CN111090263A - Customized intelligent production line control system and control method - Google Patents
Customized intelligent production line control system and control method Download PDFInfo
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Abstract
The invention discloses a customized intelligent production line control system and a control method, wherein the control system comprises a remote user client, a cloud background system, a manufacturing execution system and an industrial robot production line which are sequentially in communication connection. The invention realizes the application of the structure of the industrial control system of the manufacturing industry to the customized production line of the industrial products, realizes the integration of automation and informatization, and fulfills the aims of customized ordering and unmanned production, thereby greatly improving the industrial manufacturing efficiency and being suitable for the intelligent control of various processing and manufacturing industries or products.
Description
Technical Field
The invention relates to a control system and a control method of a production line, in particular to a customized intelligent production line control system and a control method.
Background
The integration of manufacturing industry and internet is the core of a new technological revolution and industrial change, is the main line of 'Chinese manufacture 2025', and is the key point for realizing transformation upgrade and leap-type development of manufacturing industry in China. The key point of the mutual integration of the manufacturing industry and the internet is the integration of an automatic control system and a software manufacturing industry execution management system. Currently, there is a lack of organic integration between the production line control system and the production software management system and the remote ordering system in the market. For example, most of the production of domestic industrial products such as valves and the like is not automated, and the integration of informatization and intellectualization is not completed so as to carry out large-scale customized production.
Disclosure of Invention
In view of the above problems in the prior art, the present invention provides a flexible, customized, and intelligent production system that integrates production line manufacturing technology management with mobile internet technology, and is mainly directed to the development fields of related technologies such as the integration of automatic production lines, manufacturing enterprise production process execution systems, and internet customization technology in modern intelligent manufacturing systems. The flexible manufacturing technology integrates automation technology, information technology and manufacturing and processing technology, and the processes of engineering design, manufacturing, management and the like which are isolated from each other in the past are supported by a computer, software thereof and a database to form an organic system covering the whole enterprise.
The invention provides a customized intelligent production line control system, which has the following specific technical scheme:
a customized intelligent production line control system comprises a remote user client, a cloud background system, a manufacturing execution system and an industrial robot production line which are sequentially in communication connection; the remote user client is configured to remotely release order information and remotely monitor an industrial robot production line; the cloud background system is configured to realize transmission of order information, management of user information, storage and analysis of data, remote control of a production line and data encryption; the manufacturing execution system is configured to realize real-time monitoring, production plan management, production process management, manufacturing data management and analysis of the industrial robot production line and control instruction issuing.
Preferably, the remote user client comprises a customized ordering module and a production line remote monitoring module, wherein the customized ordering module is configured to be capable of realizing user registration, login, password modification and login and addition of addresses and contact ways, and the production line remote monitoring module is configured to remotely monitor and manage the production process.
Preferably, the remote user client is a computer device or a mobile phone, and communicates with the cloud background system in a wireless manner.
Preferably, in the transmission of the order information, the order information sent by the remote user client is sent to the cloud background system in a json format, the cloud background system analyzes and extracts the order information, then the order information is transmitted according to an HTTP (hyper text transport protocol), and the order information is encrypted and transmitted to the manufacturing execution system.
Preferably, in the management of the user information, the order information is modified and deleted and the personal information is maintained through the cloud background system after the user logs in.
Preferably, the storing and analyzing of the data comprises data acquisition of user information, data acquisition of product process information and data acquisition of production line index parameters, wherein the user information comprises user characteristic information, and the product process information comprises states and parameters of equipment in the production process.
Preferably, in the data encryption, when an external user or a user with a low access level accesses the production line, the authentication is carried out through an asymmetric encryption algorithm, and the authentication process is added into the communication protocol.
Preferably, the content monitored in real time comprises the starting or stopping of the industrial robot production line, the production line speed and the processing progress; the production plan management is configured to receive orders of remote users, and form and store order information transmitted by the cloud background system into production plan data; the production process management is configured to perform process extraction on the customized parameters in the received order information and store the customized parameters in a table form; the manufacturing data management and analysis is configured to collect, analyze and store classified element variables in the production process, wherein the element variables comprise power consumption statistics, processing progress and equipment failure rate.
