CN114131907A - Safety bus control system for automobile composite interior trim part forming production line - Google Patents
Safety bus control system for automobile composite interior trim part forming production line Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 222
- 239000002131 composite material Substances 0.000 title claims abstract description 29
- 238000012544 monitoring process Methods 0.000 claims abstract description 181
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- 238000001514 detection method Methods 0.000 claims description 18
- 238000000465 moulding Methods 0.000 claims description 17
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- 238000004458 analytical method Methods 0.000 claims description 5
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- 239000000428 dust Substances 0.000 claims description 4
- 230000005684 electric field Effects 0.000 claims description 4
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C51/00—Shaping by thermoforming, i.e. shaping sheets or sheet like preforms after heating, e.g. shaping sheets in matched moulds or by deep-drawing; Apparatus therefor
- B29C51/26—Component parts, details or accessories; Auxiliary operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract
The invention provides a safety bus control system for a composite interior trim part forming production line of an automobile, which comprises the following components: the bus control module is used for determining the type of the composite interior trim part, determining a production process and executing the production process; the safety monitoring module is used for carrying out production monitoring and acquiring monitoring data when the production process is executed; the safety judgment module is used for judging whether production abnormity exists or not according to the monitoring data, and carrying out flow regulation through a safety bus when the production abnormity exists, solving the problem of potential safety hazards of the production process in a production line, comprehensively monitoring and timely processing the potential safety hazards, and carrying out production optimization.
Description
Technical Field
The invention relates to the technical field of bus control, in particular to a safety bus control system for a composite interior trim part forming production line of an automobile.
Background
At present, robots are more widely applied, so that the robots are more suitable for the automobile interior trim production industry, with the vigorous development of new energy automobiles, automobile composite interior trims also have very wide development prospects in the future, consumers have higher requirements on automobiles and have different levels of requirements on the automobile interior trims, in the automobile manufacturing industry, with the increasing localization of parts, the requirements on the automobile interior trim molding production line are increased, while the common automobile interior trim molding production line is mainly focused on improving the production speed and increasing the production quantity, and the problem of potential safety hazards of the production line is inevitably caused; according to the technical scheme, the robot is controlled, 5 process difficulties such as workpiece identification, feeding and positioning, hot press forming, workpiece grabbing and reverse blanking and material receiving can be independently completed, and the problems of difficult demoulding and grabbing in the processing process of the ultra-light automobile interior trim parts are effectively solved.
Disclosure of Invention
The invention provides a safety bus control system for a composite interior trim part forming production line of an automobile, which is used for solving the problems that the potential safety hazard of the production process of the production line and the potential safety hazard are not monitored and processed in time comprehensively and cannot be optimized.
The invention provides a safety bus control system for a composite interior trim part forming production line of an automobile, which comprises the following components:
the bus control module: the method is used for determining the type of the composite interior trim part, determining a production process and executing the production process;
the safety monitoring module: the system is used for monitoring production and acquiring monitoring data when the production process is executed;
a safety judgment module: and the safety bus is used for judging whether production abnormity exists or not according to the monitoring data and carrying out flow regulation through the safety bus when the production abnormity exists.
As an embodiment of the present invention, the bus control module includes:
a decision unit: the system is used for determining a production line operation strategy according to the type of the composite interior trim part and acquiring decision information; wherein the content of the first and second substances,
the decision information includes: the production total amount of the interior trim parts, the operation distribution information of the interior trim parts, the production time of the interior trim parts and the processing information of the interior trim parts;
a job dividing unit: the system is used for dividing the operation of the interior trim part on the production line according to the decision information, acquiring operation information, determining an operation area and acquiring the serial number of the operation area.
As an embodiment of the present technical solution, the bus control module further includes:
a production control unit: the system comprises a decision-making module, a control module and a control module, wherein the decision-making module is used for sending a control signal to a production line circuit of an operation area according to decision-making information, performing circuit control and acquiring circuit control information; wherein the content of the first and second substances,
the line control includes: line voltage control, line resistance control and line working frequency control;
an operation control unit: and the system is used for carrying out process production operation on the production line in the operation area according to the operation information and the control signal to acquire the operation control information and the production information.
As an embodiment of the present technical solution, the safety monitoring module includes:
a monitoring response unit: the monitoring system is used for determining an operation area according to the operation information, carrying out monitoring response and acquiring monitoring response information; wherein the content of the first and second substances,
the monitoring response information includes: monitoring time, monitoring range and monitoring content;
production process monitoring unit: the monitoring response information is used for monitoring the production process according to the monitoring response information to acquire process monitoring information; wherein the content of the first and second substances,
the process monitoring information includes: machine serial number, machine response time, machine operation serial number.
