CN114769020A - Early warning regulation and control method for preventing metal plate spraying line from stopping - Google Patents
Early warning regulation and control method for preventing metal plate spraying line from stopping Download PDFInfo
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- CN114769020A CN114769020A CN202210438271.XA CN202210438271A CN114769020A CN 114769020 A CN114769020 A CN 114769020A CN 202210438271 A CN202210438271 A CN 202210438271A CN 114769020 A CN114769020 A CN 114769020A
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- 238000000034 method Methods 0.000 title claims abstract description 122
- 238000005507 spraying Methods 0.000 title claims abstract description 47
- 239000002184 metal Substances 0.000 title claims abstract description 29
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 62
- 239000007788 liquid Substances 0.000 claims abstract description 45
- 230000002159 abnormal effect Effects 0.000 claims abstract description 35
- 239000003814 drug Substances 0.000 claims abstract description 34
- 238000000746 purification Methods 0.000 claims abstract description 33
- 238000004519 manufacturing process Methods 0.000 claims abstract description 20
- 238000001514 detection method Methods 0.000 claims description 33
- 238000005406 washing Methods 0.000 claims description 23
- 239000000463 material Substances 0.000 claims description 14
- 239000007921 spray Substances 0.000 claims description 14
- 239000011550 stock solution Substances 0.000 claims description 10
- 230000005856 abnormality Effects 0.000 claims description 7
- 238000010516 chain-walking reaction Methods 0.000 claims description 6
- 239000002199 base oil Substances 0.000 claims description 4
- 239000003921 oil Substances 0.000 claims description 4
- 230000007123 defense Effects 0.000 abstract description 3
- 230000001960 triggered effect Effects 0.000 abstract description 3
- 239000002585 base Substances 0.000 description 4
- 238000005238 degreasing Methods 0.000 description 4
- 238000010586 diagram Methods 0.000 description 4
- 235000021168 barbecue Nutrition 0.000 description 3
- 239000000575 pesticide Substances 0.000 description 3
- 239000000243 solution Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 238000010790 dilution Methods 0.000 description 1
- 239000012895 dilution Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
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- G—PHYSICS
- G06—COMPUTING; CALCULATING OR COUNTING
- G06K—GRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
- G06K17/00—Methods or arrangements for effecting co-operative working between equipments covered by two or more of main groups G06K1/00 - G06K15/00, e.g. automatic card files incorporating conveying and reading operations
- G06K17/0022—Methods or arrangements for effecting co-operative working between equipments covered by two or more of main groups G06K1/00 - G06K15/00, e.g. automatic card files incorporating conveying and reading operations arrangements or provisions for transferring data to distant stations, e.g. from a sensing device
- G06K17/0025—Methods or arrangements for effecting co-operative working between equipments covered by two or more of main groups G06K1/00 - G06K15/00, e.g. automatic card files incorporating conveying and reading operations arrangements or provisions for transferring data to distant stations, e.g. from a sensing device the arrangement consisting of a wireless interrogation device in combination with a device for optically marking the record carrier
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- G—PHYSICS
- G08—SIGNALLING
- G08B—SIGNALLING OR CALLING SYSTEMS; ORDER TELEGRAPHS; ALARM SYSTEMS
- G08B21/00—Alarms responsive to a single specified undesired or abnormal condition and not otherwise provided for
- G08B21/18—Status alarms
- G08B21/24—Reminder alarms, e.g. anti-loss alarms
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention discloses an early warning regulation and control method for preventing a metal plate spraying line from stopping, which relates to the technical field of metal plate spraying lines, according to the early warning and warning range information, the position number and the process name of the adjustment target range information, the volume of the liquid medicine pool, the flow rate of the dosing machine and the water purification machine per minute and the concentration value of the raw liquid of the dosing machine and the water purification machine, or, according to the early warning and alarming range information, the position number and the process name of the adjusting target range information and the power of the burner, the automatic adjusting time T1 and the space capacity time T3 are obtained, before a line stop alarm condition is triggered, three time defense lines of automatic adjustment time T1, abnormal processing time T2 and space capacity time T3 are set to adjust field process parameters to reach a target range value so as to prevent the stop of a metal plate spraying line, so that the production quality is guaranteed, the production efficiency is improved, and the problem of high cost caused by frequent line stop adjustment due to the fact that the field process parameters of the spraying line are abnormal is solved.