Preferably, the industrial robot production line comprises a main control station, a processing station, a welding station, a polishing station, a vision assembly station, a conveying station and a three-dimensional warehouse station, wherein the processing station is configured to process industrial raw materials and comprises a numerical control machine tool, a feeding and discharging robot and a lathe door opening and closing device, and industrial Ethernet communication is adopted among the devices; the welding station is configured to perform a welding operation on a work product and includes a welding robot, a welder, and a tooling system.
The invention also provides an industrial robot production method, which adopts the production system of any one of the technical schemes, and comprises the following steps:
step S1, the user issues order information remotely through the remote user client;
step S2, the order information is uploaded to a cloud background system for storage and analysis;
step S3, the cloud background system sends the analyzed information to the manufacturing execution system and manages the production plan and the process through the manufacturing execution system;
step S4, the manufacturing execution system issues an operation instruction to the industrial robot production line;
and step S5, carrying out unmanned production by an industrial robot production line and warehousing the products.
The invention realizes the application of the structure of a new manufacturing industry control system on a customized production line of industrial products, realizes the same combination of high-precision control of production process, data communication between the production line and a workshop informatization management system, workshop planning, production scheduling, production process control and production data analysis by adopting an industrial communication means, realizes the integration of automation and informatization, and finishes the purposes of customized ordering and unmanned production, thereby greatly improving the industrial manufacturing efficiency. The invention can be applied to various processing and manufacturing industries or intelligent control of products.
Drawings
FIG. 1 is a schematic diagram of a customized intelligent production line control system according to the present invention;
FIG. 2 is a flow chart of a customized intelligent production line control method to which the present invention relates;
FIG. 3 is a schematic diagram of a workstation in an industrial robot production line of a customized intelligent production line control system to which the present invention relates;
FIG. 4 is a workflow diagram of a process station in an industrial robot production line in a customized intelligent production line control system to which the present invention relates;
fig. 5 is a schematic diagram of a welding station in an industrial robot production line of a customized intelligent production line control system according to the present invention.
Reference numerals:
1. a cloud background system; 2. a remote user client; 3. a manufacturing execution system; 4. an industrial robot production line; 5. a master control station; 6. a processing station; 7. a welding station; 8. a polishing station; 9. a vision assembly station; 10. a transfer station; 11. a stereoscopic warehouse station; 12. a welding robot; 13. a welding machine; 14. welding tooling device.
Detailed Description
In order to make the technical solutions of the present invention better understood by those skilled in the art, the present invention will be described in detail below by way of examples with reference to the accompanying drawings. In this embodiment, the customized intelligent production line control system related to the present application is applied to the industrial production of valves.
As shown in fig. 1, fig. 1 is a schematic system structure diagram of a customized intelligent production line control system, wherein in this embodiment, the customized intelligent production line control system is applied to industrial production of ball valves, and of course, the customized intelligent production line control system according to the present invention can also be applied to manufacturing and production of other industrial products.
Specifically, the customized intelligent production line control System comprises a cloud background System 1, a remote user client 2, a Manufacturing Execution System 3 (MES), and an industrial robot production line 4; wherein, the industrial robot production line 4 is positioned at the bottommost layer in the customized intelligent production line control system related to the application and is upwards in communication connection with the manufacturing execution system 3; the manufacturing execution system 3 can generally execute operations and execute corresponding control through computer equipment, and is in communication connection with the cloud background system 1 upwards; the cloud background system 1 is in communication connection with a remote user client 2 on the uppermost layer in the customized intelligent production line control system.
In the industrial production of the ball valve, the general control flow is shown in fig. 2, and fig. 2 shows the flow of industrial production using the customized intelligent production line control system, wherein, step S1 is executed first, and in step S1, the user issues the order information remotely through the remote user client 2; in step S2, the order information is uploaded to the cloud backend system 1 for storage and analysis; in step S3, the cloud backend control system 1 encrypts and transmits the analyzed information to the manufacturing execution system 3, and performs management of the production plan and the process through the in-situ software in the manufacturing execution system 3; in step S4, the manufacturing execution system 3 issues an operation instruction to the industrial robot production line 4; in step S5, unmanned production is performed by the industrial robot production line 4 and the product is put in storage; it should be noted that the cloud background system 1, the remote user client 2, the manufacturing execution system 3, and the industrial robot production line 4 implement their respective functions in different working layers in the customized intelligent production line control system related to the present application.