As an embodiment of the present technical solution, the security determining module includes:
a production flow analysis unit: the system comprises a flow safety database, a flow monitoring information database and a flow safety deviation value calculation module, wherein the flow safety deviation value calculation module is used for calculating a difference value between the flow safety database and the flow monitoring information according to the preset flow safety database, acquiring a flow safety deviation value and judging the flow safety deviation value; wherein the content of the first and second substances,
when the flow safety deviation value is within a preset threshold range, normal production is performed, and flow monitoring information is stored into a flow safety database;
when the flow safety deviation value is not within the preset threshold range, abnormal production is carried out, and flow abnormity early warning is carried out;
a bus monitoring unit: the system comprises a monitoring response message sending module, a line monitoring module, a bus monitoring module and a monitoring module, wherein the monitoring response message sending module is used for sending a monitoring response message to the monitoring response message sending module; wherein the content of the first and second substances,
the bus monitoring information includes: bus temperature information, bus voltage information, control signal data and bus working frequency; wherein the content of the first and second substances,
the bus temperature information includes: the method comprises the following steps of (1) monitoring area serial numbers, line temperatures in the area serial numbers and line temperature monitoring time;
a bus analysis unit: and the system is used for performing weight fitting calculation according to a preset bus security database and bus monitoring information, determining a bus security value and performing security processing.
As an embodiment of the present invention, the job control unit includes:
intelligent identification subunit: the system comprises a control system, a control system and a control system, wherein the control system is used for respectively identifying operation workpieces in each production line operation area and acquiring workpiece information; wherein the content of the first and second substances,
the workpiece information includes: workpiece sending data and workpiece discharging data; the time of sending the workpiece and the time of taking the workpiece out of the work;
an operation control subunit: the system comprises a control signal acquisition module, a control signal processing module and a control signal processing module, wherein the control signal acquisition module is used for analyzing the control signal, respectively acquiring operation information of each production line operation area and sending an operation instruction; wherein the content of the first and second substances,
the job instruction includes: a job start instruction, a job end instruction, and a job pause instruction;
the operation information includes: the number of the operation area, the operation process, the start time of the operation area, the end time of the operation area and the number of operations; wherein the content of the first and second substances,
the working procedure comprises the following steps: workpiece identification, workpiece feeding, hot press molding, workpiece grabbing and reverse blanking;
a job judging subunit: the system is used for performing comparison judgment processing according to the operation information and the workpiece information, calculating the production condition satisfaction degree of the operation area and judging; wherein the content of the first and second substances,
when the production condition satisfaction degree is within a preset threshold value range, meeting the condition and starting operation;
when the production condition satisfaction degree is not within the preset threshold range, the condition is not met, and early warning processing is carried out;
the comparison determination process includes: executing condition comparison, executing time comparison and executing amount comparison.
As an embodiment of the present technical solution, it is that the safety monitoring module further includes:
production abnormity early warning unit: the system is used for rapidly positioning the production flow with abnormal production according to the flow monitoring information, acquiring the abnormal production position and acquiring abnormal information through camera shooting identification; wherein the content of the first and second substances,
the abnormality information includes: abnormal production line serial number, abnormal state of production line, abnormal degree of production flow and abnormal item number of production flow;
a bus abnormity early warning unit: the system comprises a bus monitoring module, a bus positioning module, a bus monitoring module, a bus alarm module, a fault line monitoring module and a fault line monitoring module, wherein the bus monitoring module is used for monitoring bus monitoring information and alarm information; wherein the content of the first and second substances,
the exception types include: abnormal workpiece identification, abnormal feeding and positioning, abnormal hot press molding, abnormal workpiece grabbing and abnormal reverse blanking and material receiving;
the safety adjustment includes: voltage regulation, resistance regulation, parallel-series regulation, temperature regulation, machine regulation and position regulation.
As an embodiment of the present technical solution, it is that the safety monitoring module further includes:
an operating environment detection unit: the system comprises a data acquisition module, a data processing module and a data processing module, wherein the data acquisition module is used for acquiring data of a job area; wherein the content of the first and second substances,
the job detection data includes: the number of the operation area, the temperature of the operation area, the electric field intensity of the operation area, the magnetic field intensity of the operation area and the dust content of the operation area;
a behavior detection unit: the method and the device are used for detecting the operation behaviors of operators in each operation area, acquiring behavior data and judging the behavior safety.
As an embodiment of the present technical solution, the method includes:
a process iteration module comprising: an operation deviation judging unit and a bus deviation judging unit;
the operation deviation determination unit: the system comprises a flow monitoring module, a data processing module and a data processing module, wherein the flow monitoring module is used for acquiring task information and actual operation information of each production line operation area according to flow monitoring information, calculating an operation difference value, comparing and judging to acquire a deviation level; wherein the content of the first and second substances,
when the operation difference value is within a preset threshold value range, the production operation is normal;
when the operation difference value is not within the preset threshold range, judging the deviation level and carrying out optimization processing;
the bus deviation determination unit: the bus monitoring device is used for acquiring task data and bus actual data of a bus control instruction according to the bus monitoring information, calculating a bus data difference value, and performing comparison and judgment; wherein the content of the first and second substances,
when the bus data difference value is within a preset safety threshold range, the bus is in an applicable state;
and when the bus data difference value is not within the preset safety threshold value range, performing iterative optimization processing on the bus.
As an embodiment of the present technical solution, the security determining module further includes:
production line optimizing unit: the system comprises a data processing module, a data processing module and a data processing module, wherein the data processing module is used for processing production line operation according to a deviation level and performing operation optimization processing on production line operation through a preset production operation data block and acquiring operation optimization information; wherein the content of the first and second substances,
the bias levels include: general deviation, gross deviation, emergency deviation;
an emergency braking unit: the system is used for acquiring the operation deviation grade of each operation area in the production line in real time and performing braking judgment; wherein the content of the first and second substances,
when the deviation level is emergency deviation, emergency braking is carried out, and manual calling processing is carried out;
and when the deviation level is not the emergency deviation, normally operating.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and drawings.
