CN113988675A - Intelligent production flexible routing control coding and decoding method - Google Patents

Abstract

The invention aims to provide an intelligent production flexible routing control coding and decoding method, which comprises the following steps: the upper computer edits a product process route to generate a route code; the routing code is stored in the server database under the product catalog for calling; the upper computer calls the database routing code and transmits the database routing code to the PLC; the PLC decodes the codes and drives an execution structure according to the decoded routing instruction; and after the current production unit finishes production, coding again and transmitting to the next-level production unit. The invention upgrades the traditional production control system, ensures that the system has intelligent production and flexible route control capabilities, provides a simple and visual production process route editor, is convenient for producers to edit the production process of new products at a low threshold, and meets the requirements of manufacturers on continuously increasing new products and customizing the production process control program.

Description

Intelligent production flexible routing control coding and decoding method

Technical Field

The invention relates to a method for adjusting a production and manufacturing process, in particular to a method for controlling the production and manufacturing.

Background

In the development process of production and manufacturing control technology, intelligent control and flexible control attract more and more attention of people, but a plurality of domestic manufacturers of traditional Chinese medicine extraction, dairy products, health-care wine and the like still keep the traditional production control system. Although the traditional production control system can keep good reliability and work efficiency on the premise of single product and fixed production process, with the increasing improvement of living standard of people, the single product of the production enterprise can not meet the continuous pursuit of the public for new things, so that the production enterprise is forced to update the existing product line, adjust the production process and produce new products by combining different production units. However, the problem also arises that the conventional control system must change the existing control program when performing the process adjustment, which must be performed by a professional software engineer, and requires much manpower and material resources, and also consumes a long debugging time. Or the production units are arranged step by step in a manual intervention mode without changing the control program, and the new product is produced in a semi-automatic mode. The result of this is that not only the production efficiency is reduced a lot, but also the manual intervention is easy to cause misoperation, which brings about no small loss.

According to the solutions provided by the existing large industrial control product enterprises (Siemens, Roxwell and the like), the existing control system needs to be upgraded to have intelligent control and flexible routing control capability, the existing system needs to be overturned to be reworked, the cost is high, the production is stopped for a long time for installation and debugging, and few enterprises can do the operation under the balance of advantages and disadvantages.

Disclosure of Invention

The invention aims to provide an intelligent production flexible routing control coding and decoding method which enables a production control system to have flexible routing control capability.

The purpose of the invention is realized as follows:

the invention discloses an intelligent production flexible routing control coding and decoding method, which is characterized by comprising the following steps:

(1) the upper computer edits a product process route to generate a route code;

(2) the routing code is stored in the server database under the product catalog for calling;

(3) the upper computer calls the database routing code and transmits the database routing code to the PLC;

(4) the PLC decodes the codes and drives an execution structure according to the decoded routing instruction;

(5) and after the current production unit finishes production, coding again and transmitting to the next-level production unit.

The present invention may further comprise:

1. the process of generating the routing code by the upper computer editing the product process route comprises the following steps:

a. selecting a product name of a new route to be edited;

b. sequentially selecting the selectable process units in sequence;

c. generating a process code, wherein the code is a binary 32-bit long integer number, the process routing code of each step occupies two bits, the expressed result is '00', '01', '10' and '11', the code supports 15 steps of processes at most and is stored in a database of a server, and the 32-bit data structure of the code is as follows: sign flag bit, route of step 1, route of step 2.

2. The transmission process of the routing code is as follows:

A. the upper computer calls a routing code in the server and transmits the routing code to the PLC;

B. the PLC decodes the received codes to obtain routing instructions of the first-step production unit and transmits the routing instructions and the routing codes to the first-step production unit;

C. the production unit starts production after receiving the instruction, transmits the product to the second step unit according to the routing instruction after the production is finished, simultaneously re-edits the routing code, writes the result of the first step finished production into the code and transmits the code back to the PLC controller;

D. the PLC re-decodes the returned codes to obtain a second-step production routing instruction, and transmits the second-step production routing instruction together with the returned codes to a second-step production unit;

E. repeating the two steps until the production is finished.

3. The specific process of encoding and decoding is as follows:

i, the first-step production unit converts the 32-bit code into WORD type;

ii, taking out the 5 th and 6 th bits of the WORD type data;

iii, converting the extracted 5 th digit and 6 th digit into decimal numbers to obtain a number of 0-3, outputting the number of 0-3 to a routing result port, wherein the number of 0-3 is the routing result of the step, and receiving the result from the routing result port by the controller and conveying the material to a corresponding next-step production unit;

iv, moving the 32-bit code by 2 bits to the left, outputting the obtained newly generated 32-bit code to a rear-stage code port, and transmitting the new 32-bit code to a next production unit after production is finished;

and v, repeating the steps by the next production unit to obtain a self routing result, and transmitting the next-stage code to the next-step production unit again until the production is finished.