The functions of the cloud backend system 1, the remote user client 2, the manufacturing execution system 3, and the industrial robot production line 4 will be further explained below.
Specifically, the remote user client 2 is used as a device for issuing a command by a remote user, and can be a computer device or a mobile terminal such as a mobile phone, and communicates with the cloud background system 1 in a wireless manner, wherein the remote user client 2 comprises a customized ordering module and a production line remote monitoring module, in this embodiment, the customized ordering module is developed by taking the production of a welded ball valve as a carrier, and user registration, login, password modification, and login and addition of information such as addresses and contact ways can be realized through the customized ordering module, so that a new user can be simply and quickly registered as a user, and thus, a customized service is started; then, when a user places an order, the ball valve parameters can be set through the customized ordering module, and the user can input other requirements, such as production quantity and the like, into the customized ordering module; then, a customized ordering button in the customized ordering module is clicked, and a customized ordering flow is started, so that customized ordering operation of the ball valve is realized; after the order placing is successful, the order list is automatically jumped to, and the remote user can check the detailed information of all confirmed orders needing to be customized and modify the order information at the same time.
In this embodiment, the production line remote monitoring module is configured to remotely monitor and manage the production process when a controller of the industrial robot production line 4 goes out remotely, so that unmanned production can be realized, and the personnel cost is remarkably reduced. Wherein, when carrying out remote monitoring and management to industrial robot production line 4, need the user to be granted and use super user's authority, here, especially need carry out authentication to user's identity and confirm to prevent that the operation of industrial robot production line 4 is controlled under the circumstances of unauthorized and discernment to outside user, furthest guarantees industrial robot production line 4's safety and reliability.
The cloud background system 1 is an intermediate link connecting the remote user client 2 and the industrial robot production line 4, and the cloud background system 1 can realize transmission of order information, management of user information, storage and analysis of data, remote control of the production line, data encryption and the like.
In the transmission of the order information, the order information sent by the remote user client 2 is communicated with the cloud background system 1 in a jspn format and is sent to the cloud background system 1, the cloud background system 1 analyzes and extracts the order information, then the order information is encrypted and transmitted according to an HTTP protocol, and the order information is encrypted and transmitted to local software of the manufacturing execution system 3.
In the management of user information, a remote user logs in before sending order information, an unregistered new user needs to be registered in advance, and after the user logs in, the cloud background system 1 can modify and delete the order information, maintain personal information and the like, wherein the personal information comprises address information, personal contact information and the like, and the information is delivery information.
In the implementation of data storage and analysis, the data acquisition of user information, the data acquisition of product process information and the data acquisition of production line index parameters are included, wherein the data acquisition of the user information can provide data support for analyzing user characteristic information, carrying out classified management on users, formulating accurate sales strategies and rapidly customizing production flows; the data acquisition of the product process information is to acquire the equipment state and parameters and other conditions in the production process so as to provide data support for improvement and iteration of the product processing process in the future; data acquisition of production line index parameters can provide data support for analysis of a big data module optimized for a production line, so that production can guide improvement of stability and efficiency of the production line after data analysis.
In the remote control of the production line, the industrial robot production line 4 can be remotely controlled, the operation control can be realized under the condition that an operator is not on the production line site and the like, and particularly, after the identity of the operator is confirmed through a safety verification mechanism, the remote control is carried out in any place with a network, so that the personnel cost can be greatly reduced.
In data encryption, when an external user or a user with a low access level accesses a production line, every time the database in the cloud background system 1 is accessed, verification is carried out through an encryption algorithm, the verification process is simultaneously added into a communication protocol, and particularly under the condition of remotely controlling the production line, a remote control request needs to be confirmed through local permission or according to a dynamic password.
The manufacturing execution system 3 is a production informatization management system facing a workshop execution layer of a manufacturing enterprise, and is configured to issue a control instruction to the industrial robot production line 4 through local software of a connection network, and the function of the manufacturing execution system is realized through the local software, and the local software is software for the manufacturing enterprise to execute management in the production process, specifically, the manufacturing execution system 3 issues the control instruction for manufacturing to the industrial robot production line 4 after receiving an analysis result of the cloud background system 1, wherein the manufacturing execution system 3 is in communication connection with the cloud background system 1 on the upper layer and the industrial robot production line 4 on the lower layer.