The technical solution of the present invention is further described in detail by the accompanying drawings and embodiments.
Drawings
The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention and not to limit the invention. In the drawings:
FIG. 1 is a functional diagram of a safety bus control system of a composite interior trim molding line of an automobile according to an embodiment of the present invention;
FIG. 2 is a functional diagram of a bus control module in a safety bus control system of a composite interior trim molding production line of an automobile according to an embodiment of the present invention;
fig. 3 is a functional diagram of a safety judgment module in a safety bus control system of a composite interior trim part forming production line of an automobile in the embodiment of the invention.
Detailed Description
The preferred embodiments of the present invention will be described in conjunction with the accompanying drawings, and it will be understood that they are described herein for the purpose of illustration and explanation and not limitation.
The embodiment of the invention provides a safety bus control system for a composite interior trim part forming production line of an automobile, which comprises the following components:
the bus control module: the method is used for determining the type of the composite interior trim part, determining a production process and executing the production process;
the safety monitoring module: the system is used for monitoring production and acquiring monitoring data when the production process is executed;
a safety judgment module: the monitoring device is used for judging whether production abnormity exists or not according to the monitoring data, and carrying out flow regulation through a safety bus when the production abnormity exists;
the working principle of the technical scheme is as follows: different from the single-index monitoring of the production line in the prior art, in the technical scheme, the molding production of the composite interior trim part of the automobile is controlled from beginning to end through bus control, and in the whole production flow of the production line, a safety monitoring module is carried out, the bus control module can control the production line according to the composite interior trim part to be produced, can carry out instant control on the part with problems in the safety monitoring, regulates and controls the production behavior and the abnormal production condition, can analyze and judge the monitored data through a safety judgment module, and if the abnormal condition occurs, quickly feeds back the data to the bus control module to realize the regulation of the abnormal condition;
the beneficial effects of the above technical scheme are: through the bus control module, the work efficiency of the automotive interior part forming production line is improved, the production safety is greatly improved through the whole-process monitoring of the production process by the safety monitoring module, the sensitivity of production abnormity and the accuracy of determining abnormal conditions are improved according to the safety judgment module, and the safety of normal operation of the system is guaranteed.
In one embodiment, the bus control module comprises:
a decision unit: the system is used for determining a production line operation strategy according to the type of the composite interior trim part and acquiring decision information; wherein the decision information comprises: the production total amount of the interior trim parts, the operation distribution information of the interior trim parts, the production time of the interior trim parts and the processing information of the interior trim parts;
a job dividing unit: the system comprises a decision-making module, a production line, a control module and a display module, wherein the decision-making module is used for dividing the operation of the interior trim part of the production line according to the decision-making information, acquiring operation information, determining an operation area and acquiring the serial number of the operation area;
the working principle of the technical scheme is as follows: different from the command response to the production line in the prior art, the technical scheme performs production line operation distribution according to the type of the automotive interior trim part to be produced through the decision unit, determines a production line operation strategy, identifies the total quantity of the automotive interior trim parts to be produced through decision information, distributes information of the interior trim parts to the production line to produce, the production time of the interior trim parts and the processing progress information of the interior trim parts to realize the control of the production line through the bus, and performs regional unit division on the production line according to the decision information to realize the distinguishing of regions with different functions and sequence number arrangement on each region;
the beneficial effects of the above technical scheme are: through determining the decision information, the production line production efficiency is improved, the operation areas are numbered by dividing the operation areas, the area accuracy is improved, the positioning accuracy is improved, and meanwhile the decision efficiency is improved.
In one embodiment, the bus control module further comprises:
a production control unit: the system comprises a decision-making module, a control module and a control module, wherein the decision-making module is used for sending a control signal to a production line circuit of an operation area according to decision-making information, performing circuit control and acquiring circuit control information; wherein, line control includes: line voltage control, line resistance control and line working frequency control;
an operation control unit: the system comprises a control module, a processing module and a processing module, wherein the control module is used for carrying out process production operation on a production line in an operation area according to operation information and a control signal to acquire operation control information and production information;
the working principle of the technical scheme is as follows: different from the prior art which performs production line control independently, the above technical scheme transmits control signals to the divided operation areas according to decision information, the control signals comprise instructions of operation time and operation content of each area, and through line control, the production control unit acquires line control information at the moment, including control of line voltage resistance; according to the operation information and the control signal, the operation control unit is used for carrying out operation control on the production line of the operation area needing operation, and the operation control information and the production information are acquired at the time through the operation control, and the two pieces of information are respectively read;
the beneficial effects of the above technical scheme are: the production control unit sends a control signal to perform line control, so that the operation efficiency of the automotive upholstery production line is greatly improved, and the operation control unit divides an operation area and improves the system bus control efficiency.
