CN112486131A - Method, system, equipment and medium for monitoring operation state of production line - Google Patents
Method, system, equipment and medium for monitoring operation state of production line Download PDFInfo
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Abstract
The invention discloses a method, a system, equipment and a medium for monitoring the operation state of a production line, wherein the method comprises the following steps: modeling an actual production line by using simulation software to obtain a three-dimensional model of the production line; simulating the three-dimensional model of the production line according to the product process and the logistics transmission mode to obtain a virtual simulation production line model; driving a virtual simulation production line model to run in real time based on real-time running data corresponding to an actual production line to form a production line virtual production system; and carrying out operation monitoring on the actual production line through the operation state of the virtual production line and the key operation parameters so as to determine whether the operation state of the actual production line is normal. The synchronous presentation of the operation data and the simulation model is realized, and the operation difficulty is reduced; the production line operation monitoring APP is generated, the traditional operation monitoring mode is changed, and a new path is provided for the production and manufacturing industry APP development.
Description
Technical Field
The invention relates to the field of production line monitoring systems, in particular to a method, a system, equipment and a medium for monitoring the operation state of a production line.
Background
Industrial internet has been a key infrastructure for smart manufacturing and has been receiving a continuous and widespread attention since 2015, and industrial APP (Application) has become a new form of future manufacturing development as a value export of industrial internet. The industrial APP is industrial application software which is based on the Internet, bears industrial knowledge and experience and meets specific requirements, and is an important achievement of industrial technology software. It is a carrier of specific industrial knowledge, and has the characteristics of customization, specialization, combination, reusability and the like. The method covers the whole process and the whole ring segment of production and manufacturing, and is divided into various types according to different division dimensions, such as application scenes, application ranges and modeling methods. From the application scene dimension, four major industrial APPs including research and development design class, production and manufacture class, operation and maintenance service class and operation management class are provided.
The production line operation monitoring belongs to a production and manufacturing link from an application scene dimension, the production line operation monitoring system mainly realizes the overall monitoring of the production process of the manufacturing production line and clearly recognizes the overall operation state and the production environment of the production line, and basically comprises a monitoring center, data acquisition, data input, data analysis, data output, various signal alarms, equipment control, measurement, parameter adjustment and other functions, and the current production line operation monitoring mainly adopts a computer-based production process control and scheduling automatic system. The production line operation monitoring system based on the traditional industrial Ethernet adopts a wire mode for transmission, the wiring is troublesome and the alarm measures are lacked; the production line operation monitoring system based on the technology of the Internet of things effectively solves the problems of wiring and alarming by adding a GPRS (General packet radio service) communicator and monitoring terminal equipment; the production line operation monitoring system based on the FPGA (Field Programmable Gate Array) controller realizes rapid instruction issuing and information transmission by introducing the FPGA controller.
However, in the current production line operation monitoring system in the prior art, no matter depending on the traditional industrial ethernet or the internet of things, no matter a cloud computing controller or a field FPGA controller is adopted, the monitoring mode basically adopts a combination form of a data analysis chart and a video picture, the mode mainly adopts the data analysis chart, the video monitoring reflects a production line operation real-time picture, and the production line real-time data is separated from the monitoring picture, so that the operation difficulty is large.
Disclosure of Invention
The invention provides a monitoring method, a system, equipment and a medium for the operating state of a production line, aiming at overcoming the defect of high operating difficulty caused by separation of real-time data and a monitoring picture of the production line, which is mainly in a form of combining a data analysis chart and a video picture in the prior art.
The invention solves the technical problems through the following technical scheme:
in a first aspect, the present invention provides a method for monitoring an operating state of a production line, where the method includes:
modeling an actual production line by using simulation software to obtain a three-dimensional model of the production line;
simulating the three-dimensional model of the production line according to the product process and the logistics transmission mode to obtain a virtual simulation production line model;
driving the virtual simulation production line model to run in real time along with the actual production line based on real-time running data corresponding to the actual production line to generate a production line virtual production system; the virtual production line virtual production system is used for displaying the running state and key parameters of a virtual production line in real time;
and carrying out operation monitoring on the actual production line through the running state of the virtual production line and the key parameters so as to determine whether the running state of each device in the actual production line is normal.
Preferably, the monitoring method further comprises:
and generating a production line operation monitoring APP, wherein the production line operation monitoring APP is used for displaying operation parameters corresponding to a product, a production line and a simulation environment, and the presenting mode of the operation parameters comprises at least one of a pie chart, a bar chart, a curve chart and a table.
Preferably, the step of simulating the three-dimensional production line model according to the product process and the logistics transportation mode to obtain the virtual simulation production line model includes:
sequentially carrying out process route simulation on key station main equipment according to a product process and carrying out production line logistics simulation on the logistics transmission state of the actual production line so as to obtain a virtual simulation production line model; the process route simulation comprises mechanical equipment definition, robot setting and production line layout planning.
Preferably, the monitoring method further comprises:
presetting the virtual simulation production line model; wherein the preset processing includes at least one of revision processing, lightweight processing, and rendering processing.
