CN113837723A - Train buffer production line master control management system and management method based on PLC - Google Patents
Train buffer production line master control management system and management method based on PLC Download PDFInfo
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Abstract
The invention discloses a train buffer production line master control management system and a management method based on a PLC (programmable logic controller), wherein the system comprises a production line main flow module, a station material management module and an auxiliary function module which are arranged on the production line master control PLC, the production line main flow module is used as a framework, the station material management module and the auxiliary function module are connected to the production line main flow module through corresponding interface programs, the production line main flow module ensures the normal production flow of a production line, the station material management module ensures the material supply of a production line side library, and the auxiliary function module provides corresponding order management and safety control guarantee; the production line master control management system is also provided with an MES system and a three-dimensional library system; the system and the method disclosed by the invention can intuitively and specifically reflect the execution condition of each process of the production line and the actual use condition of each material, so that the process of the production line is executed more smoothly and efficiently, and the intelligent level of the automatic production line of the buffer is improved.
Description
Technical Field
The invention relates to the field of production line management, in particular to a train buffer production line master control management system and method based on a PLC.
Background
With the rapid development of the society, the freight train becomes the first choice of large-tonnage and long-distance transportation, the buffer production on the current freight train is still the traditional manual production, the intelligent, informatization and automation degree is lower, and the following problems mainly exist:
the front and back connection among all the assembly processes is not smooth, and the beat is not balanced enough when the system cannot count the process usage; the records of the use condition of the materials are disordered and cannot be automatically recorded and uploaded to a system; characters cast on the surface of the buffer box body need to be checked to be repeated, and the risk of missing and wrong checking exists in manual checking; at present, pressure data of a press cannot be read and recorded, size data of a box body needs to be manually measured and recorded, and the error is large; materials used for assembly need to be manually conveyed to an assembly area, and empty pallets after use need to be manually pulled away and stacked, so that time and labor are wasted; whether the material model is correct or not cannot be confirmed, and the situation of assembling wrong materials may exist; the box body tracing one-dimensional code needs to be manually printed and then manually pasted on the box body, and the efficiency is low.
Therefore, a general control management system and a management method for a train buffer production line are needed to solve the above problems.
Disclosure of Invention
In order to solve the technical problems, the invention provides a train buffer production line master control management system and a train buffer production line master control management method based on a PLC (programmable logic controller), so that the aims of automatically controlling the whole production process of a train buffer and improving the production efficiency and automation, intellectualization and informatization are fulfilled.
In order to achieve the purpose, the technical scheme of the invention is as follows:
a train buffer production line master control management system based on a PLC comprises a production line main flow module, a station material management module and an auxiliary function module, wherein the production line main flow module, the station material management module and the auxiliary function module are arranged on the production line master control PLC and are used as frameworks; the production line master control management system is also provided with an MES system for providing work order management support and a three-dimensional library system for providing material management support;
the production line main process module comprises: the system comprises a production line starting unit, a work order application unit, a material utilization work reporting unit, a work order storage unit, a source tracing one-dimensional code application unit, an OCR character verification unit, a size measurement unit and a finished product offline unit;
the station material management module comprises: the automatic tray loading and unloading system comprises an AGV material distribution unit, a material checking unit, an empty tray checking unit, an AGV empty tray taking unit, an AGV full tray notification unit and an empty tray stacking unit;
the auxiliary unit module includes: the system comprises a production line hardware alarm unit, a production line software alarm unit, an order hanging releasing unit, a press data collecting unit and a safety control unit.
In the above scheme, the production line start-up unit is used for start-up control of the stations of the whole production line, and includes issuing order numbers, buffer models and yield information to the stations;
in the application work order dispatching unit, in production line production, a buffer of an order has an order number, each buffer has an independent work order number, and each work order has a unique work order number on each station and is used for recording the identity information of the buffer assembled by the stations;
the material reporting unit is used for reporting the number of materials used for assembling one buffer by stations;
the work station is used for recording a qualified/unqualified result after the assembly process of one buffer is completed;
the source tracing one-dimensional code application unit is used for automatically printing and pasting the buffer source tracing one-dimensional code;
the OCR character checking unit is used for automatically identifying, checking and recording characters cast on the surface of the buffer;
the size measuring unit is used for measuring the length, width, height and parallelism data of the buffer by a special measuring machine after all the processes of the buffer are assembled;
and the finished product offline unit is used for recording the positions where the assembled buffers are placed, and comprises a qualified tray, a spot check tray and an unqualified tray.