In one embodiment, the safety monitoring module comprises:
a monitoring response unit: the monitoring system is used for determining an operation area according to the operation information, carrying out monitoring response and acquiring monitoring response information; wherein monitoring the response information comprises: monitoring time, monitoring range and monitoring content;
production process monitoring unit: the monitoring response information is used for monitoring the production process according to the monitoring response information to acquire process monitoring information; wherein, the process monitoring information includes: machine serial number, machine response time, machine operation serial number;
the working principle of the technical scheme is as follows: different from the single-line monitoring of the production line in the prior art, the technical scheme firstly carries out monitoring response on an operating area on the production line through a detection response unit to obtain monitoring time, a monitoring range and monitoring content, then carries out monitoring on the production flow according to the monitoring response to obtain a monitored machine serial number, machine response time and a machine operation serial number, and integrates the information into production flow monitoring information;
the beneficial effects of the above technical scheme are: the detection area is determined by using the detection response, so that the detection utility is improved, meanwhile, the monitoring area is accurate, the monitoring cost is reduced, and the detection efficiency is improved.
In one embodiment, the security determination module comprises:
a production flow analysis unit: the system comprises a flow safety database, a flow monitoring information database and a flow safety deviation value calculation module, wherein the flow safety deviation value calculation module is used for calculating a difference value between the flow safety database and the flow monitoring information according to the preset flow safety database, acquiring a flow safety deviation value and judging the flow safety deviation value;
when the flow safety deviation value is within a preset threshold range, normal production is performed, and flow monitoring information is stored into a flow safety database;
when the flow safety deviation value is not within the preset threshold range, abnormal production is carried out, and flow abnormity early warning is carried out;
a bus monitoring unit: the system comprises a monitoring response message sending module, a line monitoring module, a bus monitoring module and a monitoring module, wherein the monitoring response message sending module is used for sending a monitoring response message to the monitoring response message sending module;
the bus monitoring information includes: bus temperature information, bus voltage information, control signal data and bus working frequency;
the bus temperature information includes: the method comprises the following steps of (1) monitoring area serial numbers, line temperatures in the area serial numbers and line temperature monitoring time;
a bus analysis unit: the bus monitoring system is used for performing weight fitting calculation according to a preset bus security database and bus monitoring information, determining a bus security value and performing security processing;
the working principle of the technical scheme is as follows: different from the common monitoring of the production line in the prior art, the production flow is analyzed firstly, the difference value calculation is carried out by using the flow safety data in the flow safety database and the flow information obtained by monitoring, the flow safety deviation value is calculated by comparing the difference value of the two information, the production flow in the area in which the production is carried out is judged, whether the production flow is in the range of normal production or not is analyzed, if the production flow is in the range, the real-time monitored flow information is also transmitted to the flow safety database, the flow safety database is enlarged, and if the production flow is unsafe, the abnormal production is required to be warned;
then according to the bus monitoring unit, calculating a fitting weight combination of bus safety influence; the calculation of the fitting weight combination of the bus security impact comprises the following steps:
step 1: acquiring weight combination of bus safety influence factors according to the bus safety database and the bus monitoring information
Integrated weight psi in case of item beta affecting bus securityβqThe corresponding factor weight is (delta)1,δ2,…,δζ) Calculating the integration weight psiβq：
Wherein psiβqIs an integrated weight for the beta term affecting bus security conditions,
are combined as weights
Weight factor of the s-th term, δcTo integrate the weight psiβqThe weighting factor of the c-th item in the corresponding factor weight,
and deltacMultiplying, calculating the integrated weight of the safety bus under the premise that the corresponding c-th weight factor and the bus safety influence factor weight are combined with the s-th item
The products of the factor weights corresponding to the integrated weight are summed to calculate an integrated weight psi for influencing the bus security condition at the beta-th itemβqRespectively multiplying the weight combination of the influence factors and the corresponding factor weight combination, and calculating the influence degree of the integrated weight on the safety bus more accurately; j is a weight combination
The number of terms of the middle weight factor, and
a factor derived for each case of bus security impact whose sum of impact weights is 1; n is 1,2, …, ζ, ζ is the integrated weight ψβqThe number of terms corresponding to the weight of the factor, and
for the same reason delta1,δ2,…,δζAs a set of weighting factors, the sum of all the influencing factors should be 1;
step 2: high-precision model maxF (delta) for constructing safety bus influence factor1,δ2,…,δζ)：
Wherein, maxF (delta)1,δ2,…,δζ) The method is a high-precision model of a safety bus influence factor, and the constraint conditions of the model are as follows: delta is not less than 0ββ ═ 1,2, …, ζ and
δnto integrate the weight psiβqThe nth weighting factor in the corresponding factor weight,
are combined as weights
The weighting factor of the beta term, deltaγTo integrate the weight psiβqThe y-th weighting factor among the corresponding factor weights,
for combining preset weights
The gamma-th weight factor in the combination is p which is a constant and is not more than j, different combinations are formed by each influence factor in the influence weight combination, the difference values of the different combinations are calculated by an exponential function and are summed, and the constraint condition 0 is not less than deltaββ ═ 1,2, …, ζ and
an objective function can be constructed;
and step 3: solving the model to obtain a solution equation set:
wherein, delta1To integrate the weight psiβqThe 1 st weighting factor in the corresponding factor weight,
is a preset weight combination
The weighting factor of the beta-th term in (b),
for combining preset weights
The beta term weight factor in (1), lambda is the target weight influence factor, deltaζTo integrate the weight psiβqThe ζ -th term weight factor in the corresponding factor weights,
is a preset weight combination
The weighting factor of item β; lambda simultaneously represents an influence coefficient in a constraint condition, an objective function can be solved through a coefficient matrix method, an equation system can also be directly solved, and therefore the condition factor weight (delta ') with influence safety monitored in real time is obtained'1,δ′2,…,δ′ζ) Fitting weight combination of
Wherein β ═ 1,2, …, j; determining a bus safety value according to the result of the weight fitting calculation, and performing safety processing; according to the monitoring responseInformation is respectively detected according to the sequence number arrangement of the operation area, and detection information of each part is obtained;
the beneficial effects of the above technical scheme are: through the analysis to the production flow, improved the production efficiency of production flow in the production line, improved the security of production flow simultaneously, bus monitoring unit is through the monitoring to each region, acquires bus monitoring information, has improved bus monitoring precision, has improved bus monitoring efficiency, has strengthened production efficiency.