Description
Technical Field
The invention relates to the technical field of metal plate spraying lines, in particular to an early warning adjusting and controlling method for preventing a metal plate spraying line from stopping.
Background
In the sheet metal industry, sheet metal spraying is an essential and especially important technological link in the machining process, and the spraying effect can directly influence the performance and quality of sheet metal products in later periods.
The current popular spraying operation mode is as follows: setting field process parameters of a plurality of medicine water tanks, the temperature of the baking oven and the running speed of a spraying line according to the type of materials and a person following the line; a plurality of pools with different pH values and a baking oven are arranged on the spraying workshop, liquid medicine in the pools is pumped up and sprayed onto the metal plates through nozzles, and finally the liquid medicine is dried through the baking oven; the on-site process parameters and the baking furnace temperature of the multiple spraying line pesticide pools are regularly checked by the on-line personnel, pesticide is manually added according to the detection result, and the furnace temperature is adjusted; when the field process parameters of a certain liquid medicine pool exceed the range or the furnace temperature of a certain baking furnace exceeds the range, the operation of the spraying line needs to be manually stopped; the person who follows the line adds liquid medicine to the pond that corresponds, will bake out the stove temperature adjustment to within the scope, restarts this and sprays the line operation.
In the current working mode, the following problems cannot be solved:
1) the material type, the field process parameters of the liquid medicine pool, the furnace temperature of the baking furnace and the running speed of the spraying line are judged and set by following line personnel. The operation is not foolproof, and once the metal plate sprayed by mistake is scrapped.
2) The automation degree is low, and on-site process parameters, the baking furnace temperature and the operation speed of the spraying lines of the pesticide pools of the multiple spraying lines need to be checked regularly by a person on line. If the inspection of the staff on the line is not timely, the speed of adding liquid medicine and adjusting the temperature of the oven is slow, the field process parameters of certain liquid medicine pools or the temperature of the baking oven can not reach the standard, and if the spraying line continues to operate, the performance and the quality of the produced sheet metal product can not meet the requirements and the quality can not be ensured.
3) For various parameter indexes, the adjustment time of the processor is not intelligent. The short adjustment time can lead to the need of greatly improving the rated power and capacity of the dosing machine, the water purifier and the burner, and increase unnecessary cost. The adjustment time overlength can be under the condition that processor automatic adjustment became invalid, and the time of remaining for the adjustment of interveneeing with the line personnel is too short, leads to the line personnel of following not yet adjusting the completion and just has taken place to spray the line and has stopped the line.
4) Often stop the line, need follow the line personnel and detect and adjust liquid medicine to a plurality of liquid medicine ponds during stopping the line, the adjustment bakes out the stove temperature, and at this moment all workman can only wait for, wait to spray all workman's ability work after the line resumes operation, lead to the human cost high, production efficiency reduces, also increased the cost in intangible.
5) Each spraying line needs to be controlled independently, and unified control cannot be achieved.
Disclosure of Invention
The invention aims to avoid the defects of the prior art and provides a pre-warning adjusting and controlling method for preventing a metal plate spray line from stopping.
