CN113837723B - 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, wherein the system comprises a production line master flow module, a station material management module and an auxiliary function module which are deployed on the production line master control PLC, wherein the production line master flow module is used as a framework, the station material management module and the auxiliary function module are connected to the production line master flow module through corresponding interface programs, the production line master 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 flow of the production line and the actual use condition of various materials, so that the flow execution of the production line is smoother and more efficient, 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 PLC.
Background
Along with the high-speed development of society, freight trains become the first choice for large-tonnage and long-distance transportation, and the production of buffers on freight trains is still traditional artificial production at present, and the intelligent, informationized and automatic degrees are low, so that the following problems mainly exist:
the front and back connection between the assembly procedures is not smooth, and when the system cannot count the procedure, the beat is not balanced enough; the material service condition is recorded in disorder and can not be recorded and uploaded to the system automatically; the characters cast on the surface of the buffer box body need to be checked whether to be repeated or not, and the risk of missed checking and wrong checking exists in manual checking; the pressure data of the existing press cannot be read and recorded, the size data of the box body needs to be measured and recorded manually, and the error is large; the materials used for assembly need to be manually transported to an assembly area, and the empty trays after being used need to be manually pulled away and stacked, thereby wasting time and labor; whether the material model is correct or not can not be confirmed, and the situation of wrong material assembly can exist; the box is traced to source and one-dimensional sign indicating number needs the manual sign indicating number of beating, then manually pastes on the box, and is inefficiency.
Therefore, there is a need for a general control management system and management method for a train buffer production line 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 as to achieve the purposes of automatically controlling the whole production flow of a train buffer, improving the production efficiency and realizing automation, intellectualization and informatization.
In order to achieve the above 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 master flow module, a station material management module and an auxiliary function module which are deployed on the production line master control PLC, wherein the production line master flow module is used as a framework, the station material management module and the auxiliary function module are connected to the production line master flow module through corresponding interface programs, the production line master flow module guarantees normal production flow of a production line, the station material management module guarantees 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;
the production line main flow module comprises: the system comprises a production line start unit, an application dispatch list unit, a material report unit for materials, a dispatch list storage unit, a tracing one-dimensional code application unit, an OCR character verification unit, a dimension measurement unit and a finished product offline unit;
the station material management module comprises: the Automatic Guided Vehicle (AGV) material distribution unit, material verification unit, empty tray verification unit, AGV empty tray taking unit, AGV full tray notification unit and 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 suspension unit, an order unhooking unit, a press data acquisition unit and a safety control unit.
In the above scheme, the production line start-up unit is used for the start-up control of the whole production line station, and comprises a list number, a buffer model number and yield information which are issued to the station;
the application dispatch list unit is characterized in that in production line production, a buffer of an order has an order number, each buffer has an independent work list number, each work list has a unique dispatch list number on each station, and the unique dispatch list number is used for recording identity information of the station in the assembled buffer;
the material reporting unit is used for reporting the material quantity used for assembling one buffer at a station;
the saving dispatch list unit is used for recording the qualified/unqualified results after the station completes the assembly process of one buffer;
the tracing one-dimensional code application unit is used for automatically printing and pasting the buffer tracing one-dimensional code;
the OCR character verification unit is used for automatically recognizing, verifying 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 through the special measuring machine after the whole flow of the buffer is assembled;
the finished product offline unit is used for recording the placement position of the assembled buffer and comprises a qualified tray, a sampling inspection tray and a disqualified tray.
In the above scheme, the AGV material distribution unit is used for the AGV to distribute the material or the empty tray to the line Bian Ku so as to facilitate the station use;
the material checking unit is used for checking the materials before use, and if the materials are not matched with the types of the buffer, the materials need to be distributed again;
the empty tray checking unit is used for checking whether the materials in the wire side warehouse tray are used or not, and preventing the condition that the residual materials exist in the tray;
the AGV takes the empty tray unit, which is used for calling the AGV to take the empty tray of the line side library;
the AGV full tray notification unit is used for calling the AGV to take away the tray fully stacked at the offline position;
the empty tray stacking unit is used for stacking the trays together on the stacker crane according to categories after the AGV takes away the empty trays, so that the automatic tray stacking machine is convenient to recycle.
