CN111932392A - Standard operation guidance system and operation method for intelligent manufacturing and processing production - Google Patents
Standard operation guidance system and operation method for intelligent manufacturing and processing production Download PDFInfo
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Abstract
The invention discloses a standard operation guidance system and an operation method for intelligent manufacturing and processing production, wherein the system comprises a Web end, an APP end and an operation platform, the Web end provides configuration information, data analysis information and an operation guidance book of a specific product standard, and a background manager can check specific operation information, master the operation condition of an operator and distribute the operation guidance book to the corresponding operation platform; the APP terminal displays an operation instruction to provide operation instructions and guides workers to operate according to the standard operation instruction system, intelligent material taking and intelligent error prevention are achieved through the coordinated operation of the operation platform, and the operation efficiency is improved; all operation information is collected in real time, and the visualization of a production field is realized.
Description
Technical Field
The invention relates to a standard operation guidance system and an operation method for processing production, in particular to a standard operation guidance system and an operation method for intelligent manufacturing and processing production.
Background
In the field of existing intelligent manufacturing and processing, a plurality of production and processing technologies cannot realize full automation, only manual processing and production can be carried out, and the manual production has the following defects: 1. since the parts such as screws are similar, the parts are easy to be selected and installed incorrectly; 2. because the assembly steps are complex, workers cannot remember all the production process steps, and the situations of missing parts and missing production operation steps are easy to occur; 3. due to the characteristics of randomness and inaccuracy of people, the situation that workers change the operation sequence at will and do not operate according to the operation standard is easy to occur; 4. the situation that product quality tracing cannot be realized and staff efficiency cannot be mastered can be caused by purely manual processing production; 5. because the mobility of factory personnel is stronger, lead to new people to train troublesome hard.
Disclosure of Invention
The purpose of the invention is as follows: the invention aims to provide a standard operation guidance system and an operation method for intelligent manufacturing and processing production, which are capable of intelligently taking materials, intelligently correcting errors and realizing field visualization.
The technical scheme is as follows: the system comprises a Web end, an APP end and a workbench, wherein the Web end and the APP end are communicated through a network; the Web end provides configuration information, data analysis information and an operation instruction book of a specific product standard, so that a background manager can check specific operation information, master the operation condition of an operator and distribute the operation instruction book to a corresponding operation platform; the Web terminal configuration information comprises bar code reading rules, operation platform information, material information, tool information, product information, step information and material shelf information; the Web end data analysis information comprises key component tracing, operation step information, operation platform production duration, operation platform yield, operation platform production rhythm, operation platform hardware fault, staff operation overtime rate and staff screw screwing NG rate; the content displayed by the APP end comprises an operation guide module and a material rack module; the APP end provides operation instructions, guides workers to guide the front-desk operators to complete assembly operation according to the operation method of the standard operation guidance system and the coordination work of the standard operation guidance system device, collects all operation information in real time and configures a graphic report.
The bar code reading rule configured at the Web end scans bar codes of products and materials in the production process to obtain product and material coding information, and identifies the products and the coded materials; the information of the operation platform configured by the Web end is information under the real environment of a factory, and comprises an operation platform IP, a PLC IP and hardware information contained in the operation platform; the operation platform is communicated with the server and the PLC; the material information configured by the Web end is all materials needed to be used in the operation; tool information configured at the Web end is all tools needed to be used in operation, wherein a screwdriver matched with the operation platform is an electric screwdriver; the product information configured by the Web end is all products required to be produced by a factory; step information configured by a Web end is a product standard operation instruction book, and each product comprises a plurality of working procedures and each working procedure comprises a plurality of steps by taking the working procedures as a unit; comprises a process of producing various products on the same operation platform and a process of producing the same product on different operation platforms. The material shelf information configured by the Web end comprises the information of the placement position, the alarm quantity and the feeding quantity of the material.
The material rack module at the APP end displays material rack information of the workbench, and the material rack information comprises material types, sequence and quantity on the material rack; when the quantity of the materials on the material rack is lower than the configured alarm quantity, the system prompts material supplement, and the one-time material supplement quantity of the material rack is the configured material supplement quantity; an operation guidance module at the APP end displays standard operation guidance requirements; the operation guidance requirement is the operation step information of the product on the operation platform, and comprises the product name, the product bar code, the step number, the step picture/video, the used material, the used tool, the step specific description text and the standard operation time.
