CN112255977A - Label production line data acquisition system - Google Patents
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- CN112255977A CN112255977A CN202011050995.4A CN202011050995A CN112255977A CN 112255977 A CN112255977 A CN 112255977A CN 202011050995 A CN202011050995 A CN 202011050995A CN 112255977 A CN112255977 A CN 112255977A
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 53
- 238000012544 monitoring process Methods 0.000 claims abstract description 14
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- 238000000034 method Methods 0.000 claims abstract description 6
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- 238000013480 data collection Methods 0.000 claims 2
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- 230000003993 interaction Effects 0.000 abstract description 3
- 238000005265 energy consumption Methods 0.000 abstract description 2
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- 239000000463 material Substances 0.000 description 4
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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]
- G05B19/4183—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 data acquisition, e.g. workpiece identification
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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
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31282—Data acquisition, BDE MDE
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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
- Y02P80/00—Climate change mitigation technologies for sector-wide applications
- Y02P80/10—Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
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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 data acquisition system for a label production line, which comprises a field layer, a data acquisition layer and a data acquisition layer, wherein the field layer is used for providing detection data of field equipment; the control layer is used for collecting detection data, issuing a control command and inquiring related information; and the monitoring layer is used for information transmission, real-time information acquisition and information archiving. The invention has the advantages that 1, the data interaction of the equipment layer and the information management system is realized; 2. the visual, digital and intelligent improvement on management processes such as products, production progress, production efficiency, quality information, equipment operation and the like is realized; 3. the production efficiency and the product quality are improved; the production cost and the energy consumption are reduced; 4. the digital control capacity of the production process is optimized; 5. the lean production advantage and the intelligent manufacturing advantage of a company are improved.
Description
Technical Field
The invention relates to the field of label production, in particular to a data acquisition system for a label production line.
Background
At present, in the label production line industry, the automatic data acquisition of the traditional field device is still a mode of manually recording a table while testing by adopting a single device and finally uniformly inputting the data of the whole production line into a computer by professional staff. Such work is not only repeated and tedious, but also can not guarantee the accuracy of data at the same time. The data acquired by the management layer is seriously lagged, and real-time display and recording cannot be achieved; these historical data cannot be displayed and stored for on-site bad product information and associated production data.
Disclosure of Invention
In view of the above, the present invention provides a data acquisition system for label production line, which comprises
The purpose of the invention is realized by the following technical scheme:
a data acquisition system for label production line comprises
A field layer for providing detection data of the field device;
the control layer is used for collecting detection data, issuing a control command and inquiring related information;
and the monitoring layer is used for information transmission, real-time information acquisition and information archiving.
Further, the control layer includes:
the PLC control cabinet is used for implementing a process control program and a communication program;
the gateway cabinet is used for realizing the communication of the service data;
and the servo control cabinet is used for realizing closed-loop control of the position.
Further, the PLC switch board includes:
the main controller is used for issuing a control instruction of a single device and inquiring production and process data;
the upper computer communication module is communicated with the upper computer, and realizes that PLC data is collected through an OPC protocol through a communication program compiled by main control;
the robot communication module is used for acquiring and controlling position data of each axis and gripper state information of the robot;
the I/O digital quantity module realizes the output control of the electromagnetic valve and the relay and the input control of the photoelectric proximity switch;
and the analog quantity acquisition module outputs a position signal of the motor or a position signal of a direct load according to the input analog quantity.
Further, the analog quantity acquisition module comprises an output module and an input module;
the output module is used for outputting control voltage of the servo motor from 0v to 10v, controlling the rotating speed through input of analog quantity or pulse frequency, and feeding back a position signal of the motor or a position signal of a direct load to a main control for operation;
the input module is used for inputting the analog quantity torsion, the tension value and the temperature value through the torsion tension meter.
Further, the monitoring layer includes:
the SCADA communication server provides real-time data to a real-time and historical server of the SCADA system to finish uploading of the data and issuing of instructions;
the SCADA real-time data server is used for managing real-time data;
the SCADA historical data server is used for filing mass historical data of the real-time data and providing historical data interface service;
the SCADA OPC server realizes data exchange to the MES system in an OPC service mode, calls an OPC protocol transmission instruction and writes a calling program to realize a communication function;
SCADA MQTT proxy server, which realizes data exchange to MES system via MQTT protocol;
and the deployment server provides an HMI client program of a C/S framework, and completes visual monitoring and operation of production real-time flow pictures, user management, real-time and historical curves, real-time alarm and historical alarm query, production report forms and the like.
Furthermore, the system also comprises a planning layer which comprises MES management software and carries out data exchange through an MQTT protocol.