In the scheme, the AGV material distribution unit is used for the AGV to distribute materials or empty trays to the line side warehouse so as to be convenient for station use;
the material checking unit is used for checking the materials before use, and if the materials are not matched with the buffer model, the materials need to be delivered again;
the empty tray checking unit is used for checking whether the materials in the tray of the line side warehouse are used up or not, so that the situation that the tray is provided with residual materials is prevented;
the AGV empty tray taking unit is used for calling the AGV to take the empty trays of the line side library;
the AGV full tray notification unit is used for calling the AGV to take away the tray which is fully stacked with the off-line position codes;
empty support pile up neatly unit for after empty tray was taken away to AGV, pile up the tray together in classification on the hacking machine to convenient cycle uses.
In the above scheme, the production line hardware fault unit is configured to monitor fault information of all hardware devices of the production line and prompt a maintenance department;
the production line software alarm unit is used for processing some predictable faults and errors in the normal production process of the production line and informing a production line management department;
the order suspending unit is used for suspending the orders which are in production and are not finished and storing data so as to start the production of another type of buffer temporarily;
the order hang-off unit is used for restarting orders which are stored in the system and are not produced, and the system continues to produce the information of the model number of the buffer and the number of the dispatching order when the orders are hung up continuously;
the press data acquisition unit is used for acquiring pressure-displacement data of the press during press mounting of the spring and judging whether the quality of the spring is qualified;
and the safety control unit is used for controlling the emergency stop of the high-risk equipment and controlling the emergency power-off of the high-risk equipment through the state of the safety element.
A train buffer production line master control management method based on PLC comprises the following steps:
(1) the master control PLC sends a production line start instruction through a production line start unit;
(2) the work order applying unit starts to apply for a work order, a work station starts after receiving the work order, the buffer box body is grabbed from the tray and moves to the front of the OCR camera; after the OCR camera scans the characters cast on the surface of the box body, the OCR character verification unit starts OCR verification, after the OCR character verification is finished, the buffer box body is placed on the turntable, and the tracing one-dimensional code application unit starts to apply for tracing one-dimensional code printing and paste the tracing one-dimensional code printing on the box body; after the pasting is finished, the work of a station is finished, at the moment, the material reporting unit starts to report the material, and the number of the used buffer boxes is reported to the master control PLC; then, the work order unit is stored to store the work orders;
(3) the buffer box body is transferred to a second station through a rotary table, a work order application unit starts to apply a work order, the second station is started after receiving the work order, an angle spring seat, an outer circle spring, an inner circle spring and a spring seat are assembled manually, a material using work reporting unit is triggered through a button after the assembly is finished, the used material quantity is reported to a master control PLC, and then the work order unit is stored for storing the work order;
(4) the buffer box body is transferred to three stations through a manipulator, a work order application unit starts to apply a work order, the three stations are started after receiving the work order, a press presses a spring to a certain position, and a pin rod is inserted into the buffer shell; in the pressing process, the press data is recorded every 0.5s by the press data acquisition unit, and the pressure-displacement data of the press is recorded and drawn into a curve to judge whether the spring is qualified or not; after the press mounting is finished, the dispatching order unit is stored to store the dispatching order;
(5) the buffer box body is transferred to four stations through a transfer mechanism, a work order application unit starts to apply a work order, the four stations are started after receiving the work order, an outer fixing plate, a fixed inclined plate, a restoring spring and a central wedge block are assembled by a robot, a material using work reporting unit is automatically triggered after the assembly is finished, the number of used materials is reported to a master control PLC, and then the work order unit is stored for storing the work order;
(6) the buffer box body is transferred to five stations through a production line, a work order application unit starts to apply a work order, the five stations are started after receiving the work order, the wedge block, the movable plate and the short pin are assembled manually, the material use reporting unit is triggered through a button after the assembly is finished, the used material quantity is reported to a master control PLC, and then the work order unit is stored for storing the work order;