The invention has the advantages that:

1. the flexibility of the control system is improved, and the production process of a new product can be adjusted at any time.

2. The upgrading is simple, the debugging is convenient, and production enterprises do not need to stop production.

3. The coding and decoding module developed according to the requirements is based on a PLC programming language, and has high execution efficiency and reliability.

4. The operation is intuitive and convenient, and the enterprise self-editing production process is realized at a low threshold.

5. Manual intervention is eliminated, and full-automatic production routing control is realized.

Drawings

FIG. 1 is a process flow for manufacturing the codec module;

FIG. 2 is a diagram of a host process route editing panel;

FIG. 3 is a flexible routing control codec module implementation;

fig. 4 shows the input and output of the lower-level machine encoding/decoding module.

Detailed Description

The invention will now be described in more detail by way of example with reference to the accompanying drawings in which:

with reference to fig. 1-4, the flexible routing control encoding and decoding method of the present invention has the following processes:

1. a producer operates an upper computer to edit a product process route to generate a route code;

2. the routing code is stored in the server database under the product catalog for later retrieval;

3. the production personnel execute the production instruction, and the upper computer automatically calls the database routing code and transmits the routing code to the PLC;

4. and the PLC decodes the codes and drives the execution structure according to the decoded routing instruction.

5. After the current production unit finishes production, the current production unit is coded again by the coding module and is transmitted to the next-level production unit.

With reference to fig. 1, it can be seen that the whole production process comprises 8 production units of extraction, vacuum concentration, alcohol precipitation, resin column, ceramic membrane, ultrafiltration membrane, nanofiltration membrane, and concentrated solution preparation. As can be seen in the figure, extraction is the first step of the process, routed through several production units and finally into the concentrate formulation unit. If the process is limited to within 15 steps, there will be as many as tens of routes going from the first step to the last step. According to the traditional control system scheme, a full-automatic control program is compiled according to several routes of the existing product varieties, or production personnel select the next place to go after the production unit finishes working in each step. The result of this is that the former can not satisfy the full-automatic production requirement of new product new technology, and the latter can not full-automatic production, and even more because the manual intervention easily produces the maloperation. The flexible routing control coding and decoding method is optimized for the production flow pair, the production routing codes of the products are called before production, and full-automatic routing production is realized after decoding.

Referring to fig. 2, a panel for editing a production process by a host computer is shown, and the specific operation process is as follows:

1. firstly, selecting a product name needing to edit a new route by a manufacturer;

2. sequentially clicking the selectable process units in sequence, displaying the selected process flow in the lower black frame every time of clicking, and prompting to reselect the process unit without displaying an error when the selected process does not meet the existing process flow conditions;

3. after the process flow is selected, a producer clicks a 'generate process code' button, and the program automatically generates the process routing code of the product, wherein the code is a binary 32-bit long integer number (DINT type). The process routing codes of each step occupy two bits, the expressed results are '00', '01', '10' and '11', namely, the number of the process routing codes of each step is no more than 4 at most, two-bit sign bits of 32-bit data are abandoned, the codes support 15 steps of processes at most, and the codes are stored in a database of a server for facilitating future retrieval. Briefly, the encoded 32-bit data structure is: sign flag bit, route of step 1, route of step 2. (in FIG. 2, 1 is a route header, 2 is a button for generating a process code, 3 is a production control unit that can be selected, and 4 is an already selected production route).

The delivery process of routing code can be seen in connection with fig. 3.