In one embodiment, the job control unit includes:
intelligent identification subunit: the system comprises a control system, a control system and a control system, wherein the control system is used for respectively identifying operation workpieces in each production line operation area and acquiring workpiece information; wherein the workpiece information includes: workpiece sending data and workpiece discharging data; the time of sending the workpiece and the time of taking the workpiece out of the work;
an operation control subunit: the system comprises a control signal acquisition module, a control signal processing module and a control signal processing module, wherein the control signal acquisition module is used for analyzing the control signal, respectively acquiring operation information of each production line operation area and sending an operation instruction; wherein the content of the first and second substances,
the operation instruction comprises the following steps: a job start instruction, a job end instruction, and a job pause instruction;
the operation information includes: the number of the operation area, the operation process, the start time of the operation area, the end time of the operation area and the number of operations; wherein the content of the first and second substances,
the working procedures comprise: workpiece identification, workpiece feeding, hot press molding, workpiece grabbing and reverse blanking;
a job judging subunit: the system is used for performing comparison judgment processing according to the operation information and the workpiece information, calculating the production condition satisfaction degree of the operation area and judging;
when the production condition satisfaction degree is within a preset threshold value range, meeting the condition and starting operation;
when the production condition satisfaction degree is not within the preset threshold range, the condition is not met, and early warning processing is carried out; the comparison judgment processing includes: comparing execution conditions, execution times and execution amounts;
the working principle of the technical scheme is as follows: compared with the single control of the production line in the prior art, the technical scheme has the advantages that the intelligent identification subunit identifies the workpieces in each operation area on the production line, identifies the data of the workpieces, including the data of the workpieces entering the operation area, the data of the workpieces leaving the operation area after the operation area is processed, including the time of entering and exiting the operation area, analyzes the control signals through the operation control subunit, sends an operation starting instruction, an operation ending instruction and an operation pause instruction according to the analysis result, manages the workpiece identification, workpiece feeding, hot press forming, workpiece grabbing and reverse blanking in the operation process, reads the specific operation information, judges whether the entering condition is met or not according to the operation judgment subunit when the workpieces enter the operation area, and can enter the operation area only if the entering condition is met, when the workpiece leaves the operation area after being processed, judging whether the workpiece meets the processing success condition or not, and leaving the operation area only if the workpiece meets the processing success condition, or performing early warning treatment;
the beneficial effects of the above technical scheme are: through the intelligent identification subunit, the quality of the workpiece is guaranteed, the high-quality-to-area ratio of the workpiece is improved, the probability of poor-quality workpieces is reduced, the operation efficiency is improved, the latest state of the workpiece is timely acquired through the operation judgment subunit, whether the processing requirement is met or not is guaranteed, the processing safety is guaranteed, and the processing efficiency is improved.
In one embodiment, the safety monitoring module further comprises:
production abnormity early warning unit: the system is used for rapidly positioning the production flow with abnormal production according to the flow monitoring information, acquiring the abnormal production position and acquiring abnormal information through camera shooting identification; wherein the content of the first and second substances,
the abnormality information includes: abnormal production line serial number, abnormal state of production line, abnormal degree of production flow and abnormal item number of production flow;
a bus abnormity early warning unit: the system comprises a bus monitoring module, a bus positioning module, a bus monitoring module, a bus alarm module, a fault line monitoring module and a fault line monitoring module, wherein the bus monitoring module is used for monitoring bus monitoring information and alarm information; wherein the content of the first and second substances,
the types of exceptions include: abnormal workpiece identification, abnormal feeding and positioning, abnormal hot press molding, abnormal workpiece grabbing and abnormal reverse blanking and material receiving;
the safety adjustment comprises the following steps: voltage regulation, resistance regulation, parallel-series regulation, temperature regulation, machine regulation and position regulation;
the working principle of the technical scheme is as follows: different from the prior art that the violation of production line operation is monitored by a camera, the production flow with abnormal production conditions is quickly positioned by a production abnormity early warning unit in the technical scheme, at the moment, the position of the production abnormity is obtained, the serial number, the state, the abnormality degree and the serial number of abnormal matters of the abnormal production are obtained by camera identification, the abnormal type is determined by a bus abnormity early warning unit, the circuit with the abnormity is safely regulated according to the bus safety value, which abnormity belongs to the abnormity of workpiece identification, abnormal feeding positioning, abnormal hot press molding, abnormal workpiece grabbing and abnormal reverse blanking and material receiving is judged, and effective regulation such as voltage regulation, resistance regulation, parallel-serial regulation, temperature regulation, machine regulation and position regulation is carried out according to the abnormity;
the beneficial effects of the above technical scheme are: through the production abnormity early warning, the monitoring cost is greatly saved, the monitoring efficiency is improved, and through the classification and safety adjustment operation of abnormal types, the safety and the practicability of the safety monitoring module are also improved.