(7) the buffer box body is transferred to six stations through a transfer mechanism, a work order application unit starts to apply a work order, the six stations are started after receiving the work order, a press presses a spring to a proper position through a pressing center wedge block and pulls out a pin rod, in the pressing process, a press data unit is collected to record press data every 0.5s, the pressure-displacement data of the press is recorded and drawn into a curve to judge whether assembled materials of an outer fixing plate, a fixed inclined plate and a movable plate are qualified or not, and then the work order unit is stored to store the work order;
(8) the buffer box shifts to seven stations through C type module, apply for the work order unit and begin to apply for the work order, seven stations receive and start after the work order, grab the box of accomplishing the equipment by the robot and measure in the special plane, the length and width height and the movable plate depth of parallelism data of test box, and grab the buffer box on the tray that corresponds according to measuring result, the code wheel is accomplished and is triggered finished product off-line unit, with buffer size data, the tray type of placing, pass to total accuse PLC on the tray number, then trigger and preserve the work order unit, whether qualified with the buffer, during the station time information preserves corresponding work order information.
Through the technical scheme, the train buffer production line master control management system and the train buffer production line master control management method based on the PLC have the following beneficial effects:
1. the stations can be connected smoothly, and the station time can be counted according to the dispatching list completion time so as to balance the beat;
2. the material use condition and the assembly completion condition can be automatically uploaded;
3. automatically identifying characters on the surface of the box body, and uploading the characters to a system for verification;
4. automatically recording and uploading pressure data of a press and size data of a box body;
5. automatic material distribution, automatic empty support taking and stacking;
6. automatically checking whether the material model is correct;
7. and automatically printing the tracing one-dimensional code and pasting the tracing one-dimensional code on the box body.
Through the cooperative work of all functional units in the main production line process module, the station material management module and the auxiliary functional module in the master control management system, the production process of the whole train buffer can be more automated, intelligent and informationized.
The invention provides production line management work by adopting the function similar to an MES system based on the PLC, so as to exert the advantages of high efficiency and high reliability of the PLC and improve the stability of a production line control system. The production line flow management, the material management and the safety management are applied to the automatic production line of the buffer, the execution conditions of all the production lines and the actual use conditions of all the materials can be visually and specifically reflected, the production line flow execution is smoother and more efficient, and the intelligent level of the automatic production line of the buffer is improved.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below.
Fig. 1 is a schematic diagram illustrating a PLC-based train buffer production line master control management system according to an embodiment of the present invention;
fig. 2 is a schematic flow chart of a master control management method for a train buffer production line based on a PLC according to an embodiment of the present invention;
FIG. 3 is a flowchart of a product offline according to an embodiment of the present invention;
FIG. 4 is a flowchart illustrating the management of work position materials according to an embodiment of the present invention.
Detailed Description
The technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention.
The invention provides a PLC-based train buffer production line master control management system, which comprises a production line main flow module, a station material management module and an auxiliary function module which are arranged on the production line master control PLC, wherein the production line main flow module is used as a framework, the station material management module and the auxiliary function module are connected to the production line main flow module through corresponding interface programs, the production line main flow module ensures the normal production flow of a production line, the station material management module ensures the timely and sufficient material supply of a production line side library, and the auxiliary function module provides corresponding order management and safety control guarantee; the production line master control management system is also provided with an MES system for providing work order management support and a three-dimensional library system for providing material management support. All module functions of the system are embodied on the touch screen, and the characteristics of informatization, intellectualization and automation are considered.
Production line main process module
The production line main process module comprises: the production line start unit, the application dispatch list unit, the material use dispatch list unit, the storage dispatch list unit, the source tracing one-dimensional code application unit, the OCR character verification unit, the size measurement unit and the finished product offline unit.