In the above scheme, the production line hardware fault unit is configured to monitor fault information of all hardware devices in the production line, and prompt an overhaul department;
the production line software alarm unit is used for processing some foreseeable faults and errors in the normal production process of the production line and notifying a production line management department;
the order suspending unit is used for suspending orders which are being produced and are not finished, and storing data so as to temporarily start buffer production of another model;
the order hanging unit is used for restarting the order which is stored in the system and is not produced, and the system continues to produce the buffer model and the dispatch order number information when continuing to hang;
the press data acquisition unit is used for acquiring pressure-displacement data when the press presses the spring and judging whether the spring quality is qualified or not;
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 issues a production line start command through a production line start unit;
(2) The dispatch bill applying unit starts to apply for a dispatch bill, a station is started after receiving the dispatch bill, and a buffer box body is grabbed by a tray and moves to the front of an 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, the buffer box body is placed on the turntable after the OCR character verification is finished, and the tracing one-dimensional code application unit starts to apply for tracing one-dimensional code printing and is adhered to the box body; when the work of the next station is completed after the pasting is completed, the material reporting unit starts material reporting, and the number of used buffer boxes is reported to the master control PLC; then the store dispatch list unit stores the dispatch list;
(3) The buffer box body is transferred to two stations through a rotary table, a dispatching order applying unit begins to apply for the dispatching order, the two stations are started after receiving the dispatching order, the angle spring seat, the outer circle spring, the inner circle spring and the spring seat are assembled manually, a material reporting unit is triggered through a button after the assembly is completed, the used material quantity is reported to a master control PLC, and then the dispatching order applying unit is stored for storing the dispatching order;
(4) The buffer box body is transferred to a three-station through a manipulator, a dispatch bill applying unit begins to apply for a dispatch bill, the three-station is started after receiving the dispatch bill, a press presses down a spring to a certain position, and a pin rod is inserted into the buffer box body; in the pressing down process, collecting press data units, recording press data every 0.5s, recording the press pressure-displacement data and drawing a curve to judge whether the spring is qualified or not; after the press fitting is completed, a work order saving unit saves the work order;
(5) The buffer box body is transferred to four stations through a transfer mechanism, a dispatching order applying unit begins to apply for the dispatching order, the four stations are started after receiving the dispatching order, an outer fixed plate, a fixed inclined plate, a restoring spring and a center wedge block are assembled by a robot, a material reporting unit is automatically triggered after the assembly is finished, the used material quantity is reported to a master control PLC, and then the dispatching order applying unit is saved for saving the dispatching order;
(6) The buffer box body is transferred to five stations through a production line, a dispatch list applying unit begins to apply for a dispatch list, the five stations are started after receiving the dispatch list, a wedge block, a movable plate and a short pin are assembled manually, a material reporting unit is triggered through a button after the assembly is completed, the used material quantity is reported to a master control PLC, and then a dispatch list storing unit stores the dispatch list;
(7) The buffer box body is transferred to six stations through a transfer mechanism, a dispatching bill applying unit begins to apply for the dispatching bill, the six stations are started after receiving the dispatching bill, a press presses down a spring to a proper position through a pressing down center wedge block, a pin rod is pulled out, in the pressing down process, press data are collected every 0.5s of a press data unit to record press data, the pressure-displacement data of the press are recorded and drawn into a curve, whether the assembled materials of an outer fixed plate, a fixed inclined plate and a movable plate are qualified or not is judged, and then the dispatching bill unit is saved for saving the dispatching bill;
(8) The buffer box body is transferred to seven stations through a C-shaped die set, a dispatching order applying unit begins to apply for a dispatching order, the seven stations are started after receiving the dispatching order, the robot grabs the assembled box body into a special measuring machine, the length, width, height and moving plate parallelism data of the box body are tested, the buffer box body is grabbed onto a corresponding tray according to a measuring result, a finished product offline unit is triggered by a code disc, the size data of the buffer, the type of the placed tray and the number of the tray are uploaded to a master control PLC, a dispatching order storing unit is triggered, and whether the buffer is qualified or not and station time information is stored in 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 smoothly connected, and the time for counting the station use time can be completed according to the dispatching order so as to balance the beats;
2. the material use condition and the assembly completion condition can be automatically uploaded;
3. automatically recognizing characters on the surface of the box body, and uploading system verification;
4. automatically recording and uploading pressure data of the press and size data of the box body;
5. automatic material distribution, automatic empty support taking and stacking;
6. the material model is automatically checked to be correct;
7. and automatically printing a tracing one-dimensional code and attaching the tracing one-dimensional code to the box body.