The operation platform comprises a PLC, an industrial PAD, a code scanning gun, an error-proofing module, an electric screwdriver, a three-color lamp, a buzzer and a button; the characters, images and videos displayed on the industrial PAD screen guide operators to operate; an LED error-proofing indicator lamp in the error-proofing module automatically guides to take materials; the electric screwdriver automatically detects whether to tighten the screw; the PLC is a communication bridge between the APP end and the operation platform; the industrial PAD is a carrier of an APP end, and on the industrial PAD, a user checks an operation instruction book; the code scanning gun reads the bar codes of the products and the materials and transmits the bar codes to the APP terminal; the error prevention module prompts a user to take materials, senses material taking actions and prompts material taking errors; the electric screwdriver detects OK and NG signals of screwing screws.
The operation method comprises the following steps:
(1) the operation personnel use the job number and the password to log in the APP terminal, and after the login is successful, the system collects all production data of the workers in real time, so that a basis is provided for performance assessment, object tracing and the like.
(2) When the operation task is executed, an operator firstly needs to scan the bar code of the product by using a bar code scanning gun, and the system obtains the current product code according to the bar code reading rule to obtain the operation instruction book of the product on the operation platform.
(3) The system can bind the work number of the operator, the bar codes of the key components, the bar codes of products, process codes, workbench codes and operation time information, and can perform related tracing when the key components are damaged or lost.
(4) The operation is started from the first step by clicking a start button on the APP side by an operator, the APP side interface prompts the materials to be used in the step, and meanwhile, a mistake-proofing module green lamp is turned on above the material box where the materials are located, so that the operator is prompted to take the materials from the material box. If the operation personnel get the material mistake, the mistake proofing module will light the red light suggestion, and APP end interface suggestion gets the material mistake.
(5) After the material taking is finished, an operator screws the screws at the corresponding positions of the installation parts by using the electric screw driver according to the step pictures, the video and the step description, and the system can detect a screw screwing result signal in real time. If the screwing fails, the three-color lamp is turned on, the buzzer sounds, and the APP end interface prompts that the screwing fails.
(6) And (5) the operator clicks the next step or physical next step button of the software to enter the second step, and the step 4 and the step 5 are repeatedly executed until all the operation steps are completed.
Has the advantages that: compared with the prior art, the invention has the following remarkable effects: 1. the intelligent material taking and intelligent mistake proofing are realized, the worker is prevented from taking the product to be produced by mistake by guiding the production operation of the worker, the worker is prevented from taking the wrong material, the material taking is ensured to be correct, and the production efficiency is improved; 2. intelligent error correction, wherein when the electric screwdriver is used for screwing the screws according to the operation instruction, the electric screwdriver automatically detects the screw screwing result, if an operator fails to screw the screws, the three-color yellow lamp is turned on, the buzzer sounds, and the interface characters at the APP end prompt that the screws fail to screw the screws, so that the intelligent error correction can be realized, and the product quality is improved; 3. collecting operation information, performing visual management, collecting operation steps, screwing information, operation time information of an operator and operation platform hardware fault information in real time, checking a graphical report form by a manager at the background, realizing visualization of a production field, mastering the operation condition of workers and optimizing and improving the production steps.
Drawings
FIG. 1 is a general schematic of the present invention;
FIG. 2 is a flowchart of the administrator configuring a work instruction of the present invention;
FIG. 3 is a flow chart of the operation of the operator at the work station of the present invention;
FIG. 4 is a feeding flow chart of the operator at the work station according to the present invention;
FIG. 5 is a flow chart of material fetching software and hardware interaction according to the present invention;
FIG. 6 is a flow chart of the interaction between hardware and software for screwing the screw according to the present invention.
Detailed Description
The invention is described in further detail below with reference to the drawings and the detailed description.