In one embodiment, the safety monitoring module further comprises:
an operating environment detection unit: the system comprises a data acquisition module, a data processing module and a data processing module, wherein the data acquisition module is used for acquiring data of a job area; wherein the content of the first and second substances,
the job detection data includes: the number of the operation area, the temperature of the operation area, the electric field intensity of the operation area, the magnetic field intensity of the operation area and the dust content of the operation area;
a behavior detection unit: the system is used for detecting the operation behaviors of operators in each operation area, acquiring behavior data and judging the behavior safety;
the working principle of the technical scheme is as follows: different from the simple detection of the operation environment in the prior art, the above technical scheme is that the operation environment detection is performed on each operation area, the operation environment non-conforming conditions are identified, the environment correction processing is performed, when the operation area is detected, the operation area sequence number, the operation area temperature, the operation area electric field strength, the operation area magnetic field strength and the operation area dust content can be obtained, the operation behavior of an operator in each operation area is detected, and whether the operator has illegal behavior or not and whether danger is generated or not is judged;
the beneficial effects of the above technical scheme are: through the monitoring and correction of the operation environment, the time for discovering after the environmental problem occurs is shortened, the production safety of the production line environment and the production of the production line is improved, the violation operation is reduced by monitoring the behavior of an operator, and the safety of the operator and the production line is improved.
In one embodiment, the method comprises the following steps:
a process iteration module comprising: an operation deviation judging unit and a bus deviation judging unit;
the operation deviation determination unit: the system comprises a flow monitoring module, a data processing module and a data processing module, wherein the flow monitoring module is used for acquiring task information and actual operation information of each production line operation area according to flow monitoring information, calculating an operation difference value, comparing and judging to acquire a deviation level;
when the operation difference value is within a preset threshold value range, the production operation is normal;
when the operation difference value is not within the preset threshold range, judging the deviation level and carrying out optimization processing;
a bus deviation determination unit: the bus monitoring device is used for acquiring task data and bus actual data of a bus control instruction according to the bus monitoring information, calculating a bus data difference value, and performing comparison and judgment;
when the bus data difference value is within a preset safety threshold range, the bus is in an applicable state;
when the bus data difference value is not within the preset safety threshold value range, performing iterative optimization processing on the bus;
the working principle of the technical scheme is as follows: different from the prior art which records the production information, the technical scheme carries out optimization judgment on the production process of the production line through the process iteration module, and calculates the operation deviation value of the task information and the actual operation information of each production line operation area through the operation deviation judgment unit to obtain the deviation level; the operation deviation value calculation comprises the following steps:
step S01: acquiring task data sequence P of operation aream＝(Pm(1),Pm(2),…,Pm(t)), calculating the actual operation data sequence Q after the operation of the jobm＝(Qm(1),Qm(2),…,Qm(t)) Q inm(α)：
Wherein, PmSequence of task data for work area, Pm(1),Pm(2),…,Pm(t) first task data, second task data, …, and mth task data in the task data sequence of the work area, respectively; qmFor actual operation data series after operation, Qm(1),Qm(2),…,Qm(t) the first actual data, the second actual data, … and the mth actual data in the actual operation data sequence; qm(alpha) alpha is alpha actual data in an actual operation data array, wherein alpha is more than or equal to 1 and is less than or equal to t, t is the number of data in a task data array and is the number of data in the actual operation data array, the number of the data in the task data array is equal to the number of the data in the actual operation data array, the assigned task generates task data, the data used at this time in the task data array is subjected to numerical value recording, if the data are not used, the data are represented by 0, the number of the data in the actual data array is the same as the number of the data in the task data array in the same way, a certain index data in the task data array is divided by a first safety data in the task data array to obtain a pre-calculated value of the corresponding actual data, and the pre-calculated value should be equal to the first safety data in the actual operation data arrayComparing the tested actual data values to ensure the accuracy of calculation;
step S02: calculating a factor difference lambda according to the data sequencei,m：
Wherein λ isi,mIs a factor of the difference, λi,m(α) is the actual operation data sequence QmComparison sequence Q of middle alpha actual data and ith group actual operation dataiOf (a) against the difference of the actual data, Qi(α) represents α -th comparison actual data in the comparison number series of actual operation data, wherein α is not less than 1 and not more than t, i is not less than 1 and not more than m; zooming according to the absolute value of the difference between the two actual values to calculate the influence value of the difference influence factor;
step S03: difference value lambda of detection factorsi,mMaximum value λ ofmaxAnd a minimum value λmin：
Wherein the content of the first and second substances,
for actual operation data series QmComparison sequence Q of middle alpha actual data and ith group actual operation dataiThe maximum difference of the alpha-th comparison to the actual data,
for actual operation data series QmComparison sequence Q of middle alpha actual data and ith group actual operation dataiThe minimum difference of the alpha-th comparison actual data; calculating the difference value of the influence factors of each situation, and screening out the largest and the smallest;
step S04: further calculating different series Qm、QiDeviation value mu of mean deviation alpha sequence datai,m：
Wherein, mui,mIs a series Qm、QiThe middle is the deviation value of alpha sequence data, epsilon is a maximum influence factor, epsilon is more than or equal to 0 and less than or equal to 1, and tau is a deviation correlation coefficient; by λmaxMultiplying the maximum influence factor to calculate the influence of the maximum deviation value in the sequence data, by multiplying the maximum influence factor by λminSumming, influencing factor lambda at different differences from different operating datai,m(alpha) to the sum of the maximum deviation values, and calculating the deviation value mu of the sequence datai,m；
For deviation value mui,mMaking a judgment when the deviation value mui,mIf the size is too large, bus optimization is carried out;
the beneficial effects of the above technical scheme are: through the judgment of the deviation value, the high efficiency of the production line is ensured, and meanwhile, the monitoring module and the bus control module are optimized, checked and judged, so that the production efficiency and the bus control efficiency are improved.
