assembly station of system are set
The standby terminals such as sensor and information scanning terminal form a network with station controller by ZigBee, RS485 communication.Specifically
: the spot sensors such as torque, oil pressure, workpiece positioning being furnished on each assembly station of system according to process difference, in addition also
There are the device sensors such as the temperature, vibration of monitoring device itself, these sensors pass through ZigBee communication and station controller structure
At wireless sensor network.The terminals such as worker's identity reader, RFID card reader, barcode scanner will be counted using RS485 communication
According to being transmitted to station controller.The signal of single station network system is as shown in Figure 3.
CAN network is built between each station.There is an industrial control computer in each workshop, and one as CAN network
A node runs data acquisition, data mining, Analysis of Policy Making, rhythm control, the control strategy based on flexible assembly in this workshop
Etc. programs.Each workshop access network based on ethernet in the form of LAN, and server is connected, summarize workshop information to monitoring center.System
Overall system diagram is as shown in Figure 2.
Entire production equipment is connected in the same control network by system.Subsystems (system in single workshop or
The system of person's single station) independent operating is linked to each other again, and guarantees every procedure when being executed accurate by its flexibility
Property.Pass through the data acquisition and integration to single device and the tracking to each subsystem.Each assembly station is respectively positioned on delivery system
On system, transportation system pallet is equipped with RFID, for tracking the transit route of each component on entire assembly line.Thus, Ren Heyi
A station can obtain information relevant to producing.For example when assembly engine, new is started in the starting point of assembly line
Machine is placed on pallet, and the sequence number of the engine is detected by bar code and bar code scanner, which is stored in number
According in library and associated with the number of RFID on pallet.Meanwhile the ID number of operator (checks card before online and records personnel ID
Number) carry out check and inspection with the identifier of lane database and record.In this way, i.e. all information of tunable, tracks each branch
The information of part and whole assembly line.By wireless sensor network and RFID technique, it is correct that production process process can be realized
Property, process integrity checking, while workpiece, equipment, the number of personnel are had recorded, chasing after for construction machinery product information may be implemented
It traces back.
Server system management processing center is the core of whole system, it is dug by state monitoring module, data
Module, Analysis of Policy Making module, network savvy module are dug, evaluation, prediction and state adjust module composition；Management level contain task
Management, maintenance resource management and health records manage three big modules；Dynamic Data Processing module is mainly responsible for storage engineering goods
The structure composed of flexible automatic setup system, characteristic information, failure mechanism, expertise and various diagnosis, prediction and reasoning mould
Type, and rule and deduction are analyzed, in order to the continuous renewal of database knowledge and perfect；Communication interface passes through integrated pipe
Platform realizes the collaborative work between user.Comprehensive management platform logical schematic is as shown in Figure 4.
Data acquisition is to utilize the related data in various sensors acquisition assembling process, including the event of workpiece information, equipment
Hinder information, quality information, personal information etc..Data processing major function be complete the fusion of data of acquisition, feature extraction and
Data transmission.The main foundation of system health prediction is the log, failure logging, outage record, accident note of system
Record and status monitoring record information.By prediction model, it can be with forecasting system and its health status in component parts future.?
Before serious shutdown event occurs, its forecast function may insure to have sufficient time to formulate and execute maintenance plan.
It provides the foundation to formulate reasonable system maintenance strategy and system maintenance plan.
The present invention is communicated by ZigBee, RS485 the sensor of each station and work microcontroller connecting into a net
Network, all station controllers in workshop connect into a network by CAN bus and industrial control computer, all workshops
Industrial control computer connects into a network by Ethernet and server.Based on fieldbus, Industrial Ethernet, wireless biography
The technologies such as sensor network, RFID, bar code construct the large-scale engineering machinery assembling line on-line monitoring system of multibus, complete
The online acquisition of pairs of industry spot multi-source data, is based on the network interconnection, the present invention can be achieved the real-time perception of production process with
It dynamically controls, the quick response and processing of abnormal conditions, and traced for wire body computable general equilibrium, system self diagnosis, product quality,
Flexible manufacturing etc. provides data and supports.
Multiple sensors, including workpiece positioning, torque, oil pressure etc. are needed on assembling line, traditional detection technique is
Through the demand for being not suitable with Internet of Things development.