Preferably, the key parameter includes at least one of a product operation parameter, a production line operation parameter and an environmental status parameter; the product operation parameters comprise at least one of yield, product quantity and qualification rate, the production line operation parameters comprise at least one of equipment utilization rate, equipment failure rate, tempo, capacity and energy consumption, and the environment state parameters comprise at least one of temperature and humidity;
and/or;
the monitoring method further comprises the following steps: testing the virtual simulation production line model by using test data, wherein the test data is historical data corresponding to the actual production line;
and/or;
the monitoring method further comprises the following steps: acquiring the key parameters from a target interface in the industrial gateway, wherein the target interface comprises a simulation interface, a serial interface, a USB interface and an Ethernet interface; the simulation interface is connected with an industrial sensor, the serial interface is connected with industrial equipment, the USB interface is connected with USB equipment, and the Ethernet interface is connected with an industrial field bus controller or a wireless communication gateway;
and/or;
the actual production line comprises a lithium battery lamination assembly production line.
In a second aspect, the present invention further provides a monitoring system for monitoring an operation state of a production line, the monitoring system comprising:
the modeling module is used for modeling the actual production line by utilizing simulation software so as to obtain a three-dimensional model of the production line;
the simulation module is used for simulating the three-dimensional model of the production line according to the product process and the logistics transmission mode so as to obtain a virtual simulation production line model;
the driving module is used for driving the virtual simulation production line model to run in real time along with the actual production line based on real-time running data corresponding to the actual production line so as to generate a production line virtual production system; the virtual production line virtual production system is used for displaying the running state and key parameters of a virtual production line in real time;
and the monitoring module is used for carrying out operation monitoring on the actual production line through the running state of the virtual production line and the key parameters so as to determine whether the running state of each device in the actual production line is normal or not.
Preferably, the monitoring system further comprises:
the operation monitoring APP module is used for generating a production line operation monitoring APP, the production line operation monitoring APP is used for displaying operation parameters corresponding to products, production lines and simulation environments, and the presenting mode of the operation parameters comprises at least one of a pie chart, a bar chart, a curve chart and a table.
Preferably, the simulation module is specifically configured to:
sequentially carrying out process route simulation on key station main equipment according to a product process and carrying out production line logistics simulation on the logistics transmission state of the actual production line so as to obtain a virtual simulation production line model; the process route simulation comprises mechanical equipment definition, robot setting and production line layout planning.
Preferably, the monitoring system further comprises:
the preprocessing module is used for carrying out preset processing on the virtual simulation production line model; wherein the preset processing includes at least one of revision processing, lightweight processing, and rendering processing.
Preferably, the key parameter includes at least one of a product operation parameter, a production line operation parameter and an environmental status parameter; the product operation parameters comprise at least one of yield, product quantity and qualification rate, the production line operation parameters comprise at least one of equipment utilization rate, equipment failure rate, tempo, capacity and energy consumption, and the environment state parameters comprise at least one of temperature and humidity;
and/or;
the monitoring system further comprises: the inspection module is used for inspecting the virtual simulation production line model by using test data, wherein the test data is historical data corresponding to the actual production line;
and/or;
the monitoring system further comprises: the key parameter acquisition module is used for acquiring the key parameters from a target interface in the industrial gateway, wherein the target interface comprises an analog interface, a serial interface, a USB interface and an Ethernet interface; the simulation interface is connected with an industrial sensor, the serial interface is connected with industrial equipment, the USB interface is connected with USB equipment, and the Ethernet interface is connected with an industrial field bus controller or a wireless communication gateway;
and/or;
the actual production line comprises a lithium battery lamination assembly production line.
In a third aspect, the present invention provides a computer-readable storage medium, on which a computer program is stored, which, when being executed by a processor, implements the steps of the monitoring method for the operating state of the production line according to the first aspect.
In a fourth aspect, the present invention provides an electronic device, which includes a processor, a memory, and a computer program stored in the memory and running on the processor, and when the computer program is executed by the processor, the method for monitoring the operation state of the production line according to the first aspect is implemented.
The positive progress effects of the invention are as follows: the method, the system, the equipment and the medium for monitoring the operation state of the production line are provided, a virtual simulation production line model is obtained by modeling and simulating an actual production line, and the virtual simulation production line model loaded with real-time operation data is operated and monitored according to the operation state of the virtual production line and key operation parameters to obtain simulation operation data, so that the synchronous presentation of the operation data and the simulation model is realized, and the operation difficulty is reduced; the production line operation monitoring APP is generated, the traditional operation monitoring mode is changed, and a new path is provided for the production and manufacturing industry APP development.
Drawings
Fig. 1 is a flowchart of a method for monitoring an operating state of a production line according to embodiment 1 of the present invention.
Fig. 2 is a flowchart of a method for monitoring an operating state of a production line according to embodiment 2 of the present invention.
Fig. 3 is a schematic block diagram of a monitoring system for monitoring an operating state of a production line according to embodiment 3 of the present invention.
Fig. 4 is a schematic block diagram of a monitoring system for generating a line operating status according to embodiment 4 of the present invention.
Fig. 5 is a schematic diagram of a hardware structure of an electronic device according to embodiment 6 of the present invention.
Detailed Description
The invention is further illustrated by the following examples, which are not intended to limit the scope of the invention.
Example 1
The embodiment provides a monitoring method for an operation state of a production line, as shown in fig. 1, the monitoring method includes the following steps:
and step S110, modeling the actual production line by using simulation software to obtain a three-dimensional model of the production line.