The production line start-up unit is used for start-up control of the stations of the whole production line and sends information including order numbers, buffer models, yield and the like to the stations;
applying for a work order dispatching unit, wherein in production line production, if 500 buffers are set as an order, the 500 buffers have an order number, each buffer has an independent work order number, and each work order has a unique work order number on each station and is used for recording the identity information of the buffers assembled by the stations;
the material reporting unit is used for reporting the number of materials used for assembling one buffer in a station;
the work order storage unit is used for recording a qualified/unqualified result after the work station finishes the assembly process of one buffer;
the source tracing one-dimensional code application unit is used for automatically printing and pasting the buffer source tracing one-dimensional code;
the OCR character checking unit is used for automatically identifying, checking and recording characters cast on the surface of the buffer;
the size measuring unit is used for measuring the length, width, height and parallelism data of the buffer by a special measuring machine after all the processes of the buffer are assembled;
and the finished product offline unit is used for recording the positions where the assembled buffers are placed, and comprises a qualified tray, a spot check tray and an unqualified tray.
Second, station material management module
The station material management module comprises: the automatic guided vehicle comprises an AGV material distribution unit, a material checking unit, an empty tray checking unit, an AGV empty tray taking unit, an AGV full tray informing unit and an empty tray stacking unit.
The AGV material distribution unit is used for the AGV to distribute materials or empty trays to the line side warehouse so as to be convenient for station use;
the material checking unit is used for checking the materials before use, and if the materials are not matched with the buffer model, the materials need to be delivered again;
the empty tray checking unit is used for checking whether the materials in the tray of the line side warehouse are used up or not, so that the situation that the tray is provided with residual materials is prevented;
the AGV empty tray taking unit is used for calling the AGV to take the empty trays of the line side library;
an AGV full tray notification unit used for calling the AGV to take away the tray which is fully stacked with the off-line position codes;
and the empty-support stacking unit is used for piling the trays together on the stacking machine in a classified manner after the empty trays are taken away by the AGV, so that the empty-support stacking unit is convenient to recycle.
Third, auxiliary unit module
The auxiliary unit module includes: the system comprises a production line hardware alarm unit, a production line software alarm unit, an order hanging releasing unit, a press data collecting unit and a safety control unit.
The production line hardware fault unit is used for monitoring fault information of all hardware equipment of the production line and prompting an overhaul department;
the production line software alarm unit is used for processing some predictable faults and errors in the normal production process of the production line and informing the management department of the production line;
the order suspending unit is used for suspending the orders which are in production and are not finished and storing the data so as to start the production of the buffer of another model temporarily;
the order hang-off unit is used for restarting orders which are stored in the system and are not produced, and the system continues to produce the information of the model number of the buffer and the number of the dispatching order when the orders are hung up continuously;
the press data acquisition unit is used for acquiring pressure-displacement data of the press during spring press-mounting and judging whether the spring quality is qualified or not;
and the safety control unit is used for controlling the emergency stop of high-risk equipment such as a mechanical arm, a press and the like and controlling the emergency power-off of the high-risk equipment through the states of safety elements such as a safety door lock, a safety grating and the like.
A train buffer production line master control management method based on PLC is disclosed, as shown in FIG. 2, and comprises the following steps:
(1) after the automatic buffer assembly production line is started, firstly, the order number, the buffer model number and the order number are issued to each station through the production line start unit by the master control PLC, and the production line is indicated to start production.