The intelligence sensor that the present invention develops develops Embedded Software Platform, realizes that intelligentized data acquire, at data
The functions such as reason have Internet of Things mainstream industry fieldbus and wireless communication function, improve the complete machine mean free error time and adopt
Sample precision meets low power dissipation design requirement, meets industrial scale applications requirement.
The amount of data on assembly line is very huge, and these state parameter informations are overlapped to a certain extent.
The present invention goes the operating status for fully describing system with feature as few as possible by the characteristic information of extraction initial data, can
To substantially reduce the complexity of system integrated management.Exception can be effectively realized by the critical performance parameters continuously monitored
Detection and trouble-saving, and performance parameter monitoring in real time ensure that the accuracy of exception monitoring and failure.It is pushed away using various
Reason technology and detection technique are effectively obtained, are transmitted, handling and using detection information, realizing to the system under test (SUT) under given environment
The state recognition of shape characteristic parameter and status predication.For complication system as flexible automatic setup system, intelligent measurement skill
Art is realized to its integrated management.
The specific structure of several sensors is illustrated below:
Torque sensor:
Torque is the index that test point is most on assembling line.As shown in figure 5, torque sensor 100 is examined including torque
Survey module 110, data processing module 120 (preferably data processing MCU), communication module 130 (preferably ZigBee module) and
Power module 140.
Torque sensor working principle are as follows: 110 real-time detection torque value of torque detection module, and detection torque value with 4-
The format of 20mA sends data processing module 120 to, and the data of torque detection module are converted to number by data processing module 120
Signal is simultaneously transmitted by ZigBee communication module handle with industrial communication format.Torque detection module passes through at line and data
Reason center is attached, the convenient torque detection module that different ranges are used in different places.
Data processing MCU uses MSP430 series monolithic, MSP430 series be a kind of strong processing capacity of super low-power consumption simultaneously
And feature-rich processor of single chip computer, there are a variety of low power mode of operation.Communication module uses ZigBee side wireless communication
Formula, ZigBee have the advantages that low complex degree and low-power consumption.Since torque sensor is to be chronically at working condition so taking
The signal processing single chip system and low-power consumption function ZigBee communication module of super low-power consumption, the energy so that this torque sensor works
It consumes low and has the characteristics of high-performance, Fast Installation use.Data acquisition is obtained most smart by least square method fitting algorithm
True torque value, and data are transferred out by communication module by the processing of data processing MCU and in time, communications portion is adopted
Ensure correctness of the data in transmission process with the transport protocol with verifying function.
Oil pressure sensor:
Fuel oil and hydraulic oil are required to detect its pressure on assembly line.As shown in fig. 6, oil pressure sensor 200 includes pressure
Power detection unit 210, signal processing unit 220, data processing unit 230, communication unit 240 and power supply unit 250.
Oil pressure sensor working principle are as follows:
Pressure sensing cell 210 uses resistive pressure sensor, and pressure sensing cell 210 is by the pressure of detected portion
For power change transitions at the variation of resistance value, the variation of faint resistance value is converted into data processing list by signal processing unit 220
Analog signal handle simultaneously handle by the manageable analog signal of member, data processing unit 230 (preferably data processing MCU)
Data conversion that treated is at digital signal, and communication unit is by ZigBee communication by digital signal with the progress of industrial communication format
Transmission.
Data processing MCU uses MSP430 series monolithic, MSP430 series be a kind of strong processing capacity of super low-power consumption simultaneously
And feature-rich processor of single chip computer, have a variety of low power mode of operation under real-time clock mode, reachable 2.5 μ A,
Under RAM holding mode, minimum reachable 0.1 μ A.Signal processing unit use with prevent, reduce the filter circuit of signal interference into
Data processing unit is given after row signal processing again.Data acquisition compensates calculating using zero-bit and sensitivity compensation algorithm, leads to
Hydraulic pressure value is obtained after crossing calculating and by communication unit real-time transmission.Communication unit uses the transmission with verifying function
Agreement ensures correctness of the data in transmission process.
Workpiece alignment sensor:
As shown in fig. 7, workpiece alignment sensor 300 includes photoelectric proximity switch 310, single-chip microcontroller 320, communication device
330 and power supply device 340.