The above object of the present invention is achieved by the following technical means:
an early warning adjusting and controlling method for preventing a metal plate spraying line from stopping comprises the following steps:
s1, the code reader scans or the person who follows the line inputs the work order bar code, and the bar code is uploaded to the MES server through the master control system and the MES network interface to match the work order information of the corresponding work order bar code, and the work order information is fed back to the master control system;
the work order information at least comprises one of spray line number, material type, total number of workpieces and chain running speed;
s2, automatically adding the work order information to the work order production statistical information, wherein the work order production statistical information at least comprises one item of spray line number, work order number, material type, total number of workpieces, chain running speed, spray starting time, hung workpiece number, line stop state and spray state;
s3, the main control system calls an MES server through an MES network interface according to the material type corresponding to the work order number to obtain early warning and warning range information, and feeds the early warning and warning range information back to the main control system and updates the early warning and warning range information; the early warning and warning range information at least comprises one early warning value and warning value of free alkalinity, pH value, total acidity, conductivity and temperature corresponding to each position number and process name;
meanwhile, the MES server obtains the adjustment target range information according to the material type of the early warning and alarm range information, wherein the adjustment target range information comprises:
each position number, each process name, one target range value of free alkalinity, phosphorization PH value and phosphorization total acidity corresponding to each dosing machine,
each position number, each process name, one of the target range values of the washing PH value and the washing conductivity corresponding to each water purifier,
each position number, each process name and a temperature target range value corresponding to each combustor;
s4, according to the early warning and warning range information, the position number and the process name of the adjustment target range information, combining the volume of the liquid medicine pool, the flow rate of the medicine adding machine and the water purification machine per minute, the concentration value of the raw liquid of the medicine adding machine and the water purification machine, or,
according to the early warning and warning range information, the position number and the process name of the adjustment target range information and the power of the burner,
obtaining automatic adjustment time T1, exception handling time T2 and space capacity time T3;
forming automatic adjustment parameter information by using the position number, the process name, the volume of the liquid medicine pool, the flow rate of the dosing machine and the water purification machine per minute, the concentration value of the raw liquid of the dosing machine and the water purification machine, the power of the burner, the automatic adjustment time T1, the exception handling time T2 and the space volume time T3, and feeding back the information to the main control system;
s5, the main control system collects field process parameters in real time through a detection sensor, wherein the field process parameters at least comprise one of parameters of a liquid medicine pool of oil removal alkalinity of a weak base oil removal pool, a water washing PH value of a water washing pool, a phosphorization PH value of a phosphorization pool, conductivity of the water washing pool, phosphorization acidity of the phosphorization pool, and temperature parameters of a baking oven;
s6, when the on-site process parameter reaches the lower limit of the early warning value of the early warning and warning range information, adjusting the on-site process parameter according to the automatic adjustment parameter information;
judging whether the field process parameters reach the target range value of the adjustment target range information within the range of the automatic adjustment time T1, if so, ending the adjustment of the field process parameters in advance; if the answer is no, the user can select the new type of the product,
the master control system displays abnormal information to remind a person following the cable to intervene in abnormal processing; the abnormal information at least comprises one of abnormal flow per minute of the dosing machine, abnormal flow per minute of the water purification machine, abnormal concentration of raw liquid of the dosing machine, abnormal concentration of raw liquid of the water purification machine and abnormal power of the burner;
judging whether the field process parameters reach the target range value of the adjustment target range information within the range of the exception handling time T2, if so, stopping adjusting the field process parameters; if the number of the current time interval is not greater than the preset threshold value,
and (4) continuing to perform exception handling within the space capacity time T3 range by the line following personnel, and within the space capacity time T3 range, ending adjusting the field process parameters if the process parameters reach the target range value of the adjustment target range information, otherwise performing line stop alarm handling.
Preferably, the code reader is an infrared code scanning device.
Further, the statistical information of the work order production also comprises,
further, the early warning and warning range information also comprises,
further, the adjustment target range information may further include,
further, the automatic adjustment parameter information further includes,
further, the space capacity time T3 is the longest space capacity time from the lower limit of the warning value to the lower limit of the warning value when the warning and warning range information is reached in the normal operation process on site, and if the longest space capacity time T3 is exceeded and the process parameter does not reach the target range value of the adjustment target range information, the wire is stopped and the warning process is performed; the abnormality processing time T2 is set between the automatic adjustment time T1 and the space capacity time T3.
Adopt the produced beneficial effect of above-mentioned technical scheme:
1. according to the invention, according to the early warning and warning range information, the position number and the process name of the adjustment target range information, the volume of a liquid medicine pool, the flow rate of a dosing machine and a water purification machine per minute, the concentration value of a raw liquid of the dosing machine and the water purification machine, or according to the early warning and warning range information, the position number and the process name of the adjustment target range information and the power of a burner, the automatic adjustment time T1 and the space capacity time T3 are obtained, before the stop line warning condition is triggered, three time defense lines of the automatic adjustment time T1, the abnormal processing time T2 and the space capacity time T3 are set to adjust the field process parameters to reach the target range value so as to prevent the stop of a metal plate spraying line, the production quality is ensured, the production efficiency is improved, and the problem of high cost caused by frequent stop line adjustment due to the abnormal field process parameters of the spraying line is solved.
2. In the steps of the invention, except for exception handling T2 and space capacity time T3, a following person is required to intervene exception handling, and other steps are carried out by a machine to intelligently adjust field process parameters, so that the automation degree is high.
3. According to the invention, T1-T3 are set to give the person following the line sufficient time for solving the abnormal processing of the spray line.
