CN110673562A - 一种智能车间工步约束及防呆方法 - Google Patents

一种智能车间工步约束及防呆方法 Download PDF

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CN110673562A
CN110673562A CN201910998929.0A CN201910998929A CN110673562A CN 110673562 A CN110673562 A CN 110673562A CN 201910998929 A CN201910998929 A CN 201910998929A CN 110673562 A CN110673562 A CN 110673562A
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郝文欣
余桂英
蒋一
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HANGZHOU FUTURE OPTICS SCIENCE AND TECHNOLOGY Co Ltd
China Jiliang University
China University of Metrology
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China University of Metrology
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    • G08B3/10—Audible signalling systems; Audible personal calling systems using electric transmission; using electromagnetic transmission
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    • G08B3/1016—Personal calling arrangements or devices, i.e. paging systems using wireless transmission
    • G08B3/1025—Paging receivers with audible signalling details
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    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

本发明涉及一种智能车间工步约束及防呆方法。传送带将产品流转箱传送至工位，当读写器读取到做工指令时，流转箱通过无线通讯模块与操作台建立连接，操作台上LED指示灯闪烁提示员工做工，流转箱上LCD显示屏显示作业序号且对应零件匣子自动弹出，红外测物条感应到动作结束后收回，流转箱向下一道工位运输，操作台左右两侧分别设有不合格和合格产品载物台，PC客户端通过TCP通讯协议与载物台和测试系统建立连接，可即时判断产品是否合格并指导员工放于对应位置。本发明有效的提高车间自动化，对工位操作人员行为进行约束，避免了误拿、重复检测、操作错误、秩序混乱错误。

Description

一种智能车间工步约束及防呆方法
技术领域
本发明涉及智能车间工步约束及防呆方法，特别是涉及小型零件生产车间工步约束及防呆方法。
背景技术
随着5G时代的到来，全球制造业发展步伐进一步加快，劳动力成本日渐上升已不能成为中国制造业的崛起优势，中国很多企业将成本压力转化为创新动力。在物联网时代背景下，中国制造业逐步向高端化、智能化、服务化发展。车间的生产加工越来越趋近全自动智能化，但在某些电子原件、光学原件领域，由于产品体积小，工艺繁杂、易破损、对产品要求的精度较高等因素，很难设计全套自动设备，因此需要设置操作台进行人工装配。通常采用流水式加工作业，要求生产线上员工长时间高度集中注意力，一个人负责多个产品的局部工序，精密零件种类繁多，容易出现误拿、误放、重复检测、操作错误、秩序混乱等问题，因此需要对操作者权限以及操作步骤进行约束限制，降低人工错误率，实现生产车间局部自动化。小型零件加工通常对每一道工序指标要求较高，需逐一检查，数据量大，因此若能在每个操作台上即时完成产品数据检测评判功能是十分必要的。
综上，若有一种智能车间工步约束及防呆的方法，对员工权限和动作进行约束，就可大大避免人工误差，提高小型零加工车间的生产效率，降低产品不合格率。
发明内容
针对背景技术的不足，本发明的目的在于提供一种小型零件生产车间工步约束及防呆方法，用于小型零件生产车间，提高车间有序性，降低由员工操作失误导致的产品不合格率，使整个生产过程透明可查。
本发明首先建立员工信息库，并对每位员工访问权限进行约束。用RFID 标签打印机打印RFID无源标签粘贴在各工位前，代加工产品原材料放在产品流转箱内，产品流转箱内设有可充电电池、RFID读写器、音响、CPU处理器、无线通讯模块，外表面有对应工位的零件匣子和LCD显示屏，零件匣子内有两条红外测物条，零件匣子数量形状及大小依据具体车间需求设计，可实现多工位同时做工的零件取用，LCD显示屏可显示箱内待加工零件数量和当前作业情况，并无线通讯模块与操作台和中央控制室进行实时通讯，产品流转箱由U型传输带传送至指定工位，工位操作台上设有LED指示灯，报警装置，产品流转箱通过WEB服务器与控制中心信息交互，操作台左右两侧分别设有不合格和合格产品的载物台，载物台台面有接触式图像传感器，操作台上PC 端通过TCP协议与测试系统和载物台建立连接，测量系统判断产品是否合格并通过PC端显示，PC客户端对不合格产品数量进行累计并指导员工将产品放于对应操作台，若规定时间内对应载物台未接收到产品操作台上报警系统报警。各操作台间通过TCP协议与数据服务器建立连接。
本发明的有益效果：本发明能够对小型零件生产车间的作业人员起到约束作用，防止员工注意力不集中导致错误操作，提高生产车间自动化水平；通过流转箱内CPU处理器与控制中心无线通讯，可即时监控生产线作业情况，使生产过程透明可视；视觉检测系统可即时判断当前作业是否达标，不合格产品直接放于指定区域，减少人为参与，降低人工成本，提高生产效率和生产有序性。
该发明可应用于光器件生产车间、电子器件生产车间等精密仪器制造车间。
附图说明
图1为本发明原理图。
图2为本发明系统整体架构示意图。
图3为本发明产品流转箱架构示意图。
具体实施方式
下面结合附图对本发明作进一步的说明。
如图2所示，本实发明用于小型零件生产车间包括①无源标签打印机②产品流转箱③U型传送带④RFID无源标签⑤PC用户端⑥报警装置⑦LED指示灯⑧不合格产品载物台⑨合格产品载物台⑩数据服务器
Figure RE-GDA0002300481760000021
WEB服务器。
如图1所示，首先建立车间操作人员信息库，对每位员工设置对应的权限并录入员工信息及所操作的设备信息。打印RFID无源标签贴在每个工序操作台前端，当生产部门下达生产指令，将一种产品的原材料放入对应的产品流转箱中，产品流转箱由U型传送带传送至首道工序工位，读写器读取RFID 无源标签信息并通过无线网络将信息传送至中心控制区。
当产品流转箱中读写器读取到作业指令时，产品流转箱在该工位停留预设时长，产品流转箱上的LCD显示屏显示该工位应对该产品进行的作业序号，操作台上LED指示灯闪烁，提醒该工序员工做工。操作台左右分别设有不合格产品和合格产品的载物台，载物台台面有接触式图像传感器。PC客户端通过TCP通讯协议与载物台和测试系统建立连接，PC客户端可实时显示测试数据和产品是否合格，对检测产品总数和不合格产品数量进行累计并指导操作者将产品放于对应操作台，若规定时间内，对应载物台未接收到产品则报警系统报警。不合格产品载物台下方是不合格产品集装箱，当台面上不合格品累计一定数量，载物台的台面自动打开将产品滑向下方不合格产品集装箱；当读写器未读取到作业指令时会直接传送下一工位，若有操作者误拿、误放或超时取件，语音播报系统会对相应错误操作进行提示。
如图3所示产品流转箱包括①硬质聚氯乙烯外壳②零件匣子③红外测物条④可充电电池⑤无线通讯模块⑥CPU处理器⑦音响⑧LCD显示屏⑨RFID 无线读写器。
每道工序都有对应的取放零件的匣子，即首道工序有两行对应的零件匣子，分别为取出待加工零件行和放入已加工器件行，放入已加工产品行同时也是次道工序的取出器件行。产品流转箱传送至某道工序时，若作业指令为需取出待加工零件，则对应零件匣子自动弹出，红外测物条感应到动作结束， CPU处理器控制零件匣子自动收回，流转箱传输向下一道工序；若作业指令为需放入本工序作业完成的产品，则对应零件匣子弹出，操作者放入已加工零件，红外测物条感应到动作结束后，零件匣子自动收回，流转箱传输向下一道工序。零件匣子数量、大小及形状依据具体车间需要设计。
以上所述，仅是本发明的较佳实施例，并非对本发明作任何限制，凡是根据本发明技术实质对以上实施例所作的任何简单修改、变更以及等效结构变化，均仍属于本发明技术方案的保护范围内。