In one embodiment, the security determination module further comprises:
production line optimizing unit: the system comprises a data processing module, a data processing module and a data processing module, wherein the data processing module is used for processing production line operation according to a deviation level and performing operation optimization processing on production line operation through a preset production operation data block and acquiring operation optimization information; wherein the content of the first and second substances,
the bias levels include: general deviation, gross deviation, emergency deviation;
an emergency braking unit: the system is used for acquiring the operation deviation grade of each operation area in the production line in real time and performing braking judgment;
when the deviation level is emergency deviation, emergency braking is carried out, and manual calling processing is carried out;
when the deviation level is not the emergency deviation, normally operating;
the working principle of the technical scheme is as follows: different from the single safety judgment of the production line in the prior art, the technical scheme carries out operation optimization processing on production line operation through a production line optimization unit, and the precondition is that the deviation grade of the production operation is identified to belong to any one of general deviation, large deviation and emergency deviation, if the deviation grade is the emergency deviation, emergency braking is required to be carried out, and the operation processing operation in an emergency deviation area is stopped;
the beneficial effects of the above technical scheme are: through grading of deviation levels and the emergency braking unit, the safety of the production process is greatly improved, and the control strength of a bus system is enhanced.
It will be apparent to those skilled in the art that various changes and modifications may be made in the present invention without departing from the spirit and scope of the invention. Thus, if such modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include such modifications and variations.
Claims (10)
1. The utility model provides a car composite interior spare shaping production line safety bus control system which characterized in that includes:
the bus control module: the method is used for determining the type of the composite interior trim part, determining a production process and executing the production process;
the safety monitoring module: the system is used for monitoring production and acquiring monitoring data when the production process is executed;
a safety judgment module: and the safety bus is used for judging whether production abnormity exists or not according to the monitoring data and carrying out flow regulation through the safety bus when the production abnormity exists.
2. The automotive composite interior trim molding line safety bus control system of claim 1, wherein the bus control module comprises:
a decision unit: the system is used for determining a production line operation strategy according to the type of the composite interior trim part and acquiring decision information; wherein the content of the first and second substances,
the decision information includes: the production total amount of the interior trim parts, the operation distribution information of the interior trim parts, the production time of the interior trim parts and the processing information of the interior trim parts;
a job dividing unit: the system is used for dividing the operation of the interior trim part on the production line according to the decision information, acquiring operation information, determining an operation area and acquiring the serial number of the operation area.
3. The automotive composite interior trim molding line safety bus control system of claim 1, wherein the bus control module further comprises:
a production control unit: the system comprises a decision-making module, a control module and a control module, wherein the decision-making module is used for sending a control signal to a production line circuit of an operation area according to decision-making information, performing circuit control and acquiring circuit control information; wherein the content of the first and second substances,
the line control includes: line voltage control, line resistance control and line working frequency control;
an operation control unit: and the system is used for carrying out process production operation on the production line in the operation area according to the operation information and the control signal to acquire the operation control information and the production information.
4. The automotive composite interior trim molding line safety bus control system of claim 1, wherein the safety monitoring module comprises:
a monitoring response unit: the monitoring system is used for determining an operation area according to the operation information, carrying out monitoring response and acquiring monitoring response information; wherein the content of the first and second substances,
the monitoring response information includes: monitoring time, monitoring range and monitoring content;
production process monitoring unit: the monitoring response information is used for monitoring the production process according to the monitoring response information to acquire process monitoring information; wherein the content of the first and second substances,
the process monitoring information includes: machine serial number, machine response time, machine operation serial number.
5. The safety bus control system for the composite interior trim part forming production line of the automobile as claimed in claim 1, wherein the safety judgment module comprises:
a production flow analysis unit: the system comprises a flow safety database, a flow monitoring information database and a flow safety deviation value calculation module, wherein the flow safety deviation value calculation module is used for calculating a difference value between the flow safety database and the flow monitoring information according to the preset flow safety database, acquiring a flow safety deviation value and judging the flow safety deviation value; wherein the content of the first and second substances,
when the flow safety deviation value is within a preset threshold range, normal production is performed, and flow monitoring information is stored into a flow safety database;
when the flow safety deviation value is not within the preset threshold range, abnormal production is carried out, and flow abnormity early warning is carried out;
a bus monitoring unit: the system comprises a monitoring response message sending module, a line monitoring module, a bus monitoring module and a monitoring module, wherein the monitoring response message sending module is used for sending a monitoring response message to the monitoring response message sending module; wherein the content of the first and second substances,
the bus monitoring information includes: bus temperature information, bus voltage information, control signal data and bus working frequency; wherein the content of the first and second substances,
the bus temperature information includes: the method comprises the following steps of (1) monitoring area serial numbers, line temperatures in the area serial numbers and line temperature monitoring time;
a bus analysis unit: and the system is used for performing weight fitting calculation according to a preset bus security database and bus monitoring information, determining a bus security value and performing security processing.