Single-chip microcontroller selects TI company MSP430 series low-power scm as main control chip.Photoelectric proximity switch sensing
Device selects the adjustable E3F-DS70 series of products of detecting distance, in use according to by the actual size of material can before, during and after
A sensor is respectively placed, increases redundancy determination, enhances the stability and reliability of system.Communication device is ZigBee channel radio
Believe module, ZigBee wireless communication module carries out the transmission of data using CC2531 series of products, has convenient and reliable, reduction cloth
The advantages that line, communication distance is remote.
The working principle of workpiece alignment sensor: power supply device is whole system power supply, and MSP430 single-chip microcontroller passes through reading
Relevant information data after carrying out comprehensive descision, is passed through ZigBee channel radio by the information of photoelectric proximity switch detection back
Letter module is transmitted.
The present invention is directed to the detection demand of assembly shop, and different device sensors is arranged, and device sensor 4 can wrap
The switch sensor of collector's operating state data is included, the temperature sensor of equipment operation temperature and environment temperature is acquired, adopts
Collect the acceleration transducer of equipment operational vibration situation, the voltage sensor of detection device working condition acquires station material number
The Hall sensor of data is measured, the weighing sensor of weight of material data is acquired, the dust of detection manufacturing shop working environment passes
Sensor etc..
In order to avoid generating malfunction when sensor is by noise jamming, spot sensor and device sensor include
Fault queue's counter, being exclusively used in setting allows measurand to be more than the number of upper and lower limit, when measurand continues to exceed
The upper limit or when reaching pre-determined number lower than the number of lower limit, triggering is interrupted.If the number of stoppages is unsatisfactory for above-mentioned condition or failure not
It recurs, failure counter is just resetted without the broken ends of fractured bone in triggering.This means that accidentally by noise once or twice
Interference, will not influence the normal work of industry spot diagnostic system.
To prevent from damaging chip because of human body electro static discharge (ESD).Sensor can also increase esd protection circuit, make it can
Bear the static discharge voltage of 1000~4000V.Usually human body is equivalent to by 100PF capacitor and the series connection of 1.2K Ohmic resistance
Made of circuit model, as human body discharge, the serial line interface end of sensor, interruption/comparator signal output end and address are defeated
The static discharge voltage of 1000V~4000V can be born by entering end.
Sensor fault self-diagnosing function is also one of the measure for enhancing system reliability, and the sensor of the application can
Automatic detection open circuit or short trouble.And sensor by external interference or other reasons cause program operation error when,
System can voluntarily be restored in a very short period of time, further enhance system reliability.The present invention is real using the method for data-driven
Existing fault diagnosis, this method do not need physical model or the dependent probability distribution of prior clear system, but by
The analysis processing of the data of acquisition carrys out the implicit information between mining data, and carries out predicted operation to it.Using regression model
Time series analysis and neural network method.The advantages of this method is that required data can be quickly obtained by sensor,
The disadvantage is that due to obtain the typical historical data of system core equipment (quality information, fault message, person related information etc.) at
This is higher, and the uncertainty and incompleteness of the data due to having obtained, the method based on data-driven have implemented
Certain difficulty, but the present invention is based on multi-sensor datas, will can solve this using multivariate information fusion in overall control center
Problem.
The present invention ultimately forms a huge internet of things, and local site uses communication.On each station
Each sensor and station controller between use ZigBee communication, the communication between each station uses CAN communication, each
Workshop data are summarized to monitoring center with ether net mode networking.
Assembly shop needs that multi-source, magnanimity status information are perceived and monitored.It needs to construct by a large amount of wireless sensings
The catenet of device network node composition, establishes between node and plant site physical entity and is effectively associated with steadily in the long term, leads to
The interaction of real time information is crossed, the overall monitor to assembly shop is reached.ZigBee technology low cost, large capacity, low-power consumption, in short-term
The characteristics of prolonging meets the application of higher wireless sensor network requirement of assembly shop.
" tentacle " of various types of sensors as system, complete perception shop floor status carry out relevant data acquisition；It will
The medium that wireless sensor network is transmitted as information, wireless sensor network converge collected data；System connects
Corresponding data processing is carried out after receiving data, while providing related service to system user；User can not limited by region
In the case where system, the shop floor status monitored is remotely obtained, and carries out corelation behaviour decision accordingly.