Further, the gateway cabinet comprises an optical fiber transceiver, an optical end box and a gateway module;
the gateway module contains the pass-through function and converts the field modbusRTU protocol to modbusTCP.
Further, the gateway module is provided with a network port and is accessed to the switch through the optical fiber transceiver and the optical end box.
Further, the field device comprises a photoelectric sensor, a thermometer, an electromagnetic valve, a servo motor, a manipulator and a torsional tension detector.
Further, the system also comprises an SCADA alarm server which is used for displaying field device alarm, automatic control logic alarm, limit value alarm and communication alarm.
The invention has the beneficial effects that:
1. data interaction of an equipment layer and an information management system is realized;
2. the visual, digital and intelligent improvement on management processes such as products, production progress, production efficiency, quality information, equipment operation and the like is realized;
3. the production efficiency and the product quality are improved; the production cost and the energy consumption are reduced;
4. the digital control capacity of the production process is optimized;
5. the lean production advantage and the intelligent manufacturing advantage of a company are improved.
Additional advantages, objects, and features of the invention will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the invention. The objectives and other advantages of the invention may be realized and attained by the means of the instrumentalities and combinations particularly pointed out hereinafter.
Drawings
In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention will be further described in detail with reference to the accompanying drawings, in which:
FIG. 1 is a schematic diagram of the structure of a field layer and a control layer;
fig. 2 is a schematic diagram of the structure of the monitoring layer and the planning layer.
Detailed Description
Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. It should be understood that the preferred embodiments are illustrative of the invention only and are not limiting upon the scope of the invention.
The embodiment provides a data acquisition system for a label production line, which comprises a field layer, a control layer, a monitoring layer and a planning layer, as shown in fig. 1 and 2.
The field layer is used for providing field device's testing data, including photoelectric sensor, thermometer, solenoid valve, servo motor, manipulator and torsional tension detector, and wherein testing data still contains the realization action including opening and shutting down, output, pulling force, moment of torsion etc.: the conveyer belt rotates, controls the manipulator to stack materials, and controls the tray to ascend and descend through the motor.
The control layer is used for collecting detection data, issuing a control command and inquiring related information and comprises a PLC control cabinet, a gateway cabinet and a servo control cabinet.
The PLC control cabinet is used for realizing the implementation of a process control program and a communication program and mainly comprises a main controller, an upper computer communication module, a robot communication module, an I/O digital quantity module and an analog quantity acquisition module.
The main controller is the core of the PLC control cabinet, a process control program and a communication program are stored in the main controller, the touch screen is communicated with the main controller through a network cable, and an operator issues a control instruction of a single device through the touch screen to inquire production and process data such as fault information, yield information and the like.
The upper computer communication module is communicated with the upper computer, and the PLC data is acquired through an OPC protocol through a communication program compiled by the main controller.
And the robot communication module is communicated with the communication module through the robot communication board card to realize the acquisition and control of the position data of each axis and the gripper state information of the robot.
And the I/O digital quantity module realizes the output control of the electromagnetic valve and the relay and the input control of the photoelectric proximity switch.
And the analog quantity acquisition module outputs a position signal of the motor or a position signal of a direct load according to the input analog quantity and comprises an analog quantity input and output module. Comprises an input module and an output module.
An output module: the control voltage of the servo motor is output, the rotating speed is controlled through the input of analog quantity or the frequency of pulse, and the position signal of the motor or the position signal of direct load is fed back to the main control for operation.
An input module: the torque force, the tension value and the temperature value of the analog quantity are input through a torque tension meter.
The gateway cabinet comprises an optical fiber transceiver, an optical end box and a gateway module.
The gateway module comprises a transparent transmission function, and is only responsible for transmitting the transmitted content from a source address to a destination address regardless of the transmitted service content in communication, and does not change the service data content. And converts the field modbusRTU protocol to modbusTCP. And (3) physical interface aspect: the gateway module is provided with a network port and is accessed to the switch through the optical fiber transceiver and the optical end box.
The servo drive cabinet comprises a servo drive. The servo motor is connected with the servo driver, analog signals are input into the driver, position closed-loop control is achieved through feedback of the pressure sensor, the repetition precision is 0.01mm or pressure closed-loop control, and the repetition precision is less than or equal to +/-1%.
The monitoring layer comprises a SCADA communication server, a SCADA historical data server, a SCADA OPC server, an SCADA MQTT server and a deployment server.
The SCADA communication server collects and controls the control equipment with the geography dispersion in real time in various communication modes such as wired communication, wireless communication and the like, and the communication server provides real-time data to a real-time and historical server of the SCADA system to finish uploading of the data and issuing of instructions. The communication server supports redundant configuration, and supports equipment redundancy and link redundancy. The communication service program of the SCADA platform configuration software can be independently deployed. And an MQTT protocol is configured to communicate with upper-layer plan management software. And the OPC and modbusTCP server are communicated with the lower layer gateway and the PLC.