Further, the manufacturing execution system 3 can realize functions of real-time monitoring of the production line, production plan management, production process management, manufacturing data management and analysis, and the like. The real-time monitoring content comprises the starting or stopping of the industrial robot production line 4, the production line speed, the processing progress and the like; the production plan management can receive orders of remote users, form the order information transmitted by the cloud background system 1 into production plan data and store the production plan data in a local or cloud database, wherein the production plan data is stored in the local database to facilitate local subsequent analysis operation; the production process management can perform process extraction on the customized parameters in the received order information, store the customized parameters in a local or cloud database in a table form and provide data accumulation for the next product analysis; the manufacturing data management and analysis is to collect and store element variables in the production process in a classified manner, and provide data support for the next data analysis, wherein the element variables comprise power consumption statistics, processing progress, equipment failure rate and the like.
The industrial robot production line 4 is located at the lowest layer of the customized intelligent production line control system related to the application, and serves as a process equipment system for machining the ball valve. The industrial robot production line 7 enables unmanned production of valves, and specifically, the system structure of the industrial robot production line 4 is shown in fig. 3, which includes a main control station 5, a processing station 6, a welding station 7, a polishing station 8, a vision assembly station 9, a transfer station 10, and a stereo garage station 11.
The machining station 6 is a main link for machining the ball valve pipe fitting and comprises a numerical control machine, a feeding and discharging robot and a lathe door opening and closing device, wherein the numerical control lathe can be a general numerical control lathe in the prior art; in particular, in the operation of the machining station 6, as shown in fig. 4, fig. 4 shows the main flow of machining of the ball valve pipe in the machining station 6, comprising the following steps: s11, sending the raw material of the ball valve pipe fitting to a specified position by a trolley; s12, grabbing the raw materials by a feeding and discharging robot; s13, starting a lathe door opening and closing device to open a lathe door of the numerical control machine; s14, placing the raw materials into a lathe chuck of the numerical control lathe by a feeding and discharging robot; s15, after the raw materials are placed, the feeding and discharging robot leaves, a lathe door of the numerical control machine tool is closed, and the numerical control machine tool starts to process, wherein in the opening and closing process of the lathe door of the numerical control machine tool, the door opening and closing speed of the lathe can be increased according to the production speed requirement; and S16, after the ball valve pipe fitting is processed, conveying the finished product material to the welding station 7 by the feeding and discharging robot.
It should be noted that the communication mode used between the devices in the processing station 6 is industrial ethernet communication, so that efficient and fast control can be realized, the system risk is reduced, and the system precision and efficiency are improved. Preferably, the numerical control machine tool, the loading and unloading robot and the lathe door opening and closing device can be connected through a network cable to perform data transmission.
Further, the welding station 7 is configured to perform welding operation on the finished material of the ball valve pipe fitting, profinet full-digital communication can be achieved between the welding station 7 and the main control station 5, and during the welding operation, the welding station 7 uses an automatic welding system and can perform efficient and high-quality welding. Specifically, in the welding station 7, the ball valve pipe processed by the processing station 6 is subjected to automatic tooling, automatic welding, automatic clamping and other operations, so that full-automatic welding operation is realized. To achieve the above purpose, as shown in fig. 5, fig. 5 shows a schematic structural diagram of the welding station 7, wherein the welding station 7 comprises a welding robot 12, a welder 13 and a tooling system 14, wherein the welding robot 12 is connected with the welder 13 and is driven by the welder 13 to work, and a Device net bus format is adopted for communication among the welding robot 12, the welder 13 and the tooling system 14, so that full digital control can be realized.
After welding, the machining materials are sent to a grinding station 8 to be ground and then are conveyed to a vision assembling station 9, wherein the vision assembling station 9 is configured to complete assembling of a ball valve ball body and a ball valve rod through matching of two robots, and in the ball valve ball body assembling process, visual centering assembling of the ball body placed in the pipe can be conducted through an industrial vision system.