ZigBee coordinator node 10, ZigBee association is arranged in engineering machinery assemble production line online awareness system in the present invention
Adjusting device node 10 includes microprocessor module 101, RS232 interface 102, antenna 103, FLASH 104, control panel 105 and electricity
Source 106, RS232 interface 102 are connect by conditioning circuit 107 with the UART unit of microprocessor module 101, and antenna 103 passes through
Radio frequency conditioning circuit 108 is connect with the 2.4G transceiver of microprocessor module 101, FLASH 104 and microprocessor module 101
The connection of SPI unit, control panel 105 are connect with the man-machine interaction unit of microprocessor module 101, as shown in Figure 8.
ZigBee coordinator node may be implemented wireless sensor network and set up and safeguard, complete data convergence and forwarding function
Energy.In order to keep network stabilization, the external 5V DC power supply of the power supply of ZigBee coordinator node, and pass through AMS1117-
3.3 chips provide stable 3.3V voltage for ZigBee coordinator node；In RS232 interface, MAX232 special chip is used
Realize the conversion between Transistor-Transistor Logic level and RS232 level, control panel includes key and indicator light, is carried out using LED light
ZigBee coordinator node operating status is shown.
It is introduced below with the effect of the ZigBee coordinator node in material allocation: in material allocation, according to matching
After sending task, dispatching control system to receive the information remotely sent, data parsing is carried out, according to the node IEEE for including in data
Address information filters out corresponding meshed network short address from database, concurrent with start command and station information one
ZigBee coordinator node is given, while being recorded in database；After ZigBee coordinator node receives information, to the network
Short address sends start command and station information；After the corresponding control node in network short address receives information, pass through serial ports handle
Start command and station information are sent to controller；Controller driving motor works and drives material tray, when aiming station pair
When the sensor current potential answered changes, it was demonstrated that material arrived correct station, and driving motor stops operating, to complete station
Material allocation.
After completing station material allocation, status information is sent completely to corresponding control node；Control node connects
After receiving information, data packing is carried out, ZigBee coordinator node is sent to by wireless sensor network；ZigBee coordinator
Node parses the network short address of data source while receiving data, then sends out network short address and status information
Give host server；Host server inquires its address corresponding node IEEE in database according to network short address, thus
Identification information source, and long-range monitor client is sent to by socket connection；User can be from long-range monitor client
See that station material allocation completes information.
The present invention can get the real-time position information of logistic distribution vehicle when needed, believe in station material
On the basis of breath, under the premise of production line continuous production, with the smallest distribution cost, realize the accurate dispatching of material, obtain compared with
High production efficiency, and can handle interim production dispatching task in emergency situations, ensure the quick sound of production task
It answers.
There are three types of communication modes for the assembly shop of the application: ZigBee, CAN, Ethernet.The fusion of three networks, which is converted, to be needed
Rely on intelligent network.The network switching node of erecting yard is not that three kinds of networks require to convert simultaneously, but in order to improve
The utilization rate and extent for multiplexing of equipment, the present invention include a kind of intelligent gateway of multiple bus fusion.The intelligent gateway uses two kinds
Mode, one kind being based on industrial control computer, a kind of based on using ARM as the embedded system of processor.As shown in figure 9, using
Embedded system is to save space and reduce the cost and consider.
Intelligent gateway based on industrial control computer, can be equipped with CAN bus PCI board card and ZigBee communication mould
Block.Embedded intelligence gateway is equipped with CAN communication module, Profibus communication module, ZigBee communication module and ethernet communication
Module, while expansion RAM is in case data space is insufficient.
Data type is numerous on assembly line, and number of sensors is more, need to merge from sensor obtain initial data into
Row integrated treatment.Due to the diversity of information, it is necessary to by multisensor remote assistance go forward side by side row information fusion, these can just be obtained
Information that is true and determining must be compared.Compared with single sensing system, from multisensor obtain information have redundancy,
The characteristics of complementary and relevance, multi-sensor fusion system fault-tolerant ability by force, high reliablity.It is more accurate in order to obtain and can
The conclusion leaned on improves the precision and robustness of abnormality detection and fault diagnosis, needs to integrate the much information obtained
Processing and fusion.