The system software comprises a Web end, an APP end and a workbench, wherein the Web end and the APP end are communicated through a network. The workstation includes PLC, industry PAD, sweeps a yard rifle, mistake proofing module, electric screwdriver, three-color lamp, bee calling organ, button etc. wherein, sweeps a yard rifle and passes through USB with industry PAD to be connected, and mistake proofing module, electric screwdriver, three-color lamp, bee calling organ, button pass through the wiring with PLC and are connected, and PLC passes through internet access with industry PAD to can realize hardware device and APP's real-time communication, the working schematic diagram is like figure 1.
(1) The flow of the manager configuring the product (P) job instruction book at the Web end is shown in FIG. 2. And the manager logs in the system by using the own job number, and after the login is successful, the system binds all the configuration behavior information with the number of the currently logged-in manager. The method comprises the steps of firstly, carrying out initial setting (the setting is only configured once by a manufacturer when the system is on line), including bar code reading rules and workbench information (workbench codes are 1,2,3,4,5,6, …, n), and ensuring the normal operation of software. Secondly, configuring product information, including product code, product name, etc., wherein the product code is a unique identification for identifying the product. Next, if the material is required to be used in the production process of the product P, all the material information required and the material rack information of each work table are configured. If a tool is required to be used in the production process of the product P, all tool information required, including the electric screwdriver on the work bench, is configured. And (3) after the materials and tools are configured, configuring a product P (1-1,2-1,3-1,4-1,5-1,6-1, …, n-1). Each process comprises a plurality of operation steps, and the operation steps comprise: step names, standard operation time, materials used in the steps, tools used in the steps, detailed description of the steps, and step pictures/videos. Finally, the prepared product process is distributed to the work bench (1-1 → 1,2-1 → 2,3-1 → 3,4-1 → 4,5-1 → 5,6-1 → 6, …, n-1 → n).
(2) The work flow of the worker on the work bench n to produce the product P is shown in fig. 3. The operator logs in the APP terminal by using the own job number, and after the login is successful, the system collects all production data of the worker in real time, so that the performance assessment, the object tracing and the like are based. After the product P reaches the workbench n, an operator firstly uses the code scanning gun to scan the bar code of the product, the APP end sends the scanned product bar code to the server end, the server end identifies that the product P simultaneously sends the operation instruction book of the process n-1 of the product P on the workbench n to the APP end, and the APP end obtains and displays the operation instruction book. After the APP displays the operation instruction, an operator clicks a start button, the system judges whether materials in the material rack are lower than the material alarm quantity set by the Web end, if so, the user needs to feed materials first, otherwise, the operation cannot be started. Before the operation is started, the operator needs to scan the bar codes of all key components by using the code scanning gun, and the system binds information such as the job number of the operator, the bar codes of the key components, the bar codes of products, codes of an operation platform and the like and sends the information to the server, so that the related tracing can be performed when the scenes such as damage and loss of the key components occur. And after the operation is started, the APP end interface displays step information of the process n-1 step by step. Meanwhile, a green light of the mistake-proofing module above the material box where the used materials are located is required to be turned on in the step, and an operator is prompted to take the materials from the material box. The inductor of mistake proofing module responds to the operation personnel in real time and gets the material action, if sense the operation personnel and get the material in wrong material frame, then the bright red light suggestion of mistake proofing module, and APP end interface suggestion gets the material error. After the material taking is finished, an operator screws the screw by using the electric screwdriver at the corresponding position of the installation part according to the step pictures, the step videos and the step descriptions, and the system can detect a screw screwing result signal of the electric screwdriver in real time. If the screwing fails, the three-color lamp is turned on, the buzzer sounds, and the APP end interface prompts that the screwing fails. The operating personnel clicks the next button, the system sends the operation information of the step to the server, and the operation information comprises: the working personnel number, the working platform number, the product bar code, the process number, the step starting time, the step ending time, the screw screwing NG information in the step and the like. And after the product P is successfully sent, the next step is carried out, the operator continues to execute related operations until all the operation steps are completed, and the product P flows to the next operation platform to enter the next procedure for production.