6. The safety bus control system for the composite interior trim part forming production line of an automobile according to claim 3, wherein the operation control unit comprises:
intelligent identification subunit: the system comprises a control system, a control system and a control system, wherein the control system is used for respectively identifying operation workpieces in each production line operation area and acquiring workpiece information; wherein the content of the first and second substances,
the workpiece information includes: workpiece sending data and workpiece discharging data; the time of sending the workpiece and the time of taking the workpiece out of the work;
an operation control subunit: the system comprises a control signal acquisition module, a control signal processing module and a control signal processing module, wherein the control signal acquisition module is used for analyzing the control signal, respectively acquiring operation information of each production line operation area and sending an operation instruction; wherein the content of the first and second substances,
the job instruction includes: a job start instruction, a job end instruction, and a job pause instruction;
the operation information includes: the number of the operation area, the operation process, the start time of the operation area, the end time of the operation area and the number of operations; wherein the content of the first and second substances,
the working procedure comprises the following steps: workpiece identification, workpiece feeding, hot press molding, workpiece grabbing and reverse blanking;
a job judging subunit: the system is used for performing comparison judgment processing according to the operation information and the workpiece information, calculating the production condition satisfaction degree of the operation area and judging; wherein the content of the first and second substances,
when the production condition satisfaction degree is within a preset threshold value range, meeting the condition and starting operation;
when the production condition satisfaction degree is not within the preset threshold range, the condition is not met, and early warning processing is carried out;
the comparison determination process includes: executing condition comparison, executing time comparison and executing amount comparison.
7. The automotive composite interior trim molding line safety bus control system of claim 1, wherein the safety monitoring module further comprises:
production abnormity early warning unit: the system is used for rapidly positioning the production flow with abnormal production according to the flow monitoring information, acquiring the abnormal production position and acquiring abnormal information through camera shooting identification; wherein the content of the first and second substances,
the abnormality information includes: abnormal production line serial number, abnormal state of production line, abnormal degree of production flow and abnormal item number of production flow;
a bus abnormity early warning unit: the system comprises a bus monitoring module, a bus positioning module, a bus monitoring module, a bus alarm module, a fault line monitoring module and a fault line monitoring module, wherein the bus monitoring module is used for monitoring bus monitoring information and alarm information; wherein the content of the first and second substances,
the exception types include: abnormal workpiece identification, abnormal feeding and positioning, abnormal hot press molding, abnormal workpiece grabbing and abnormal reverse blanking and material receiving;
the safety adjustment includes: voltage regulation, resistance regulation, parallel-series regulation, temperature regulation, machine regulation and position regulation.
8. The automotive composite interior trim molding line safety bus control system of claim 1, wherein the safety monitoring module further comprises:
an operating environment detection unit: the system comprises a data acquisition module, a data processing module and a data processing module, wherein the data acquisition module is used for acquiring data of a job area; wherein the content of the first and second substances,
the job detection data includes: the number of the operation area, the temperature of the operation area, the electric field intensity of the operation area, the magnetic field intensity of the operation area and the dust content of the operation area;
a behavior detection unit: the method and the device are used for detecting the operation behaviors of operators in each operation area, acquiring behavior data and judging the behavior safety.
9. The safety bus control system for the composite interior trim part forming production line of the automobile as claimed in claim 1, comprising:
a process iteration module comprising: an operation deviation judging unit and a bus deviation judging unit;
the operation deviation determination unit: the system comprises a flow monitoring module, a data processing module and a data processing module, wherein the flow monitoring module is used for acquiring task information and actual operation information of each production line operation area according to flow monitoring information, calculating an operation difference value, comparing and judging to acquire a deviation level; wherein the content of the first and second substances,
when the operation difference value is within a preset threshold value range, the production operation is normal;
when the operation difference value is not within the preset threshold range, judging the deviation level and carrying out optimization processing;
the bus deviation determination unit: the bus monitoring device is used for acquiring task data and bus actual data of a bus control instruction according to the bus monitoring information, calculating a bus data difference value, and performing comparison and judgment; wherein the content of the first and second substances,
when the bus data difference value is within a preset safety threshold range, the bus is in an applicable state;
and when the bus data difference value is not within the preset safety threshold value range, performing iterative optimization processing on the bus.
10. The system of claim 1, wherein the safety determination module further comprises:
production line optimizing unit: the system comprises a data processing module, a data processing module and a data processing module, wherein the data processing module is used for processing production line operation according to a deviation level and performing operation optimization processing on production line operation through a preset production operation data block and acquiring operation optimization information; wherein the content of the first and second substances,
the bias levels include: general deviation, gross deviation, emergency deviation;
an emergency braking unit: the system is used for acquiring the operation deviation grade of each operation area in the production line in real time and performing braking judgment; wherein the content of the first and second substances,
when the deviation level is emergency deviation, emergency braking is carried out, and manual calling processing is carried out;
and when the deviation level is not the emergency deviation, normally operating.
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