In the present invention, the turn-key system on industrial control computer needs to carry out the fusion of following three aspects, industry control
Computer processed includes:
Data fusion module, for extracting characteristic from the data that spot sensor and device sensor obtain；
Fusion Features module obtains believable failure and examines for the feature that intelligent comprehensive is obtained from data fusion module
Disconnected information；
Information Fusion Module finally determines failure for integrating historical experience information and failure diagnosis information, improves failure
The precision of prediction.
The information fusion method that the present invention uses has: classical reasoning algorithm, Kalman filtering method, Bayesian Estimation,
Dampster-Shafer Evidential reasoning algorithm, clustering, parameterized template method, physical model method, Information Entropy, quality factor method,
Estimation theory method and expert system etc..
This system information fusion model can merge this station using centralization and distributed hybrid mode, most of station
Sensor information is pre-processed, then the information fusion center of the turn-key system of workshop industrial control computer is transferred to be melted
It closes, the sensing data of the close station of small part forward-backward correlation is directly sent to the turn-key system of industrial control computer.Part
Fusion uses Kalman filtering method, and fusion center is based on Bayes' assessment, last applied statistics decision-making technique, difference sensing
The data robust pole that the data of device acquisition have to pass through robust integration test to examine its consistency, after consistency check
It is worth decision rule and carries out fusion treatment.
The above is a preferred embodiment of the present invention, it is noted that for those skilled in the art
For, without departing from the principles of the present invention, it can also make several improvements and retouch, these improvements and modifications
It should be regarded as protection scope of the present invention.
Claims (10)
1. a kind of engineering machinery assemble production line online awareness system, which is characterized in that described automatic including automatic production line
Metaplasia producing line includes multiple assembly stations；It is whole that spot sensor, device sensor, information scanning are provided on each assembly station
End and station controller, the spot sensor and device sensor are connect by ZigBee communication with the station controller,
The information scanning terminal is communicated by RS485 and is connect with the station controller；All station controllers in same workshop
It is connect by CAN bus with an industrial control computer；All industrial control computers are connect by Ethernet with server,
The server is connected with factory's monitoring center.
2. engineering machinery assemble production line online awareness system according to claim 1, which is characterized in that the scene passes
Sensor includes torque sensor, oil pressure sensor and/or workpiece alignment sensor.
3. engineering machinery assemble production line online awareness system according to claim 2, which is characterized in that the torque passes
Sensor includes torque detection module, data processing module, communication module and power module, the torque detection module real-time detection
The torque value is converted to digital signal by torque value, the data processing module, and the communication module passes through ZigBee communication
The digital signal is transmitted with industrial communication format.
4. engineering machinery assemble production line online awareness system according to claim 2, which is characterized in that the oil pressure passes
Sensor includes pressure sensing cell, signal processing unit, data processing unit, communication unit and power supply unit, the pressure inspection
It surveys unit and the pressure change of detected portion is transformed into the variation of resistance value, the signal processing unit is by the resistance value
Variation is converted into analog signal, and the analog signal handle and treated data conversion by the data processing unit
At digital signal, the communication unit is transmitted the digital signal with industrial communication format by ZigBee communication.
5. engineering machinery assemble production line online awareness system according to claim 2, which is characterized in that the workpiece is fixed
Level sensor includes photoelectric proximity switch, single-chip microcontroller, communication device and power supply device.
6. engineering machinery assemble production line online awareness system according to claim 1, which is characterized in that the equipment passes
Sensor includes the switch sensor of collector's operating state data, acquires the temperature sensing of equipment operation temperature and environment temperature
Device, acquires the acceleration transducer of equipment operational vibration situation, and the voltage sensor of detection device working condition acquires station object
Expect the Hall sensor of incremental data, acquire the weighing sensor of weight of material data, detects the powder of manufacturing shop working environment
Dust sensor.
7. -6 any engineering machinery assemble production line online awareness system according to claim 1, which is characterized in that described
Spot sensor and device sensor include fault queue's counter, when measurand continues to exceed the upper limit or lower than lower limit
Number when reaching pre-determined number, triggering is interrupted.