The SCADA real-time data server and the distributed real-time database support information data types and structures of various factory models and provide various functional point types. The hierarchical structure design of the real-time database facilitates massive data management and historical data archiving management, a load balancing mechanism of dynamic registration of parameters is provided, and a complex and flexible distributed production scheduling system can be constructed by adopting a separation structure for the graphic monitoring system and the data processing and archiving.
And the SCADA historical data server is used for filing mass historical data of the real-time data and providing historical data interface service. The historical data storage filing supports multiple technologies such as data timing storage, condition storage, change compression storage and trend compression storage, and has stronger production data analysis and statistical functions.
The system also comprises an SCADA alarm server which is a flexible distributed alarm framework, has strong functions of alarm storage, statistics, analysis, display, query, event triggering, printing and the like, and can be linked with voice, video and multimedia to complete a large-scale production alarm management system.
The SCADA warning server is divided into three levels from high to low according to the important degree of the SCADA data and the communication state information, and the three levels are sequentially as follows: class i alarm, class ii alarm and class iii alarm. The I-level alarm directly influences or threatens the safe operation of the label system, and emergency treatment measures are required to be taken immediately after the alarm is generated, otherwise serious adverse effects can be caused, and the alarm belongs to serious event alarm. The level II alarm is that the running state of the system running equipment is changed abnormally, and appropriate measures or important attention needs to be taken, and the alarm belongs to important event alarm. The class III alarm is other alarms except the class I alarm and the class II alarm, and belongs to general alarms.
And the SCADA OPC server realizes data exchange to the MES in an OPC service mode, calls an OPC protocol transmission instruction and writes a calling program to realize a communication function.
SCADA MQTT proxy server, and realizes data exchange to MES system via MQTT protocol. And writing a calling program to realize a communication function by calling the MQTT protocol transmission instruction.
And the deployment server provides functions of development deployment, picture configuration and the like of the whole system. And providing an HMI client program of a C/S framework to complete visual monitoring and operation of production real-time flow pictures, user management, real-time and historical curves, real-time alarm and historical alarm query, production report forms and the like. The Runtime client computer is connected with the television through a high-definition HDMI interface to display a configuration picture.
The planning layer comprises MES management software, and data exchange is carried out through an MQTT protocol to issue process data such as order numbers, order quantity, model numbers and the like.
The system realizes human-computer interaction display, and specifically comprises the following steps:
1. and displaying that the automatic feeding and discharging mechanism of each device of the automatic production line has a material shortage early warning function on the field HMI touch screen, and reminding an operator to prepare a feeding action in advance. And displaying the output state data of the equipment on the on-site monitoring television: the starting and stopping state, the starting and stopping time and the like, and the detection data of yield, tension, torque, tray position and the like.
2. And when the field monitoring television displays that the feeding equipment receives an MES production task, counting the feeding quantity, comparing the counting with the planned quantity, alarming and stopping when the counting exceeds the planned quantity, and adjusting and issuing the planned quantity again by the MES in the production process.
The system realizes the uploading and downloading of data of the upper computer and the lower computer, and specifically comprises the following steps:
1. the field controlled equipment (lower computer) acquisition aspect: 1. the state data are uploaded to the PLC in real time through the modbus rtu module, and the content comprises a start-up and shut-down state, an environment temperature, electric quantity, a shut-down code, a detection result, a detection value and the like. 2. The state data are uploaded to the server through the gateway module, the MODBUS TCP and the upper computer module and the switch.
2. Data acquisition system to MES system aspects (upper computer): the automatic production line management system has the functions of material loading counting and product offline counting of a production line, when work orders are switched, the counting is automatically reset, MES can be uploaded in real time, and an interface protocol adopts MQTT. The MES issues production task data to the production line, which mainly comprises: work order information, material information, plan information, program templates, printing data and the like, wherein the interface protocol adopts MQTT.
Finally, the above embodiments are only intended to illustrate the technical solutions of the present invention and not to limit the present invention, and although the present invention has been described in detail with reference to the preferred embodiments, it will be understood by those skilled in the art that modifications or equivalent substitutions may be made on the technical solutions of the present invention without departing from the spirit and scope of the technical solutions, and all of them should be covered by the claims of the present invention.
Claims (10)
1. The utility model provides a label production line data acquisition system which characterized in that: comprises that
A field layer for providing detection data of the field device;
the control layer is used for collecting detection data, issuing a control command and inquiring related information;
and the monitoring layer is used for information transmission, real-time information acquisition and information archiving.