Wherein, this actual production line includes lithium cell lamination assembly line.
In this embodiment, CATIAV6 (a modeling software) may be used to perform three-dimensional simulation modeling on the actual production line, and during the modeling process, in order to enhance the display effect of the three-dimensional model of the production line after modeling and increase the sense of reality, the modeling may be performed according to the size of each device in the actual lithium battery lamination assembly production line, and details such as chamfers and fillets may also be adaptively retained.
Namely, according to the layout and design of the real lithium battery lamination assembly line, the production line is modeled by CATIAV6 production line simulation software, and a three-dimensional model of the production line is generated.
It should be noted that the lithium battery lamination assembly line is an industrial automatic production line in the discrete industry, and generally comprises elements such as a robot, an AGV (Automated Guided Vehicle), a numerical control device, a conveyor belt, a tooling fixture, a product in process, a shelf and the like.
And S120, simulating the three-dimensional model of the production line according to the product process and the logistics transmission mode to obtain a virtual simulation production line model.
The method comprises the following steps of sequentially carrying out process route simulation on key station main equipment and production line logistics simulation on the logistics transmission state of an actual production line according to a product process so as to obtain a virtual simulation production line model; the process route simulation comprises mechanical equipment definition, robot setting and production line layout planning.
Specifically, the lithium battery lamination assembly production line is divided into two parts, namely a production line and a logistics system, wherein the production line is mainly used for finishing the processing process of products and can comprise a machine table, a mechanical arm and a conveying belt; and the logistics system is responsible for the transfer process of the products in the whole production line. According to the product process, namely, the process requirements of loading, detection, sorting, transportation, lamination, welding and cutting, the subordinate mechanical equipment definition, production line layout planning, robot simulation and human-machine engineering module of a Delmia module in CATIAV6 are adopted to carry out process route simulation on key station main equipment on a production line.
Further, the logistics transmission state of the lithium battery lamination in the automatic assembly line workshop is determined by analyzing the components of the production line processing equipment, the warehouse and the AVG trolley. And according to the logistics transmission state corresponding to the actual production line, carrying out production line logistics simulation by adopting a logistics simulation module subordinate to Delmia so as to generate a virtual simulation production line model.
Step S130, driving a virtual simulation production line model to run in real time along with an actual production line based on real-time running data corresponding to the actual production line to generate a production line virtual production system; and the virtual production line operation state and the key parameters are presented in the virtual production system of the production line in real time.
To drive the operation of the virtual simulation production line model, related simulation operation data needs to be imported, and the simulation operation data can comprise the processing time of products, the delivery capacity of the AGVs, the delivery speed of the AGVs, the distribution quantity of production line equipment and the like. When the setting of the simulation operation data is completed, that is, after the setting of the static data in the virtual simulation production line model is completed, the real-time operation data corresponding to the actual production line is obtained, and the real-time operation data may be the operation data corresponding to the actual production line of 1 hour, 2 hours or 1 day.
It should be noted that, the real-time operation data of each process device in the actual production line may be collected through an industrial gateway docking sensor, a PLC (Programmable Logic Controller), and the like, and the real-time operation data is imported into the industrial internet platform. The industrial internet refers to an industrial cloud platform which supports ubiquitous connection, flexible supply and efficient configuration of manufacturing resources and comprises three core levels, namely an edge layer, a platform layer and an application layer. Real-time operation data access is carried out from an industrial internet platform, a virtual simulation production line model is driven to synchronously operate along with an actual production line based on the real-time operation data access, a virtual production line production system is generated, the virtual production line production system comprises a virtual production line operation state, and the virtual production line operation state can comprise a production line layout state, state information corresponding to the start or stop of a production line and state information corresponding to the start or stop of virtual production line equipment.
Step S140, the operation of the actual production line is monitored through the running state of the virtual production line and the key parameters, so as to determine whether the running state of each device in the actual production line is normal.
The method comprises the steps of obtaining key parameters from an industrial gateway according to the operation requirements of an actual production line, listing a data list containing the key parameters, determining the monitored key parameters according to the operation requirements of the actual lithium battery lamination assembly production line, and enabling the monitored key parameters to comprise product operation parameters, production line operation parameters and environment state parameters. And monitoring the simulation operation data based on the determined key parameters. For example, if the standard yield a, the standard yield B, and the standard yield C corresponding to the device 1, the device 2, and the device 3 in the virtual simulation production line model are used as key parameters to monitor the actual yield of the device in the actual production line, and determine whether the actual yield of the device 1 reaches the standard yield a, the actual yield of the device 2 reaches the standard yield B, and the actual yield of the device 3 reaches the standard yield C within a preset time period, and if the actual yield of the device 1 does not reach the standard yield a, it is determined that a fault exists in the operation of the device 1.
It should be noted that the key parameters may include product related parameters such as yield, quantity of products being processed, and qualification rate, production line operation related parameters such as utilization rate of each device, failure rate of the device, tempo, capacity, and energy consumption, and environmental state parameters such as temperature and humidity.
The embodiment provides a monitoring method for the operation state of a production line, which includes modeling and simulating an actual production line to obtain a virtual simulation production line model, and performing operation monitoring on the virtual simulation production line model loaded with real-time operation data according to the operation state of the virtual production line and key parameters, so that the operation data and the simulation model are presented synchronously, the operation difficulty is reduced, further, the efficiency of the operation monitoring of the production line is improved, and a fault copy is reproduced more clearly.