Claims (7)

1.一种智能车间工步约束及防呆方法，其特征在于：建立工序操作人员信息库，U型传送带将产品流转箱传送于每一生产工序操作台，操作台前贴有该工序的RFID无源标签，操作台上安有PC客户端、报警装置、和LED指示灯，操作台右侧有载物台，载物台上方装有视觉检测系统，载物台下方有不合格产品集装箱，各工位通过TCP协议进行通讯，传送带外设有数据服务器和WEB服务器。
2.根据权利要求1所述的一种智能车间工步约束及防呆方法，其特征在于：建立工序操作人员的信息库，录入每位员工个人信息和设备的操作权限信息，用于产品流转箱的判断模块，每位操作人员只能进行自己作业领域的相关操作。
3.根据权利要求1所述的一种智能车间工步约束及防呆方法，其特征在于：每个操作台贴有RFID无源标签；产品流转箱内装有RFID读写器，当产品流转箱传送至工位，RFID读写器可实时读取到目前做工员工信息及该工位设备信息，通过判断模块判断该员工是否对该产品有操作权限，并通过无线通讯模块上传至WEB服务器，控制中心可实时监控产品作业情况。
4.根据权利要求1所述的一种智能车间工步约束及防呆方法，其特征在于：产品流转箱有多个零件匣子，可供多个工位同时使用。零件匣子底部有两条红外线测物条，依据读写器读取到的指令，LCD显示屏显示待做作业编号，产品流转箱可自动弹出对应序号匣子，测物条检测到零件已被拿出或放入后，零件匣子自动收回。
5.根据权利要求1所述的一种智能车间工步约束及防呆方法，其特征在于：产品流转箱内装有语音播报系统，当读写器未读取到作业指令的操作台员工误取时，语音播报系统提示操作者错误操作，当产品流转箱停留超过预设时间仍未有人员操作，语音播报系统提示操作者动作超时，并通过无线通讯模块向控制中心反馈。
6.根据权利要求1所述的一种智能车间工步约束及防呆方法，其特征在于：工位操作台装有LED作业指示灯。当产品流转箱传送至该工位，当读写器读取RFID无源标签信号，通过CPU处理器进行工号核对，满足操作指令时，产品流转箱在该工位停留预设作业时长，并通过无线通讯向与该工位建立连接，LED指示灯闪烁提醒员工开始做工，当读取器未读到操作指令，产品流转箱直接传送至下一工位，不做停留。
7.根据权利要求1所述的一种智能车间工步约束及防呆方法，其特征在于：工位操作台左右两侧分别设有不合格产品和合格产品的载物台，载物台面内装有接触式图像传感器。由于不同车间不同工序的测试系统不同，操作台上PC端通过TCP协议与测试系统和载物台建立连接，测量系统判断产品是否合格并通过PC端显示，PC客户端对不合格产品数量进行累计并指导员工将产品放于对应操作台，若规定时间内对应载物台未接收到产品操作台上报警系统报警。
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