(3) The feeding flow of the operator on the operation platform is shown in figure 4. After the material W reaches the operation platform, an operator firstly uses the work number of the operator to log in the APP end, and after the log-in is successful, the material rack information of the operation platform configured by the Web end in the material rack device is obtained from the server. The operating personnel click to enter the material rack module and click the material supplementing button to start the material supplementing operation. The operation personnel use and sweep the material bar code on the sign indicating number rifle scanning material W wrapping bag, and the APP end sends the service end to the material bar code that scans, and the service end discernment is material W and sends for the APP end, and the APP end obtains this material and judges the positional information of material W on the material frame behind material W to send the order to PLC, light the green light of this position mistake proofing module, suggestion operation personnel put into the material. At the moment, the inductor of the mistake-proofing module can induce the discharging action of the operator, and if the discharging action is not induced within 30 s(s), the material supplementing is abandoned; if the material placing action is sensed within 30s but the placing position is wrong, the error-proof module lights a red light to prompt, and the APP end interface prompts the material placing error; if the discharging action is sensed within 30s and the discharging position is correct, the error-proofing module green light is turned off, the APP interface prompts that the material supplement is successful, and the residual quantity is increased (the new residual quantity is equal to the original residual quantity plus the material supplement quantity) and is uploaded to the server.
(4) The material taking software and hardware interaction flow is shown in fig. 5. After the operator logs in the system successfully, the APP terminal obtains the material rack information of the workbench configured by the Web terminal from the server. When entering a certain step, the APP terminal obtains the materials required by the step. According to the position information of the material frame, the APP end sends a light-on command to the address bit of the error-proofing module green light PLC at the position of the material frame, and prompts an operator to take materials. At this moment, PLC real-time detection all mistake proofing module sensors's sensing signal, when mistake proofing module senses operation personnel's the action of getting the material, then this mistake proofing module sensors's PLC address position sends the signal to the APP end. After receiving the material taking signal, the APP end judges whether the position of the material needing to be taken is located, and if not, a light-on command is sent to a red light PLC address bit of the error-proof module to prompt that the material taking is wrong; if yes, material taking is correct.
(5) The screwing software and hardware interaction flow is shown in figure 6. After the operator logs in the system successfully and enters a certain step, the APP terminal interface displays related information of screwing screws, and the operator uses an electric screwdriver to screw the screws at corresponding positions according to the information of screwing the screws. The PLC monitors the screwing result information of the electric screwdriver in real time and sends the screwing result information to the APP end, if the APP end receives a signal sent by an NG address bit of the electric screw, the screw is not screwed, at the moment, the APP end sends a command to a PLC address bit of a three-color yellow light and a PLC address bit of a buzzer, the three-color yellow light is turned on, the buzzer sounds, and an operator is prompted that the screw is not screwed and needs to be screwed again; and if the APP end receives a signal sent by an OK address bit of the electric screwdriver, screwing down the screw.
Claims (10)
1. A standard operation guidance system and an operation method for intelligent manufacturing and processing production are characterized in that: the system comprises a Web end, an APP end and a workbench, wherein the Web end and the APP end are communicated through a network; the Web end provides configuration information, data analysis information and an operation instruction book of a specific product standard, so that a background manager can check specific operation information, master the operation condition of an operator and distribute the operation instruction book to a corresponding operation platform; the APP end provides operation instructions, guides workers to guide front-desk operators to complete assembly operation according to the operation method of the standard operation guidance system through coordination work of the operation desk, collects all operation information in real time and configures a graphic report.
2. The standard operation guidance system for intelligent manufacturing and processing production according to claim 1, wherein the Web configuration information includes barcode reading rules, workbench information, material information, tool information, product information, step information, and material shelf information; the Web end data analysis information comprises key component tracing, operation step information, operation platform production duration, operation platform yield, operation platform production rhythm, operation platform hardware fault, staff operation overtime rate and staff screw screwing NG rate.
3. The standard operation guidance system for intelligent manufacturing and processing production according to claim 1, wherein the bar code reading rule configured at the Web end obtains product and material coding information by scanning bar codes of products and materials in the production process, and identifies the products and the coded materials; the workbench information configured by the Web end is information under a real factory environment, and comprises a workbench IP, a PLC IP and hardware contained in the workbench; the operation platform is communicated with the server and the PLC; the material information configured by the Web end is all materials needed to be used in the operation; tool information configured by the Web end is all tools needed to be used in operation, wherein a screwdriver matched with the operation platform is an electric screwdriver; the product information configured by the Web end is all products required to be produced by a factory.