Example 2
The present embodiment is further improved based on embodiment 1, and as shown in fig. 2, a method for monitoring an operation state of a production line is provided, the method for monitoring an operation state of a production line includes the following steps:
and step S110, modeling the actual production line by using simulation software to obtain a three-dimensional model of the production line.
And S120, simulating the three-dimensional model of the production line according to the product process and the logistics transmission mode to obtain a virtual simulation production line model.
Step S1201, presetting a virtual simulation production line model; wherein the preset processing includes at least one of revision processing, lightweight processing, and rendering processing.
Specifically, in order to ensure that the production tacts of the virtual simulation production line corresponding to the same product in the virtual simulation production line model and the actual production line are the same, the virtual simulation production line model needs to be modified to obtain a revised virtual simulation production line.
In this embodiment, the subordinate module of the CATIAV6 software may be used to perform the weight reduction processing and the rendering processing on the virtual simulation production line model, and in addition, the remaining independent software may be used to perform the weight reduction processing and the rendering processing on the model, so that the simulation effect of the model is more vivid.
Step S130, driving a virtual simulation production line module to run in real time along with an actual production line based on real-time running data corresponding to the actual production line, and generating a production line virtual production system, wherein a virtual production line running state and key parameters are presented in the production line virtual production system in real time.
The virtual production line production system comprises a virtual production line running state, wherein the virtual production line running state can comprise a production line layout state, state information corresponding to the starting or stopping of a production line, and state information corresponding to the starting or stopping of virtual production line equipment.
And S1301, acquiring key parameters from a target interface in the industrial gateway.
In this embodiment, the industrial gateway is an industrial data acquisition system, and can conveniently collect data of different data sources and formats of factory enterprises to an industrial cloud server. The industrial gateway may include an analog interface, a serial interface, a USB interface, and an ethernet interface. The simulation interface is connected with an industrial sensor, the serial interface is connected with industrial equipment, the USB interface is connected with USB equipment, and the Ethernet interface is connected with an industrial field bus controller or a wireless communication gateway.
It should be noted that the key parameters may include direct parameters and indirect parameters, the direct parameters may include parameters related to the product and parameters related to the production line, and the indirect parameters may include environmental status parameters.
Step S140, the operation of the actual production line is monitored through the running state of the virtual production line and the key parameters, so as to determine whether the running state of each device in the actual production line is normal.
The key parameters comprise at least one of product operation parameters, production line operation parameters and environment state parameters; the product operation parameters comprise at least one of yield, product quantity and qualification rate, the production line operation parameters comprise at least one of equipment utilization rate, equipment failure rate, tempo, capacity and energy consumption, and the environment state parameters comprise at least one of temperature and humidity.
And S1401, generating a production line operation monitoring APP. The production line operation monitoring APP is used for displaying operation parameters corresponding to products, production lines and simulation environments, and the presenting mode of the operation parameters comprises at least one of a pie chart, a bar chart, a curve chart and a table.
In step S1401, a production line operation monitoring page may be designed and developed based on an industrial internet platform, where the operation monitoring page uses a real-time data-driven 3D virtual production line as a core, and a finally generated production line operation monitoring APP may be installed on a terminal device, where the terminal device may be a mobile device, a notebook computer, a desktop computer, a wearable device, or other terminal devices. When the terminal device is a mobile device, the operating system of the terminal may be an IOS operating system or an Android operating system, where the IOS operating system is a proprietary mobile operating system developed by apple for the mobile device.
The page of the production line operation monitoring APP can comprise various products, a virtual simulation production line corresponding to each product and operation parameters such as temperature and humidity corresponding to a virtual simulation environment. Various operating parameters can be displayed in the form of tables and graphs, so that the operating parameters can be updated and presented clearly and intuitively.
In a possible implementation mode, rollback of historical production conditions of each production line can be achieved through production line operation monitoring APP, daily simulation operation data generated by daily real-time operation of virtual simulation production line models in APP pages are analyzed, whether each production line has faults or not is determined, and fault copy reproduction is conducted on a target production line with faults.
Step S1402, the virtual simulation production line model is checked by using test data, wherein the test data is historical data corresponding to an actual production line.
Illustratively, the data output by the PLC may be connected through an OPC UA (OLE for Process Control Unified Architecture) protocol, or a RRS (Simple information aggregation) communication protocol is used to obtain historical data corresponding to devices such as robots and numerical Control machines in the actual production line, where the historical data represents operation data of the actual production line in a past period of time, and the historical data is used to perform test and check on the virtual simulation production line model to verify the simulation effect of the virtual simulation generation line model. And testing the running state of each device in the virtual simulation production line model, wherein the testing can comprise normal working condition detection of the device and fault working condition detection of the device.