2. The label production line data acquisition system of claim 1, wherein: the control layer includes:
the PLC control cabinet is used for implementing a process control program and a communication program;
the gateway cabinet is used for realizing the communication of the service data;
and the servo control cabinet is used for realizing closed-loop control of the position.
3. The label production line data collection system of claim 2, wherein: the PLC switch board includes:
the main controller is used for issuing a control instruction of a single device and inquiring production and process data;
the upper computer communication module is communicated with the upper computer, and realizes acquisition of PLC data through an OPC protocol through a communication program compiled by main control;
the robot communication module is used for acquiring and controlling position data of each axis and gripper state information of the robot;
the I/O digital quantity module realizes the output control of the electromagnetic valve and the relay and the input control of the photoelectric proximity switch;
and the analog quantity acquisition module outputs a position signal of the motor or a position signal of a direct load according to the input analog quantity.
4. The label production line data acquisition system of claim 3, wherein: the analog quantity acquisition module comprises an output module and an input module;
the output module is used for outputting control voltage of the servo motor from 0v to 10v, controlling the rotating speed through input of analog quantity or pulse frequency, and feeding back a position signal of the motor or a position signal of a direct load to a main control for operation;
the input module is used for inputting the analog quantity torsion, the tension value and the temperature value through the torsion tension meter.
5. The label production line data acquisition system of claim 1, wherein: the monitoring layer includes:
the SCADA communication server provides real-time data to a real-time and historical server of the SCADA system to finish uploading of the data and issuing of instructions;
the SCADA real-time data server is used for managing real-time data;
the SCADA historical data server is used for filing mass historical data of the real-time data and providing historical data interface service;
the SCADA OPC server realizes data exchange to the MES system in an OPC service mode, calls an OPC protocol transmission instruction and writes a calling program to realize a communication function;
SCADA MQTT proxy server, which realizes data exchange to MES system via MQTT protocol;
and the deployment server provides an HMI client program of a C/S framework, and completes visual monitoring and operation of production real-time flow pictures, user management, real-time and historical curves, real-time alarm and historical alarm query, production report forms and the like.
6. The label production line data acquisition system of claim 1, wherein: the system also comprises a planning layer which comprises MES management software and carries out data exchange through an MQTT protocol.
7. The label production line data acquisition system of claim 2, wherein: the gateway cabinet comprises an optical fiber transceiver, an optical end box and a gateway module;
the gateway module contains the pass-through function and converts the field modbusRTU protocol to modbusTCP.
8. The label production line data collection system of claim 7, wherein: the gateway module is provided with a network port and is accessed to the switch through the optical fiber transceiver and the optical end box.
9. The label production line data acquisition system of claim 1, wherein: the field device comprises a photoelectric sensor, a thermometer, an electromagnetic valve, a servo motor, a manipulator and a torsional tension detector.
10. The label production line data acquisition system of claim 5, wherein: the system also comprises an SCADA alarm server which is used for displaying field device type alarm, automatic control logic type alarm, limit value type alarm and communication system type alarm.
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| CN202011050995.4A CN112255977A (en) | 2020-09-29 | 2020-09-29 | Label production line data acquisition system |
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| CN202011050995.4A CN112255977A (en) | 2020-09-29 | 2020-09-29 | Label production line data acquisition system |
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Cited By (5)
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| CN112731895A (en) * | 2021-02-08 | 2021-04-30 | 上海凯盛朗坤信息技术股份有限公司 | Real-time acquisition and monitoring system for glass factory production |
| CN114281035A (en) * | 2021-12-03 | 2022-04-05 | 北京京仪自动化装备技术股份有限公司 | Production safety operation and maintenance monitoring and management system |
| CN114476293A (en) * | 2022-01-11 | 2022-05-13 | 厦门聚视智创科技有限公司 | Coil stock stripping control system |
| CN114625039A (en) * | 2021-12-07 | 2022-06-14 | 浙江中控技术股份有限公司 | SCADA (supervisory control and data acquisition) -based 3D effect monitoring display method in pharmaceutical industry |
| CN116521763A (en) * | 2023-07-04 | 2023-08-01 | 深圳市汇众智慧科技有限公司 | Workshop production data collection statistical method and system based on Mes system |
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Cited By (5)
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| CN112731895A (en) * | 2021-02-08 | 2021-04-30 | 上海凯盛朗坤信息技术股份有限公司 | Real-time acquisition and monitoring system for glass factory production |
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| CN116521763A (en) * | 2023-07-04 | 2023-08-01 | 深圳市汇众智慧科技有限公司 | Workshop production data collection statistical method and system based on Mes system |
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