The production process of the whole train buffer can be more automatic, intelligent and informationized through the cooperative work of each functional unit in the main flow module, the station material management module and the auxiliary functional module of the production line in the general control management system.
The invention adopts the function similar to the MES system based on the PLC to provide the production line management work so as to exert the advantages of high efficiency and high reliability of the PLC and improve the stability of the production line control system. The production line flow management, material management and safety management are applied to the buffer automatic production line, the execution condition of each flow of the production line and the actual use condition of various materials can be intuitively and specifically reflected, the production line flow execution is smoother and more efficient, and the intelligent level of the buffer automatic production line 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 of a train buffer production line master control management system based on a PLC according to an embodiment of the present invention;
fig. 2 is a schematic flow chart of a method for master control management of a train buffer production line based on a PLC according to an embodiment of the present invention;
FIG. 3 is a flow chart of a finished product down-line process according to an embodiment of the present invention;
fig. 4 is a flow chart of station material management according to an embodiment of the present invention.
Detailed Description
The technical solutions 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 train buffer production line master control management system based on a PLC (programmable logic controller), which is shown in figure 1 and comprises a production line main flow module, a station material management module and an auxiliary function module which are deployed 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 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.
1. Main flow module of production line
The main flow process module of the production line comprises: the device comprises a production line start unit, an application dispatch list unit, a material report unit for materials, a preservation dispatch list unit, a tracing one-dimensional code application unit, an OCR character verification unit, a dimension measurement unit and a finished product offline unit.
The production line start-up unit is used for controlling the start-up of the whole production line work station and transmitting information including order numbers, buffer models, output and the like to the work station;
applying for a dispatch list unit, in production line production, assuming that 500 buffers are set as an order, the 500 buffers have an order number, each buffer has an independent work list number, each work list has an unique dispatch list number on each station, and the unique dispatch list number is used for recording identity information of the station in the assembled buffer;
the material reporting unit is used for reporting the material quantity used for assembling one buffer at a station;
a dispatch list unit is saved and used for recording the qualified/unqualified results after the station completes the assembly process of one buffer;
the tracing one-dimensional code application unit is used for automatically printing and pasting the buffer tracing one-dimensional code;
the OCR character verification unit is used for automatically recognizing, verifying 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 through the special measuring machine after the whole flow of the buffer is assembled;
and the finished product offline unit is used for recording the placement position of the assembled buffer and comprises a qualified tray, a spot check tray and a disqualified tray.
2. Station material management module
The station material management module comprises: AGV material delivery unit, material check-up unit, empty support check-up unit, AGV get empty tray unit, AGV full support notice unit, empty support pile up neatly unit.
The AGV material distribution unit is used for distributing materials or empty trays to the line Bian Ku by the AGV so as to facilitate station use;
the material checking unit is used for checking the materials before use, and if the materials are not matched with the types of the buffers, the materials need to be distributed again;
the empty tray checking unit is used for checking whether the materials in the wire side warehouse tray are used or not, and preventing the condition that the residual materials exist in the tray;
the AGV takes the empty tray unit, is used for calling AGV to take the empty tray of the line side library;
the AGV full-support notification unit is used for calling the AGV to take away the tray fully stacked at the offline position;
the empty tray stacking unit is used for stacking the trays together on the stacker crane according to categories after the AGV takes away the empty trays, so that the automatic tray stacking machine is convenient to recycle.
3. 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 suspension unit, an order unhooking unit, a press data acquisition 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 foreseeable faults and errors in the normal production process of the production line and notifying a production line management department;
an order suspending unit for suspending orders which are being produced and are not finished, and storing data so as to temporarily start buffer production of another model;
the order hanging unit is used for restarting the order which is stored in the system and is not produced, and the system continues to produce the buffer model and the dispatch order number information when continuing to hang;
the press data acquisition unit is used for acquiring pressure-displacement data when the press presses the spring and judging whether the spring quality is qualified or not;
and the safety control unit is used for controlling emergency stop of high-risk equipment such as a manipulator, a press and the like, and controlling emergency power-off of the high-risk equipment through 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, as shown in figure 2, comprises the following steps:
(1) After the automatic buffer assembly production line is started, the master control PLC firstly issues order numbers, buffer models and order quantity to each station through the production line starting unit, and the production line is indicated to start production.