In this embodiment, a monitoring method of a production line operation state is provided, which obtains a virtual simulation production line model by modeling and simulating an actual production line, and performs operation monitoring on the virtual simulation production line model loaded with real-time operation data according to the virtual production line operation state and key parameters, so that the operation data and the simulation model are presented synchronously, and the operation difficulty is reduced; the production line operation monitoring APP is generated, the traditional operation monitoring mode is changed, the virtual simulation production line model is embedded into the industrial APP formed by the industrial internet platform, the real-time data of the production line and the 3D model can be combined into a whole, and a new path is provided for the production and manufacturing industrial APP development; the virtual simulation production line model not only can realize production line operation monitoring, but also can simulate production line operation conditions under different discharge capacities and duplicate production line fault states.
Example 3
The present embodiment provides a monitoring system for a production line operation state, as shown in fig. 3, the monitoring system includes: a modeling module 210, a simulation module 220, a driving module 230, and a monitoring module 240.
And the modeling module 210 is used for modeling the actual production line by using simulation software to obtain a three-dimensional model of the production line.
Wherein, this actual production line includes lithium cell lamination assembly line.
In this embodiment, CATIAV6 (a modeling software) may be used to perform three-dimensional simulation modeling on the actual production line, and during the modeling process, in order to enhance the display effect of the three-dimensional model of the production line after modeling and increase the sense of reality, the modeling may be performed according to the size of each device in the actual lithium battery lamination assembly production line, and details such as chamfers and fillets may also be adaptively retained.
Namely, according to the layout and design of the real lithium battery lamination assembly line, the production line is modeled by CATIAV6 production line simulation software, and a three-dimensional model of the production line is generated.
It should be noted that the lithium battery lamination assembly line is an industrial automatic production line in the discrete industry, and generally comprises elements such as a robot, an AGV (Automated Guided Vehicle), a numerical control device, a conveyor belt, a tooling fixture, a product in process, a shelf and the like.
And the simulation model 220 is used for simulating the three-dimensional model of the production line according to the product process and the logistics transmission mode so as to obtain a virtual simulation production line model.
The method comprises the following steps of sequentially carrying out process route simulation on key station main equipment and production line logistics simulation on the logistics transmission state of an actual production line according to a product process so as to obtain a virtual simulation production line model; the process route simulation comprises mechanical equipment definition, robot setting and production line layout planning.
Specifically, the lithium battery lamination assembly production line is divided into two parts, namely a production line and a logistics system, wherein the production line is mainly used for finishing the processing process of products and can comprise a machine table, a mechanical arm and a conveying belt; and the logistics system is responsible for the transfer process of the products in the whole production line. According to the product process, namely, the process requirements of loading, detection, sorting, transportation, lamination, welding and cutting, the subordinate mechanical equipment definition, production line layout planning, robot simulation and human-machine engineering module of a Delmia module in CATIAV6 are adopted to carry out process route simulation on key station main equipment on a production line.
Further, the logistics transmission state of the lithium battery lamination in the automatic assembly line workshop is determined by analyzing the components of the production line processing equipment, the warehouse and the AVG trolley. And according to the logistics transmission state corresponding to the actual production line, carrying out production line logistics simulation by adopting a logistics simulation module subordinate to Delmia so as to generate a virtual simulation production line model.
The driving module 230 is configured to drive the virtual simulation production line model to run in real time along with the actual production line based on real-time running data corresponding to the actual production line, so as to generate a production line virtual production system; and the virtual production line operation state and the key parameters are presented in the virtual production system of the production line in real time.
To drive the operation of the virtual simulation production line model, related simulation operation data needs to be imported, and the simulation operation data can comprise the processing time of products, the delivery capacity of the AGVs, the delivery speed of the AGVs, the distribution quantity of production line equipment and the like. When the setting of the simulation operation data is completed, that is, after the setting of the static data in the virtual simulation production line model is completed, the real-time operation data corresponding to the actual production line is obtained, and the real-time operation data may be the operation data corresponding to the actual production line of 1 hour, 2 hours or 1 day.
It should be noted that, the real-time operation data of each process device in the actual production line may be collected through an industrial gateway docking sensor, a PLC (Programmable Logic Controller), and the like, and the real-time operation data is imported into the industrial internet platform. The industrial internet platform is an industrial cloud platform which supports ubiquitous connection, elastic supply and efficient configuration of manufacturing resources and comprises three core levels, namely an edge layer, a platform layer and an application layer. Real-time operation data access is carried out from an industrial internet platform, a virtual simulation production line model is driven to synchronously operate along with an actual production line based on the real-time operation data access, a virtual production line production system is generated, the virtual production line production system comprises a virtual production line operation state, and the virtual production line operation state can comprise a production line layout state, state information corresponding to the start or stop of a production line and state information corresponding to the start or stop of virtual production line equipment.
The monitoring module 240 performs operation monitoring on the actual production line through the operation state of the virtual production line and the key parameters to determine whether the operation state of each device in the actual production line is normal.
The method comprises the steps of obtaining key parameters from an industrial gateway according to the operation requirements of an actual production line, listing a data list containing the key parameters, determining the monitored key parameters according to the operation requirements of the actual lithium battery lamination assembly production line, and enabling the monitored key parameters to comprise product operation parameters, production line operation parameters and environment state parameters. And monitoring the simulation operation data based on the determined key parameters. For example, if the standard yield a, the standard yield B, and the standard yield C corresponding to the device 1, the device 2, and the device 3 in the virtual simulation production line model are used as key parameters to monitor the actual yield of the device in the actual production line, and determine whether the actual yield of the device 1 reaches the standard yield a, the actual yield of the device 2 reaches the standard yield B, and the actual yield of the device 3 reaches the standard yield C within a preset time period, and if the actual yield of the device 1 does not reach the standard yield a, it is determined that a fault exists in the operation of the device 1.