The customized intelligent production line control system can adapt to a new mode of future intelligent manufacturing, and a new production and sales mode is created. Through the remote user client 2 in the system, a client can log in a customized website at any place with a network, submit the customized requirements and see the actual effect. The order placing information of a user is stored in the cloud background system 1 and is transmitted to the manufacturing execution system 3 through the cloud background system 1, a newly received order can be seen through refreshing the customization plan, the newly received order is confirmed to be correct after being selected, execution is clicked, each parameter of the order generates an order process, the order process enters a production line control page after being confirmed by the user, the industrial robot production line 4 is started, finally, the industrial robot production line 4 can automatically produce products, and finally, the produced products are automatically put in storage.
The foregoing is, of course, a preferred embodiment of this invention and it should be noted that modifications and adaptations may occur to one skilled in the art without departing from the spirit of the invention and are intended to be within the scope of the invention.
Claims (10)
1. A customized intelligent production line control system comprises a remote user client (2), a cloud background system (1), a manufacturing execution system (3) and an industrial robot production line (4), which are in communication connection in sequence; wherein the remote user client (2) is configured to remotely publish order information and to remotely monitor the industrial robot production line (4); the cloud background system (1) is configured to realize transmission of order information, management of user information, storage and analysis of data, remote control of a production line and data encryption; the manufacturing execution system (3) is configured to realize real-time monitoring, production plan management, production process management, manufacturing data management and analysis of the industrial robot production line (4) and control instruction issuing.
2. The system according to claim 1, wherein the remote user client (2) comprises a customized ordering module configured to enable user registration, login, password modification, and login and addition of addresses and contacts, and a production line remote monitoring module configured to remotely monitor and manage the production process.
3. The customized intelligent production line control system according to claim 2, wherein the remote user client (2) is a computer device or a mobile phone, and is in wireless communication with the cloud backend system (1).
4. The customized intelligent production line control system according to claim 1, wherein in the transmission of the order information, the order information sent by the remote user client (2) is sent to the cloud backend system (1) in a json format, the cloud backend system (1) analyzes and extracts the order information, then transmits the order information according to an HTTP protocol, and encrypts and transmits the order information to the manufacturing execution system (3).
5. The customized intelligent production line control system according to claim 1, wherein in the management of the user information, the order information is modified, deleted, and the personal information is maintained through the cloud backend system (1) after the user logs in.
6. The customized intelligent production line control system according to claim 1, wherein the storage and analysis of data comprises data collection of user information, data collection of product process information, and data collection of production line index parameters, wherein the user information comprises user characteristic information, and the product process information comprises status and parameters of equipment in the production process.
7. The system of claim 1, wherein the data encryption requires authentication by an asymmetric encryption algorithm when an external user or a user with a low access level accesses the production line, and the authentication process is incorporated into the communication protocol.
8. The customized intelligent line control system according to claim 1, wherein the real-time monitored content comprises start or stop of an industrial robot production line (4), line speed, process progress; the production plan management is configured to form and store order information transmitted by the cloud background system (1) into production plan data; the production process management is configured to perform process extraction on the customized parameters in the received order information and store the customized parameters in a table form; the manufacturing data management and analysis is configured to collect, analyze and store classified element variables in the production process, wherein the element variables comprise power consumption statistics, processing progress and equipment failure rate.
9. The customized intelligent production line control system according to claim 1, wherein the industrial robot production line (4) comprises a main control station (5), a processing station (6), a welding station (7), a polishing station (8), a vision assembly station (9), a conveying station (10) and a three-dimensional warehouse station (11), wherein the processing station (6) is configured to process industrial raw materials and comprises a numerical control machine, a loading and unloading robot and a lathe door opening and closing device, and industrial Ethernet communication is adopted among the devices; the welding station (3) is configured to perform a welding operation on a work product and comprises a welding robot (12), a welder (13) and a tooling system (14).
10. A customized intelligent production line control method using the control system of any one of claims 1-9, comprising the steps of:
step S1, the user issues order information remotely through the remote user client (2);
step S2, the order information is uploaded to the cloud background system (1) for storage and analysis;
step S3, the cloud background system (1) sends the analyzed information to the manufacturing execution system (3) and manages the production plan and the process through the manufacturing execution system (3);
a step S4, the manufacturing execution system (3) issues an operation instruction to the industrial robot production line (4);
and step S5, carrying out unmanned production by the industrial robot production line (4) and warehousing the products.
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