(2) The work order applying unit starts to apply for a work order, a work station starts after receiving the work order, the buffer box body is grabbed from the tray and moves to the front of the OCR camera; after the OCR camera scans the characters cast on the surface of the box body, the OCR character verification unit starts OCR verification, after the OCR character verification is finished, the buffer box body is placed on the turntable, and the tracing one-dimensional code application unit starts to apply for tracing one-dimensional code printing and paste the tracing one-dimensional code printing on the box body; after the pasting is finished, the work of a station is finished, at the moment, the material reporting unit starts to report the material, and the number of the used buffer boxes is reported to the master control PLC; then, the work order storage unit stores the work orders, including whether the work orders are qualified, the time for the work station, the tray number corresponding to the box body and other information, into the corresponding work order information;
(3) the buffer box body is transferred to a second station through a rotary table, a work order applying unit starts to apply a work order, the second station is started after receiving the work order, a corner spring seat, an outer circle spring, an inner circle spring and a spring seat are assembled manually, a material use material reporting unit is triggered through a button after the assembly is finished, the used material quantity is reported to a master control PLC, then the work order applying unit is triggered and stored in sequence, and information such as whether the work order is qualified, when the work station is used, a tray number corresponding to the material and the like is stored in corresponding work order information;
(4) the buffer box body is transferred to three stations through a manipulator, a work order application unit starts to apply a work order, the three stations are started after receiving the work order, a press presses a spring to a certain position, and a pin rod is inserted into the buffer shell; in the pressing process, the press data is recorded every 0.5s by the press data acquisition unit, and the pressure-displacement data of the press is recorded and drawn into a curve to judge whether the spring is qualified or not; after the press mounting is finished, triggering and storing a work order dispatching unit, and storing information such as whether the work order is qualified or not, station time and the like into corresponding work order information;
(5) the buffer box body is transferred to a quadruplex position through a transfer mechanism, a work order application unit starts to apply a work order, the quadruplex position is started after receiving the work order, an outer fixing plate, a fixed inclined plate, a return spring and a central wedge block are assembled by a robot, a material use work reporting unit is automatically triggered after the assembly is finished, the used material quantity is reported to a master control PLC, then the work order storage unit is sequentially triggered, and information such as whether the work order is qualified, when the work position is used, a tray number corresponding to the material and the like is stored in corresponding work order information;
(6) the buffer box body is transferred to five stations through a production line, a work order applying unit starts to apply a work order, the five stations are started after receiving the work order, a wedge block, a movable plate and a short pin are assembled manually, a material using and reporting unit is triggered through a button after the assembly is finished, the used material quantity is reported to a master control PLC, then the work order storing unit is triggered and stored sequentially, and information such as whether the work order is qualified, the work station is used, and a tray number corresponding to the material is stored in corresponding work order information;
(7) the buffer box body is transferred to six stations through a transfer mechanism, a work order application unit starts to apply a work order, the six stations are started after receiving the work order, a press presses a spring to a proper position through a pressing center wedge block and pulls out a pin rod, in the pressing process, a press data unit is collected every 0.5s to record press data, the pressure-displacement data of the press is recorded and drawn into a curve to judge whether the assembled outer fixing plate, fixed inclined plate and movable plate materials are qualified or not, the work order application unit is triggered and stored, and information such as whether the assembled outer fixing plate, fixed inclined plate and movable plate materials are qualified or not, and the work order application time is stored into corresponding work order information;
(8) the buffer box shifts to seven stations through C type module, apply for the work order unit and begin to apply for the work order, seven stations receive and start after the work order, grab the box of accomplishing the equipment by the robot and measure in the special plane, the length and width height and the movable plate depth of parallelism data of test box, and grab the buffer box on the tray that corresponds according to measuring result, the code wheel is accomplished and is triggered finished product off-line unit, with buffer size data, the tray type of placing, pass to total accuse PLC on the tray number, then trigger and preserve the work order unit, whether qualified with the buffer, during the station time information preserves corresponding work order information.
In fig. 3, after the production line is started, if seven stations detect that there is no empty tray, an empty tray is automatically delivered to the station side library by the AGV, so that the stations can place the finished product buffer; when the tray is full, the master control initiates an AGV full tray notification, calls the AGV to take the full tray away and place the full tray in a specified finished product area, and then delivers an empty tray to the station side library so as to place the buffer in the station.
In fig. 4, after production line is started, at first, the AGV delivers all the materials required for production to the station line side library, after the station receives the tray, the tray number (one-dimensional code) is scanned through the code scanner, then material verification is initiated, the master control system compares the material model number contained in the tray number of the stereo library system by inquiring the database in the system, the matching is successful, the materials are correct, the station can be used, otherwise, the AGV is called to take the materials away, and new materials are delivered again. After the material of the line side warehouse tray is used up by the station, the main control system checks whether the tray has residual materials through the empty tray checking unit, if no residual materials exist, the AGV is called to take the empty tray away, and the empty tray is stacked on the stacker crane through the empty tray stacking function.