It should be noted that the key parameters may include product related parameters such as yield, quantity of products being processed, and qualification rate, production line operation related parameters such as utilization rate of each device, failure rate of the device, tempo, capacity, and energy consumption, and environmental state parameters such as temperature and humidity.
In the embodiment, a monitoring system of production line operation state is provided, a virtual simulation production line model is obtained by modeling and simulating an actual production line, the virtual simulation production line model after real-time operation data is loaded is operated and monitored according to the virtual production line operation state and key parameters, the operation data and the simulation model are presented synchronously, the operation difficulty is reduced, furthermore, the efficiency of production line operation monitoring is improved, and a fault copy is reproduced more clearly.
Example 4
The present embodiment is further improved on the basis of embodiment 3, and provides a monitoring system for an operation state of a production line, as shown in fig. 4, the monitoring system includes: the system comprises a modeling module 210, a simulation model 220, a preprocessing module 2201, a driving module 230, a key parameter acquiring module 2301, a monitoring module 240, an operation monitoring APP module 2401 and a checking module 2402.
And the modeling module 210 is used for modeling the actual production line by using simulation software to obtain a three-dimensional model of the production line.
And the simulation module 220 is configured to simulate the three-dimensional model of the production line according to the product process and the logistics transmission manner, so as to obtain a virtual simulation production line model.
The preprocessing module 2201 is used for performing preset processing on the virtual simulation production line model; wherein the preset processing includes at least one of revision processing, lightweight processing, and rendering processing.
Specifically, in order to ensure that the production tacts of the virtual simulation production line corresponding to the same product in the virtual simulation production line model and the actual production line are the same, the virtual simulation production line model needs to be modified to obtain a revised virtual simulation production line.
In this embodiment, the subordinate module of the CATIAV6 software may be used to perform the weight reduction processing and the rendering processing on the virtual simulation production line model, and in addition, the remaining independent software may be used to perform the weight reduction processing and the rendering processing on the model, so that the simulation effect of the model is more vivid.
And the driving module 230 is configured to drive the virtual simulation production line module to run in real time along with the actual production line based on real-time running data corresponding to the actual production line, so as to generate a virtual production line production system, where the virtual production line production system displays a virtual production line running state and key parameters in real time.
The key parameter acquiring module 2301 is configured to acquire a key parameter from a target interface in the industrial gateway.
In this embodiment, the industrial gateway is an industrial data acquisition system, and can conveniently collect data of different data sources and formats of factory enterprises to an industrial cloud server. The industrial gateway may include an analog interface, a serial interface, a USB interface, and an ethernet interface. The simulation interface is connected with an industrial sensor, the serial interface is connected with industrial equipment, the USB interface is connected with USB equipment, and the Ethernet interface is connected with an industrial field bus controller or a wireless communication gateway.
It should be noted that the key parameters may include direct parameters and indirect parameters, the direct parameters may include parameters related to the product and parameters related to the production line, and the indirect parameters may include environmental status parameters.
And the monitoring module 240 is configured to perform operation monitoring on the actual production line through the running state of the virtual production line and the key parameter, so as to determine whether the running state of each device in the actual production line is normal.
The key parameters comprise at least one of product operation parameters, production line operation parameters and environment state parameters; the product operation parameters comprise at least one of yield, product quantity and qualification rate, the production line operation parameters comprise at least one of equipment utilization rate, equipment failure rate, tempo, capacity and energy consumption, and the environment state parameters comprise at least one of temperature and humidity.
An operation monitoring APP module 2401 for generating a production line operation monitoring APP. The production line operation monitoring APP is used for displaying operation parameters corresponding to products, production lines and simulation environments, and the presenting mode of the operation parameters comprises at least one of a pie chart, a bar chart, a curve chart and a table.
In operation control APP module 2401, can produce the design and the development of line operation control page based on industry internet platform, this operation control page is produced the line operation control APP and can be installed on terminal equipment with real-time data driven 3D virtual production as the core, the line operation control APP that produces at last, this terminal equipment can be mobile device, notebook computer, desktop computer, wearable equipment etc. also can be other terminal class equipment. When the terminal device is a mobile device, the operating system of the terminal may be an IOS operating system or an Android operating system, where the IOS operating system is a proprietary mobile operating system developed by apple for the mobile device.
The page of the production line operation monitoring APP can comprise various products, a virtual simulation production line corresponding to each product and operation parameters such as temperature and humidity corresponding to a virtual simulation environment. Various operating parameters can be displayed in the form of tables and graphs, so that the operating parameters can be updated and presented clearly and intuitively.
In a possible implementation mode, rollback of historical production conditions of each production line can be achieved through production line operation monitoring APP, daily simulation operation data generated by daily real-time operation of virtual simulation production line models in APP pages are analyzed, whether each production line has faults or not is determined, and fault copy reproduction is conducted on a target production line with faults.
The verifying module 2402 is configured to verify the virtual simulation production line model by using test data, where the test data is historical data corresponding to an actual production line.