8. engineering machinery assemble production line online awareness system according to claim 7, which is characterized in that the engineering machine
Tool assemble production line online awareness system further includes ZigBee coordinator node, and the ZigBee coordinator node includes micro process
Device module, RS232 interface, antenna, FLASH, control panel and power supply, the RS232 interface by conditioning circuit with it is described micro-
The UART unit of processor module connects, and the antenna is received and dispatched by the 2.4G of radio frequency conditioning circuit and the microprocessor module
Device connection, the FLASH are connect with the SPI unit of the microprocessor module, the control panel and the microprocessor mould
The man-machine interaction unit of block connects.
9. engineering machinery assemble production line online awareness system according to claim 1, which is characterized in that the industry control
Computer processed includes:
Data fusion module, for extracting characteristic from the data that spot sensor and device sensor obtain；
Fusion Features module obtains believable failure diagnosis information for the comprehensive feature obtained from data fusion module；
Information Fusion Module finally determines failure for integrating historical experience information and failure diagnosis information.
10. engineering machinery assemble production line online awareness system according to claim 1, which is characterized in that the information
End of scan includes worker's identity reader, RFID card reader and/or barcode scanner.
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| CN109759755A (en) * | 2019-02-28 | 2019-05-17 | 武汉三工智能装备制造有限公司 | AI intelligent process anomalous identification processing system and solar cell chip bonding machine |
| CN110109411A (en) * | 2019-05-24 | 2019-08-09 | 河南恒展智能科技有限公司 | A kind of PLC cooperative control system of engine line |
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| CN111506027A (en) * | 2020-03-10 | 2020-08-07 | 厦门理工学院 | Intelligent assembling method and system for electrical equipment |
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| WO2020215475A1 (en) * | 2019-04-24 | 2020-10-29 | 南京航空航天大学 | Method and apparatus for monitoring internal running status of device |
| CN110109411A (en) * | 2019-05-24 | 2019-08-09 | 河南恒展智能科技有限公司 | A kind of PLC cooperative control system of engine line |
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| CN112935604A (en) * | 2019-12-10 | 2021-06-11 | 刘振英 | Central control system for hardfacing production |
| CN111142484A (en) * | 2019-12-24 | 2020-05-12 | 南京轩世琪源软件科技有限公司 | Industrial control system and control method |
| CN111142484B (en) * | 2019-12-24 | 2021-04-30 | 南京轩世琪源软件科技有限公司 | Industrial control system and control method |
| CN111506027A (en) * | 2020-03-10 | 2020-08-07 | 厦门理工学院 | Intelligent assembling method and system for electrical equipment |
| CN111624970A (en) * | 2020-06-16 | 2020-09-04 | 武汉精立电子技术有限公司 | Information reporting method, device, equipment and production control system |
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| CN114076680A (en) * | 2020-08-17 | 2022-02-22 | 北京福田康明斯发动机有限公司 | Engine assembly detection method, system, storage medium and electronic device |
| CN112309091A (en) * | 2020-11-04 | 2021-02-02 | 爱珂勒电子元器件（珠海）有限公司 | Production alarm system with remind function |
| CN112506097A (en) * | 2020-11-27 | 2021-03-16 | 江苏科技大学 | Jig frame remote monitoring system and method based on industrial internet |
| CN112650166A (en) * | 2020-12-14 | 2021-04-13 | 云南迦南飞奇科技有限公司 | Production line condition big data system based on wireless network and diagnosis method thereof |
| CN113111987A (en) * | 2021-04-12 | 2021-07-13 | 苏州威达智电子科技有限公司 | Product detection management system |
| CN113780753A (en) * | 2021-08-20 | 2021-12-10 | 深圳市广和通无线股份有限公司 | Data processing method, data processing device, computer equipment and storage medium |
| CN113770260A (en) * | 2021-08-23 | 2021-12-10 | 富伟机械科技(淮安)有限公司 | Die clamper position detection device |
| CN115079658A (en) * | 2022-08-22 | 2022-09-20 | 安徽新境界自动化技术有限公司 | Intelligent production line monitoring system |
| CN116679639A (en) * | 2023-05-26 | 2023-09-01 | 广州市博煌节能科技有限公司 | Optimization method and system of metal product production control system |
| CN116679639B (en) * | 2023-05-26 | 2024-01-05 | 广州市博煌节能科技有限公司 | Optimization method and system of metal product production control system |
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