The master control system monitors fault information of all hardware equipment of the production line through a production line hardware fault unit, prompts a maintenance department to repair the equipment in time when the hardware of the equipment is in fault, and displays the fault information and a solution method;
the production line software alarm unit prompts some predictable faults and error handling in the normal production process of the production line, such as material verification failure or robot operation fault and the like, and informs a production line management department or a production line operator to handle the faults in time;
through the order hanging unit and the order hanging-off unit, a temporary emergent production task can be inserted into a normal production task, the information of the original order is stored in the system, and the production plan of the original order can be recovered after the order of the temporary queue is produced;
through the safety control unit, can gather safety equipment information such as safe PLC and safety relay, safety door lock to in case safety equipment detects the state change, total control system accessible safety control module immediately with equipment outage processing such as arm, the press that correspond through easy wounded's equipment such as safety information control manipulator, press, with prevent to take place personal harm.
The previous description of the disclosed embodiments is provided to enable any person skilled in the art to make or use the present invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the present invention is not intended to be limited to the embodiments shown herein but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.
Claims (5)
1. A train buffer production line master control management system based on a PLC is characterized by comprising a production line main flow module, a station material management module and an auxiliary function module, wherein the production line main flow module, the station material management module and the auxiliary function module are arranged on the production line master control PLC and are used as frameworks; the production line master control management system is also provided with an MES system for providing work order management support and a three-dimensional library system for providing material management support;
the production line main process module comprises: the system comprises a production line starting unit, a work order application unit, a material utilization work reporting unit, a work order storage unit, a source tracing one-dimensional code application unit, an OCR character verification unit, a size measurement unit and a finished product offline unit;
the station material management module comprises: the automatic tray loading and unloading system comprises an AGV material distribution unit, a material checking unit, an empty tray checking unit, an AGV empty tray taking unit, an AGV full tray notification unit and an empty tray stacking unit;
the auxiliary unit module includes: the system comprises a production line hardware alarm unit, a production line software alarm unit, an order hanging releasing unit, a press data collecting unit and a safety control unit.
2. The PLC-based train buffer production line master control management system as claimed in claim 1, wherein the production line start-up unit is used for start-up control of stations of the whole production line, and comprises an order number, a buffer model number and output information which are issued to the stations;
in the application work order dispatching unit, in production line production, a buffer of an order has an order number, each buffer has an independent work order number, and each work order has a unique work order number on each station and is used for recording the identity information of the buffer assembled by the stations;
the material reporting unit is used for reporting the number of materials used for assembling one buffer by stations;
the work station is used for recording a qualified/unqualified result after the assembly process of one buffer is completed;
the source tracing one-dimensional code application unit is used for automatically printing and pasting the buffer source tracing one-dimensional code;
the OCR character checking unit is used for automatically identifying, checking and recording characters cast on the surface of the buffer;
the size measuring unit is used for measuring the length, width, height and parallelism data of the buffer by a special measuring machine after all the processes of the buffer are assembled;
and the finished product offline unit is used for recording the positions where the assembled buffers are placed, and comprises a qualified tray, a spot check tray and an unqualified tray.
3. The PLC-based train buffer production line master control management system as claimed in claim 1, wherein the AGV material distribution unit is used for AGV distributing materials or empty trays to a line side warehouse for convenient station use;
the material checking unit is used for checking the materials before use, and if the materials are not matched with the buffer model, the materials need to be delivered again;
the empty tray checking unit is used for checking whether the materials in the tray of the line side warehouse are used up or not, so that the situation that the tray is provided with residual materials is prevented;
the AGV empty tray taking unit is used for calling the AGV to take the empty trays of the line side library;
the AGV full tray notification unit is used for calling the AGV to take away the tray which is fully stacked with the off-line position codes;
empty support pile up neatly unit for after empty tray was taken away to AGV, pile up the tray together in classification on the hacking machine to convenient cycle uses.