(2) The dispatch bill applying unit starts to apply for a dispatch bill, a station is started after receiving the dispatch bill, and a buffer box body is grabbed by a tray and moves to the front of an 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, the buffer box body is placed on the turntable after the OCR character verification is finished, and the tracing one-dimensional code application unit starts to apply for tracing one-dimensional code printing and is adhered to the box body; when the work of the next station is completed after the pasting is completed, the material reporting unit starts material reporting, and the number of used buffer boxes is reported to the master control PLC; then, a work order saving unit saves the work order, wherein the work order saving unit saves information such as whether the work order is qualified, the work station time, the tray number corresponding to the box body and the like into corresponding work order information;
(3) The buffer box body is transferred to two stations through a rotary table, a dispatch bill applying unit begins to apply for a dispatch bill, the two stations are started after receiving the dispatch bill, a corner spring seat, an outer spring, an inner spring and a spring seat are assembled manually, a material reporting unit is triggered through a button after the assembly is completed, the used material quantity is reported to a master control PLC, and then a dispatch bill storing unit is triggered sequentially, so that whether the information such as the use of the station, the tray number corresponding to the material is qualified or not is stored in corresponding work bill information;
(4) The buffer box body is transferred to a three-station through a manipulator, a dispatch bill applying unit begins to apply for a dispatch bill, the three-station is started after receiving the dispatch bill, a press presses down a spring to a certain position, and a pin rod is inserted into the buffer box body; in the pressing down process, collecting press data units, recording press data every 0.5s, recording the press pressure-displacement data and drawing a curve to judge whether the spring is qualified or not; after the press fitting is completed, triggering and storing a work order unit, and storing information such as whether the work order unit is qualified, the station time and the like into corresponding work order information;
(5) The buffer box body is transferred to four stations through a transfer mechanism, a dispatch bill applying unit begins to apply for a dispatch bill, the four stations are started after receiving the dispatch bill, an external fixed plate, a fixed inclined plate, a restoring spring and a central wedge block are assembled by a robot, a material reporting unit is automatically triggered after the assembly is finished, the used material quantity is reported to a master control PLC, a dispatch bill storing unit is sequentially triggered, and whether the information such as the qualification, the station use time, the tray number corresponding to the material and the like is stored in corresponding work bill information;
(6) The buffer box body is transferred to five stations through a production line, a dispatch list applying unit begins to apply for a dispatch list, the five stations are started after receiving the dispatch list, a wedge block, a movable plate and a short pin are assembled manually, a material reporting unit is triggered through a button after the assembly is completed, the used material quantity is reported to a master control PLC, a dispatch list storing unit is triggered sequentially, and whether the information such as qualification, station use time, tray number corresponding to the material and the like is stored in corresponding work list information;
(7) The buffer box body is transferred to six stations through a transfer mechanism, a dispatch list applying unit begins to apply for a dispatch list, the six stations are started after receiving the dispatch list, a press presses down a spring to a proper position through a pressing down center wedge block, pins are pulled out, in the pressing down process, press data are collected every 0.5s of a press data unit to record press data, the pressure-displacement data of the press are recorded and drawn into a curve, whether the assembled materials of an outer fixed plate, a fixed inclined plate and a movable plate are qualified or not is judged, a dispatch list storing unit is triggered, and information such as whether the materials are qualified or not, the working position time is used or not is stored in corresponding work list information;
(8) The buffer box body is transferred to seven stations through a C-shaped die set, a dispatching order applying unit begins to apply for a dispatching order, the seven stations are started after receiving the dispatching order, the robot grabs the assembled box body into a special measuring machine, the length, width, height and moving plate parallelism data of the box body are tested, the buffer box body is grabbed onto a corresponding tray according to a measuring result, a finished product offline unit is triggered by a code disc, the size data of the buffer, the type of the placed tray and the number of the tray are uploaded to a master control PLC, a dispatching order storing unit is triggered, and whether the buffer is qualified or not and station time information is stored in corresponding work order information.
In fig. 3, after the production line is started, the seven stations detect that there is no empty tray, and first, an empty tray is automatically distributed to the station line Bian Ku by the AGV so that the stations can place finished product buffers; when the pallet is full, the master control initiates an AGV full-pallet notification, calls the AGV to take the full pallet off and place it in the prescribed finished product area, and then dispenses an empty pallet to the station line Bian Ku for the stations to place buffers.