4. The standard operation instruction system for intelligent manufacturing and processing production according to claim 1, wherein the step information configured by the Web side is a product standard operation instruction book, and each product comprises a plurality of steps and each step comprises a plurality of steps; comprises a process of producing various products on the same operation platform and a process of producing the same product on different operation platforms.
5. The standard operation guidance system for intelligent manufacturing and processing production according to claim 1, wherein the material shelf information configured at the Web end includes information on placement position of materials, alarm amount, and feeding amount.
6. The quasi operation guidance system for the target intelligent manufacturing and processing production according to claim 1 or 5, wherein the material rack module at the APP end displays the material rack information of the operation platform, including the type, sequence and quantity of materials on the material rack; when the material quantity on the material rack is lower than the configured alarm quantity, the system prompts material supplement, and the material supplement quantity of the material rack at one time is the material supplement quantity configured by the Web end.
7. The standard operation guidance system for intelligent manufacturing and processing production according to claim 1, wherein the operation guidance module at the APP end displays standard operation guidance requirements; the operation guidance requirement is operation step information of the product on the operation platform, and the operation step information comprises product names, product bar codes, step numbers, step pictures/videos, used materials, used tools, step specific description words and standard operation time.
8. The system of claim 1, wherein the work station comprises a PLC, an industrial PAD, a code scanning gun, a mistake proofing module, an electric screwdriver, a tri-color light, a buzzer, and a button; the characters, images and videos displayed on the industrial PAD screen guide operators to operate; an LED error-proofing indicator lamp in the error-proofing module automatically guides to take materials; the electric screwdriver automatically detects whether screws are screwed.
9. The system of claim 8, wherein the PLC is a communication bridge between the APP end and a work bench; the industrial PAD is a carrier of the APP end, and a user views an operation instruction book on the industrial PAD; the code scanning gun reads the product and the material bar code and transmits the product and the material bar code to the APP terminal; the mistake-proofing module prompts a user to take materials, senses material taking actions and prompts material taking errors; the electric screwdriver detects OK and NG signals of screwing screws.
10. The method of claim 1, wherein the operator comprises the steps of:
(1) an operator logs in an APP terminal by using a job number and a password, and after the login is successful, the system collects all production data of the worker in real time, so that a basis is provided for performance assessment, object tracing and the like;
(2) when an operation task is executed, an operator firstly needs to scan a bar code of a product by using a bar code scanning gun, and a system obtains a current product code according to a bar code reading rule to obtain an operation instruction book of the product on an operation platform;
(3) an operator needs to scan the bar codes of all key components by using a code scanning gun, the system can bind the work number of the operator, the bar codes of the key components, the bar codes of products, process codes, workbench codes and operation time information, and relevant tracing can be carried out when scenes such as damage and loss of the key components occur;
(4) an operator clicks a start button on an APP end to start operation from the first step, an APP end interface prompts materials needed to be used in the step, and meanwhile, a mistake-proofing module green light above a material box where the materials are located is turned on to prompt the operator to take the materials from the material box; if the operator takes the material wrongly, the mistake-proofing module prompts a red light, and the APP end interface prompts the material taking mistake;
(5) after the material taking is finished, an operator screws the screws at the corresponding positions of the installation part by using an electric screwdriver according to the step pictures, the step videos and the step descriptions, and a system can detect a screw screwing result signal in real time; if the screwing fails, a three-color lamp is turned on, a buzzer sounds, and the APP end interface prompts that the screwing fails;
(6) and (4) the operator clicks the next step or physical next step button of the software to enter the second step, and the step (4) and the step (5) are repeatedly executed until all the operation steps are completed.
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| CN113917861A (en) * | 2021-09-06 | 2022-01-11 | 中国电子科技集团公司第十一研究所 | Intelligent guide system and method for preparing product by using same |
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