4. The PLC-based train buffer production line master control management system as claimed in claim 1, wherein the production line hardware fault unit is configured to monitor fault information of all hardware devices in a production line and prompt a maintenance department;
the production line software alarm unit is used for processing some predictable faults and errors in the normal production process of the production line and informing a production line management department;
the order suspending unit is used for suspending the orders which are in production and are not finished and storing data so as to start the production of another type of buffer temporarily;
the order hang-off unit is used for restarting orders which are stored in the system and are not produced, and the system continues to produce the information of the model number of the buffer and the number of the dispatching order when the orders are hung up continuously;
the press data acquisition unit is used for acquiring pressure-displacement data of the press during press mounting of the spring and judging whether the quality of the spring is qualified;
and the safety control unit is used for controlling the emergency stop of the high-risk equipment and controlling the emergency power-off of the high-risk equipment through the state of the safety element.
5. The management method of the PLC-based train buffer production line master control management system according to claim 1, comprising the following steps:
(1) the master control PLC sends a production line start instruction through a production line start unit;
(2) the work order applying unit starts to apply for a work order, a work station starts after receiving the work order, the buffer box body is grabbed from the tray and moves to the front of the OCR camera; after the OCR camera scans the characters cast on the surface of the box body, the OCR character verification unit starts OCR verification, after the OCR character verification is finished, the buffer box body is placed on the turntable, and the tracing one-dimensional code application unit starts to apply for tracing one-dimensional code printing and paste the tracing one-dimensional code printing on the box body; after the pasting is finished, the work of a station is finished, at the moment, the material reporting unit starts to report the material, and the number of the used buffer boxes is reported to the master control PLC; then, the work order unit is stored to store the work orders;
(3) the buffer box body is transferred to a second station through a rotary table, a work order application unit starts to apply a work order, the second station is started after receiving the work order, an angle spring seat, an outer circle spring, an inner circle spring and a spring seat are assembled manually, a material using work reporting unit is triggered through a button after the assembly is finished, the used material quantity is reported to a master control PLC, and then the work order unit is stored for storing the work order;
(4) the buffer box body is transferred to three stations through a manipulator, a work order application unit starts to apply a work order, the three stations are started after receiving the work order, a press presses a spring to a certain position, and a pin rod is inserted into the buffer shell; in the pressing process, the press data is recorded every 0.5s by the press data acquisition unit, and the pressure-displacement data of the press is recorded and drawn into a curve to judge whether the spring is qualified or not; after the press mounting is finished, the dispatching order unit is stored to store the dispatching order;
(5) the buffer box body is transferred to four stations through a transfer mechanism, a work order application unit starts to apply a work order, the four stations are started after receiving the work order, an outer fixing plate, a fixed inclined plate, a restoring spring and a central wedge block are assembled by a robot, a material using work reporting unit is automatically triggered after the assembly is finished, the number of used materials is reported to a master control PLC, and then the work order unit is stored for storing the work order;
(6) the buffer box body is transferred to five stations through a production line, a work order application unit starts to apply a work order, the five stations are started after receiving the work order, the wedge block, the movable plate and the short pin are assembled manually, the material use reporting unit is triggered through a button after the assembly is finished, the used material quantity is reported to a master control PLC, and then the work order unit is stored for storing the work order;
(7) the buffer box body is transferred to six stations through a transfer mechanism, a work order application unit starts to apply a work order, the six stations are started after receiving the work order, a press presses a spring to a proper position through a pressing center wedge block and pulls out a pin rod, in the pressing process, a press data unit is collected to record press data every 0.5s, the pressure-displacement data of the press is recorded and drawn into a curve to judge whether assembled materials of an outer fixing plate, a fixed inclined plate and a movable plate are qualified or not, and then the work order unit is stored to store the work order;
(8) the buffer box shifts to seven stations through C type module, apply for the work order unit and begin to apply for the work order, seven stations receive and start after the work order, grab the box of accomplishing the equipment by the robot and measure in the special plane, the length and width height and the movable plate depth of parallelism data of test box, and grab the buffer box on the tray that corresponds according to measuring result, the code wheel is accomplished and is triggered finished product off-line unit, with buffer size data, the tray type of placing, pass to total accuse PLC on the tray number, then trigger and preserve the work order unit, whether qualified with the buffer, during the station time information preserves corresponding work order information.
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