Illustratively, the data output by the PLC may be connected through an OPC UA (OLE for Process Control Unified Architecture) protocol, or a RRS (Simple information aggregation) communication protocol is used to obtain historical data corresponding to devices such as robots and numerical Control machines in the actual production line, where the historical data represents operation data of the actual production line in a past period of time, and the historical data is used to perform test and check on the virtual simulation production line model to verify the simulation effect of the virtual simulation generation line model. And testing the running state of each device in the virtual simulation production line model, wherein the testing can comprise normal working condition detection of the device and fault working condition detection of the device.
In this embodiment, a monitoring system of a production line operation state is provided, which obtains a virtual simulation production line model by modeling and simulating an actual production line, and performs operation monitoring on the virtual simulation production line model loaded with real-time operation data according to the virtual production line operation state and key parameters, so that the operation data and the simulation model are presented synchronously, and the operation difficulty is reduced; the production line operation monitoring APP is generated, the traditional operation monitoring mode is changed, the virtual simulation production line model is embedded into the industrial APP formed by the industrial internet platform, the real-time data of the production line and the 3D model can be combined into a whole, and a new path is provided for the production and manufacturing industrial APP development; the virtual simulation production line model not only can realize production line operation monitoring, but also can simulate production line operation conditions under different discharge capacities and duplicate production line fault states.
Example 5
The present embodiment provides a computer-readable storage medium on which a computer program is stored, the program implementing the steps of the monitoring method of the production line operation state of embodiment 1 or embodiment 2 when executed by a processor.
More specific examples, among others, that the readable storage medium may employ may include, but are not limited to: a portable disk, a hard disk, random access memory, read only memory, erasable programmable read only memory, optical storage device, magnetic storage device, or any suitable combination of the foregoing.
In a possible implementation, the invention can also be implemented in the form of a program product comprising program code for causing a terminal device to carry out the steps of the method for monitoring the operational status of a production line implementing embodiment 1 or embodiment 2, when said program product is run on said terminal device.
Where program code for carrying out the invention is written in any combination of one or more programming languages, the program code may be executed entirely on the user device, partly on the user device, as a stand-alone software package, partly on the user device and partly on a remote device or entirely on the remote device.
Example 6
Fig. 5 is a schematic structural diagram of an electronic device provided in this embodiment. The electronic device includes a memory, a processor and a computer program stored in the memory and running on the processor, and the processor executes the program to implement the method for monitoring the operation status of the production line according to embodiment 1 or embodiment 2, and the electronic device 30 shown in fig. 5 is only an example and should not bring any limitation to the function and the scope of the embodiment of the present invention.
The electronic device 30 may be embodied in the form of a general purpose computing device, which may be, for example, a server device. The components of the electronic device 30 may include, but are not limited to: the at least one processor 31, the at least one memory 32, and a bus 33 connecting the various system components (including the memory 32 and the processor 31).
The bus 33 includes a data bus, an address bus, and a control bus.
The memory 32 may include volatile memory, such as Random Access Memory (RAM)321 and/or cache memory 322, and may further include Read Only Memory (ROM) 323.
The processor 31 executes various functional applications and data processing, such as a monitoring method of the operation state of the production line of embodiment 1 or embodiment 2 of the present invention, by running the computer program stored in the memory 32.
The electronic device 30 may also communicate with one or more external devices 34 (e.g., keyboard, pointing device, etc.). Such communication may be through input/output (I/O) interfaces 35. Also, model-generating device 30 may also communicate with one or more networks (e.g., a Local Area Network (LAN), a Wide Area Network (WAN), and/or a public network, such as the Internet) via network adapter 36. As shown, network adapter 36 communicates with the other modules of model-generating device 30 via bus 33. It should be understood that although not shown in the figures, other hardware and/or software modules may be used in conjunction with the model-generating device 30, including but not limited to: microcode, device drivers, redundant processors, external disk drive arrays, RAID (disk array) systems, tape drives, and data backup storage systems, etc.
It should be noted that although in the above detailed description several units/modules or sub-units/modules of the electronic device are mentioned, such a division is merely exemplary and not mandatory. Indeed, the features and functionality of two or more of the units/modules described above may be embodied in one unit/module according to embodiments of the invention. Conversely, the features and functions of one unit/module described above may be further divided into embodiments by a plurality of units/modules.
While specific embodiments of the invention have been described above, it will be appreciated by those skilled in the art that this is by way of example only, and that the scope of the invention is defined by the appended claims. Various changes and modifications to these embodiments may be made by those skilled in the art without departing from the spirit and scope of the invention, and these changes and modifications are within the scope of the invention.
Claims (12)
1. A monitoring method for the operation state of a production line is characterized by comprising the following steps:
modeling an actual production line by using simulation software to obtain a three-dimensional model of the production line;
simulating the three-dimensional model of the production line according to the product process and the logistics transmission mode to obtain a virtual simulation production line model;
driving the virtual simulation production line model to run in real time along with the actual production line based on real-time running data corresponding to the actual production line to generate a production line virtual production system; the virtual production line virtual production system is used for displaying the running state and key parameters of a virtual production line in real time;
and carrying out operation monitoring on the actual production line through the running state of the virtual production line and the key parameters so as to determine whether the running state of each device in the actual production line is normal.