In fig. 4, after the production line starts working, the AGV firstly distributes all materials required for production to the station line Bian Ku, after the station receives the tray, the tray number (one-dimensional code) is scanned by the code scanner, then the material verification is initiated, the main control system inquires the type of the materials contained in the tray number of the three-dimensional warehouse system, compares the type with the database in the system, successfully indicates that the materials are correct, the station can be used, otherwise, the AGV is called to take the materials away, and new materials are distributed again. When the station finishes using the materials of the wire side warehouse tray, the main control system checks whether the tray is provided with the residual materials through the empty tray checking unit, if no residual materials exist in the tray, the AGV is called to take the empty tray, and the empty tray is stacked on the stacker through the empty tray stacking function.
The main control system monitors fault information of all hardware devices of the production line through a hardware fault unit of the production line, prompts an overhaul department to repair in time when the hardware of the devices is in fault, and displays the fault information and a solution;
the production line software alarm unit prompts predictable faults and error handling in the normal production process of the production line, such as material verification failure or robot operation failure, and informs a production line management department or a production line operator to timely handle the faults;
the order suspending unit and the order unhooking unit can insert a temporarily-generated and urgent production task in a normal production task, store the information of an original order in a system, and restore the production plan of the original order after the order of the temporary queue is produced;
the safety control unit can collect safety equipment information such as a safety PLC, a safety relay, a safety door lock and the like, and can control equipment such as a manipulator, a press and the like which is easy to hurt people through the safety information, once the safety equipment detects the state change, the master control system can immediately power off the corresponding equipment such as the manipulator, the press and the like through the safety control module so as to prevent personal hazard.
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 (4)
1. The management method of the train buffer production line master control management system based on the PLC is characterized in that the master control management system comprises a production line master flow module, a station material management module and an auxiliary function module which are deployed on the production line master control PLC, wherein the production line master flow module is used as a framework, the station material management module and the auxiliary function module are connected to the production line master flow module through corresponding interface programs, the production line master flow module guarantees normal production flow of a production line, the station material management module guarantees 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;
the production line main flow module comprises: the system comprises a production line start unit, an application dispatch list unit, a material report unit for materials, a dispatch list storage unit, a tracing one-dimensional code application unit, an OCR character verification unit, a dimension measurement unit and a finished product offline unit;
the station material management module comprises: the Automatic Guided Vehicle (AGV) material distribution unit, material verification unit, empty tray verification unit, AGV empty tray taking unit, AGV full tray notification unit and 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 suspension unit, an order unhooking unit, a press data acquisition unit and a safety control unit;
the management method comprises the following steps:
(1) The master control PLC issues a production line start command through a production line start unit;
(2) The dispatch bill applying unit starts to apply for a dispatch bill, a station is started after receiving the dispatch bill, and a buffer box body is grabbed by a tray and moves to the front of an 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, the buffer box body is placed on the turntable after the OCR character verification is finished, and the tracing one-dimensional code application unit starts to apply for tracing one-dimensional code printing and is adhered to the box body; when the work of the next station is completed after the pasting is completed, the material reporting unit starts material reporting, and the number of used buffer boxes is reported to the master control PLC; then the store dispatch list unit stores the dispatch list;
(3) The buffer box body is transferred to two stations through a rotary table, a dispatching order applying unit begins to apply for the dispatching order, the two stations are started after receiving the dispatching order, the angle spring seat, the outer circle spring, the inner circle spring and the spring seat are assembled manually, a material reporting unit is triggered through a button after the assembly is completed, the used material quantity is reported to a master control PLC, and then the dispatching order applying unit is stored for storing the dispatching order;
(4) The buffer box body is transferred to a three-station through a manipulator, a dispatch bill applying unit begins to apply for a dispatch bill, the three-station is started after receiving the dispatch bill, a press presses down a spring to a certain position, and a pin rod is inserted into the buffer box body; in the pressing down process, collecting press data units, recording press data every 0.5s, recording the press pressure-displacement data and drawing a curve to judge whether the spring is qualified or not; after the press fitting is completed, a work order saving unit saves the work order;