1. A string of codes is generated by the upper computer, the process route of the production unit can support 15 steps at most, and the codes are stored in the server and can be called at any time;

2. before production, the upper computer calls a routing code in the server and transmits the routing code to the PLC;

3, decoding the received codes by the PLC to obtain a routing instruction of the first-step production unit and transmitting the routing instruction and the routing codes to the first-step production unit;

4. the production unit starts production after receiving the instruction, transmits the product to the second step unit according to the routing instruction after the production is finished, simultaneously re-edits the routing code, writes the result of the first step finished production into the code and transmits the code back to the PLC controller;

the PLC re-decodes the returned codes to obtain a second-step production routing instruction, and transmits the second-step production routing instruction together with the returned codes to a second-step production unit;

6. repeating the above two steps until the production is finished

Referring to fig. 4, the codec module edited by the PLC programming language is shown. It can be seen from the figure that the left end of the module is a code input port, and the 32-bit routing code transmitted from the upper computer or the production unit enters the module from the input port. Then, the decoding module performs encoding and decoding, and the specific steps are as follows (explained by production units a and B):

1. production unit A converts the 32-bit code to WORD type for the next bit operation;

2. taking out the 5 th and 6 th bits of WORD type data;

3. converting the taken 5 th digit and the taken 6 th digit into decimal numbers, obtaining numbers of 0-3, outputting the numbers to a routing result port, wherein the numbers of 0-3 are the routing result of the step, and receiving the result from the routing result port by a controller and conveying the material to a corresponding next-step production unit B;

4. the 32-bit code is shifted to the left by 2 bits, the obtained newly generated 32-bit code is output to a 'rear-stage code' port, and the new 32-bit code is transmitted to a production unit B after the production is finished;

5. the production unit B repeats the 4 steps to obtain a routing result of the production unit B, and transmits the rear-level code to the next production unit again until the production is finished.

Claims (4)

1. The intelligent production flexible routing control coding and decoding method is characterized by comprising the following steps:

(1) the upper computer edits a product process route to generate a route code;

(2) the routing code is stored in the server database under the product catalog for calling;

(3) the upper computer calls the database routing code and transmits the database routing code to the PLC;

(4) the PLC decodes the codes and drives an execution structure according to the decoded routing instruction;

(5) and after the current production unit finishes production, coding again and transmitting to the next-level production unit.

2. The intelligent production flexible routing control coding and decoding method according to claim 1, wherein: the process of generating the routing code by the upper computer editing the product process route comprises the following steps:

a. selecting a product name of a new route to be edited;

b. sequentially selecting the selectable process units in sequence;

c. generating a process code, wherein the code is a binary 32-bit long integer number, the process routing code of each step occupies two bits, the expressed result is '00', '01', '10' and '11', the code supports 15 steps of processes at most and is stored in a database of a server, and the 32-bit data structure of the code is as follows: sign flag bit, route of step 1, route of step 2.

3. The intelligent production flexible routing control coding and decoding method according to claim 1, wherein: the transmission process of the routing code is as follows:

A. the upper computer calls a routing code in the server and transmits the routing code to the PLC;

B. the PLC decodes the received codes to obtain routing instructions of the first-step production unit and transmits the routing instructions and the routing codes to the first-step production unit;

C. the production unit starts production after receiving the instruction, transmits the product to the second step unit according to the routing instruction after the production is finished, simultaneously re-edits the routing code, writes the result of the first step finished production into the code and transmits the code back to the PLC controller;

D. the PLC re-decodes the returned codes to obtain a second-step production routing instruction, and transmits the second-step production routing instruction together with the returned codes to a second-step production unit;

E. repeating the two steps until the production is finished.

4. The intelligent production flexible routing control coding and decoding method according to claim 1, wherein: the specific process of encoding and decoding is as follows:

i, the first-step production unit converts the 32-bit code into WORD type;

ii, taking out the 5 th and 6 th bits of the WORD type data;

iii, converting the extracted 5 th digit and 6 th digit into decimal numbers to obtain a number of 0-3, outputting the number of 0-3 to a routing result port, wherein the number of 0-3 is the routing result of the step, and receiving the result from the routing result port by the controller and conveying the material to a corresponding next-step production unit;

iv, moving the 32-bit code by 2 bits to the left, outputting the obtained newly generated 32-bit code to a rear-stage code port, and transmitting the new 32-bit code to a next production unit after production is finished;

and v, repeating the steps by the next production unit to obtain a self routing result, and transmitting the next-stage code to the next-step production unit again until the production is finished.

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