2. The monitoring method for the operating state of the production line according to claim 1, wherein the monitoring method further comprises:
and generating a production line operation monitoring APP, wherein the production line operation monitoring APP is used for displaying operation parameters corresponding to a product, a production line and a simulation environment, and the presenting mode of the operation parameters comprises at least one of a pie chart, a bar chart, a curve chart and a table.
3. The method for monitoring the operation status of the production line according to claim 1, wherein the step of simulating the three-dimensional model of the production line according to the product process and the logistics transportation manner to obtain the virtual simulation production line model comprises:
sequentially carrying out process route simulation on key station main equipment according to a product process and carrying out production line logistics simulation on the logistics transmission state of the actual production line so as to obtain a virtual simulation production line model; the process route simulation comprises mechanical equipment definition, robot setting and production line layout planning.
4. The monitoring method for the operating state of the production line according to claim 3, wherein the monitoring method further comprises:
presetting the virtual simulation production line model; wherein the preset processing includes at least one of revision processing, lightweight processing, and rendering processing.
5. The method for monitoring the operating status of the production line according to claim 1, wherein the key parameters include at least one of product operating parameters, production line operating parameters and environmental status parameters; the product operation parameters comprise at least one of yield, product quantity and qualification rate, the production line operation parameters comprise at least one of equipment utilization rate, equipment failure rate, tempo, capacity and energy consumption, and the environment state parameters comprise at least one of temperature and humidity;
and/or;
the monitoring method further comprises the following steps: testing the virtual simulation production line model by using test data, wherein the test data is historical data corresponding to the actual production line;
and/or;
the monitoring method further comprises the following steps: acquiring the key parameters from a target interface in the industrial gateway, wherein the target interface comprises a simulation interface, a serial interface, a USB interface and an Ethernet interface; the simulation interface is connected with an industrial sensor, the serial interface is connected with industrial equipment, the USB interface is connected with USB equipment, and the Ethernet interface is connected with an industrial field bus controller or a wireless communication gateway;
and/or;
the actual production line comprises a lithium battery lamination assembly production line.
6. A monitoring system for monitoring an operational status of a production line, the monitoring system comprising:
the modeling module is used for modeling the actual production line by utilizing simulation software so as to obtain a three-dimensional model of the production line;
the simulation module is used for simulating the three-dimensional model of the production line according to the product process and the logistics transmission mode so as to obtain a virtual simulation production line model;
the driving module is used for driving the virtual simulation production line model to run in real time along with the actual production line based on real-time running data corresponding to the actual production line so as to generate a production line virtual production system; the virtual production line virtual production system is used for displaying the running state and key parameters of a virtual production line in real time;
and the monitoring module is used for carrying out operation monitoring on the actual production line through the running state of the virtual production line and the key parameters so as to determine whether the running state of each device in the actual production line is normal or not.
7. The monitoring system for the operating state of the production line as set forth in claim 6, wherein the monitoring system further comprises:
the operation monitoring APP module is used for generating a production line operation monitoring APP, the production line operation monitoring APP is used for displaying operation parameters corresponding to products, production lines and simulation environments, and the presenting mode of the operation parameters comprises at least one of a pie chart, a bar chart, a curve chart and a table.
8. The system for monitoring the operating state of the production line according to claim 6, wherein the simulation module is specifically configured to:
sequentially carrying out process route simulation on key station main equipment according to a product process and carrying out production line logistics simulation on the logistics transmission state of the actual production line so as to obtain a virtual simulation production line model; the process route simulation comprises mechanical equipment definition, robot setting and production line layout planning.
9. The monitoring system for the operating state of the production line as set forth in claim 8, wherein the monitoring system further comprises:
the preprocessing module is used for carrying out preset processing on the virtual simulation production line model; wherein the preset processing includes at least one of revision processing, lightweight processing, and rendering processing.
10. The system for monitoring the operating status of a production line as set forth in claim 6, wherein the key parameters include at least one of product operating parameters, production line operating parameters, and environmental status parameters; the product operation parameters comprise at least one of yield, product quantity and qualification rate, the production line operation parameters comprise at least one of equipment utilization rate, equipment failure rate, tempo, capacity and energy consumption, and the environment state parameters comprise at least one of temperature and humidity;
and/or;
the monitoring system further comprises: the inspection module is used for inspecting the virtual simulation production line model by using test data, wherein the test data is historical data corresponding to the actual production line;
and/or;
the monitoring system further comprises: the key parameter acquisition module is used for acquiring the key parameters from a target interface in the industrial gateway, wherein the target interface comprises an analog interface, a serial interface, a USB interface and an Ethernet interface; the simulation interface is connected with an industrial sensor, the serial interface is connected with industrial equipment, the USB interface is connected with USB equipment, and the Ethernet interface is connected with an industrial field bus controller or a wireless communication gateway;
and/or;
the actual production line comprises a lithium battery lamination assembly production line.
11. A computer-readable storage medium, characterized in that the computer-readable storage medium has stored thereon a computer program which, when being executed by a processor, carries out the steps of the method for monitoring the operational status of a production line according to any one of claims 1 to 5.
12. An electronic device, characterized by a computer program comprising a processor, a memory and a computer stored on the memory and operable on the processor, the computer program, when executed by the processor, implementing the monitoring method of the production line operational status according to any one of claims 1-5.
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