(5) The buffer box body is transferred to four stations through a transfer mechanism, a dispatching order applying unit begins to apply for the dispatching order, the four stations are started after receiving the dispatching order, an outer fixed plate, a fixed inclined plate, a restoring spring and a center wedge block are assembled by a robot, a material reporting unit is automatically triggered after the assembly is finished, the used material quantity is reported to a master control PLC, and then the dispatching order applying unit is saved for saving the dispatching order;
(6) The buffer box body is transferred to five stations through a production line, a dispatch list applying unit begins to apply for a dispatch list, the five stations are started after receiving the dispatch list, a wedge block, a movable plate and a short pin are assembled manually, a material reporting unit is triggered through a button after the assembly is completed, the used material quantity is reported to a master control PLC, and then a dispatch list storing unit stores the dispatch list;
(7) The buffer box body is transferred to six stations through a transfer mechanism, a dispatching bill applying unit begins to apply for the dispatching bill, the six stations are started after receiving the dispatching bill, a press presses down a spring to a proper position through a pressing down center wedge block, a pin rod is pulled out, in the pressing down process, press data are collected every 0.5s of a press data unit to record press data, the pressure-displacement data of the press are recorded and drawn into a curve, whether the assembled materials of an outer fixed plate, a fixed inclined plate and a movable plate are qualified or not is judged, and then the dispatching bill unit is saved for saving the dispatching bill;
(8) The buffer box body is transferred to seven stations through a C-shaped die set, a dispatching order applying unit begins to apply for a dispatching order, the seven stations are started after receiving the dispatching order, the robot grabs the assembled box body into a special measuring machine, the length, width, height and moving plate parallelism data of the box body are tested, the buffer box body is grabbed onto a corresponding tray according to a measuring result, a finished product offline unit is triggered by a code disc, the size data of the buffer, the type of the placed tray and the number of the tray are uploaded to a master control PLC, a dispatching order storing unit is triggered, and whether the buffer is qualified or not and station time information is stored in corresponding work order information.
2. The management method of the train buffer production line master control management system based on the PLC of claim 1, wherein the production line start-up unit is used for the start-up control of the whole production line work station and comprises order number, buffer model number and yield information issuing to the work station;
the application dispatch list unit is characterized in that in production line production, a buffer of an order has an order number, each buffer has an independent work list number, each work list has a unique dispatch list number on each station, and the unique dispatch list number is used for recording identity information of the station in the assembled buffer;
the material reporting unit is used for reporting the material quantity used for assembling one buffer at a station;
the saving dispatch list unit is used for recording the qualified/unqualified results after the station completes the assembly process of one buffer;
the tracing one-dimensional code application unit is used for automatically printing and pasting the buffer tracing one-dimensional code;
the OCR character verification unit is used for automatically recognizing, verifying 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 through the special measuring machine after the whole flow of the buffer is assembled;
the finished product offline unit is used for recording the placement position of the assembled buffer and comprises a qualified tray, a sampling inspection tray and a disqualified tray.
3. The method of claim 1, wherein the AGV material delivery unit is configured to deliver material or empty trays to the line Bian Ku by an AGV for use at a station;
the material checking unit is used for checking the materials before use, and if the materials are not matched with the types of the buffer, the materials need to be distributed again;
the empty tray checking unit is used for checking whether the materials in the wire side warehouse tray are used or not, and preventing the condition that the residual materials exist in the tray;
the AGV takes the empty tray unit, which is used for calling the AGV to take the empty tray of the line side library;
the AGV full tray notification unit is used for calling the AGV to take away the tray fully stacked at the offline position;
the empty tray stacking unit is used for stacking the trays together on the stacker crane according to categories after the AGV takes away the empty trays, so that the automatic tray stacking machine is convenient to recycle.
4. The method for managing the train buffer production line master control management system based on the PLC according to claim 1, wherein the production line hardware alarm unit is used for monitoring fault information of all hardware devices of a production line and prompting an overhaul department;
the production line software alarm unit is used for processing some foreseeable faults and errors in the normal production process of the production line and notifying a production line management department;
the order suspending unit is used for suspending orders which are being produced and are not finished, and storing data so as to temporarily start buffer production of another model;
the order hanging unit is used for restarting the order which is stored in the system and is not produced, and the system continues to produce the buffer model and the dispatch order number information when continuing to hang;
the press data acquisition unit is used for acquiring pressure-displacement data when the press presses the spring and judging whether the spring quality is qualified or not;
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.
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