4. According to the invention, on-site process parameters such as a plurality of spraying line chemical water tanks, a barbecue oven, a water purification machine, a dosing machine and the like do not need to be checked regularly by a person following the line, the running speed of the spraying line is increased, and the on-site process parameters can be monitored in real time through the cooperation of various detection sensors and on-site process equipment, so that the product performance and the quality of a sprayed sheet metal workpiece can reach the standard.
Drawings
FIG. 1 is a schematic diagram of an early warning regulation and control method for preventing a sheet metal spray line from stopping in an embodiment;
FIG. 2 is a schematic diagram of an embodiment of a master control system;
FIG. 3 is a detailed logic diagram of the early warning regulation and control method for preventing the stop of the sheet metal spraying line according to the embodiment;
FIG. 4 is a schematic diagram of the steps for adjusting the parameters of the in situ process according to the embodiments.
Wherein, 1, a master control system; MES server; 3. a code reader; 4. a workpiece counter; 5, a PLC stop line control module; 6. a drive chain; 7. a workpiece; 8. a liquid medicine pool; 9. a baking oven; 10. a medicine adding machine control module; 11. a spray head; 12. a burner control module; 13. a detection sensor; 14. a temperature detection sensor; 15. a water purifier control module; 16. and (5) a person following the line.
Detailed Description
The technical solutions in the embodiments of the present invention are clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments obtained by persons skilled in the art without any creative work based on the embodiments in the present invention belong to the protection scope of the present invention.
In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention, but the present invention may be practiced in other ways than those specifically described herein, and it will be apparent to those skilled in the art that the present invention may be practiced without departing from the spirit and scope of the invention, and therefore the invention is not limited to the specific embodiments disclosed below.
Embodiment 1, as shown in fig. 1 and 3, an early warning adjustment and management control method for preventing a sheet metal spraying line from stopping includes the following steps:
s1, the code reader scans or the person who follows the line inputs the work order bar code, and the bar code is uploaded to the MES server through the master control system and the MES network interface to match the work order information of the corresponding work order bar code, and the work order information is fed back to the master control system;
the work order information at least comprises one of spray line number, material type, total number of workpieces and chain running speed;
s2, automatically adding the work order information to the work order production statistical information, wherein the work order production statistical information at least comprises one of a spraying line number, a work order number, a material type, a total number of workpieces, a chain running speed, a spraying starting time, a hung workpiece number, a line stop state and a spraying state;
s3, the main control system calls an MES server through an MES network interface according to the material type corresponding to the work order number to obtain early warning and warning range information, and feeds the early warning and warning range information back to the main control system and updates the early warning and warning range information; the early warning and warning range information at least comprises one of early warning values and warning values of free alkalinity, pH value, total acidity, conductivity and temperature, which correspond to each position number and process name;
meanwhile, the MES server obtains the adjustment target range information according to the material type of the early warning and alarm range information, wherein the adjustment target range information comprises:
each position number, each process name, one target range value of free alkalinity, phosphorization PH value and phosphorization total acidity corresponding to each dosing machine,
each position number, each process name, one target range value of the washing PH value and the washing conductivity corresponding to each water purifier,
each position number, each process name and a temperature target range value corresponding to each combustor;
s4, according to the position number and the process name of the early warning and warning range information and the adjustment target range information, combining the volume of the liquid medicine pool, the flow rate of the dosing machine and the water purification machine per minute, the concentration value of the raw liquid of the dosing machine and the water purification machine, or,
according to the early warning and warning range information, the position number and the process name of the adjustment target range information and the power of the burner,
obtaining automatic adjustment time T1, exception handling time T2 and space capacity time T3;
forming automatic adjustment parameter information by using the position number, the process name, the volume of the liquid medicine tank, the flow rates of the dosing machine and the water purification machine per minute, the concentration values of the stock solutions of the dosing machine and the water purification machine, the power of the burner, the automatic adjustment time T1, the exception handling time T2 and the space volume time T3, and feeding back the information to the master control system;
s5, the main control system collects the field process parameters in real time through a detection sensor, wherein the field process parameters at least comprise one of parameters of a liquid medicine pool of the oil removal alkalinity of the weak alkali oil removal pool, the water washing PH value of the water washing pool, the phosphating PH value of the phosphating pool, the conductivity of the water washing pool and the phosphating acidity of the phosphating pool, and the temperature parameter of the baking oven;
s6, when the on-site process parameters reach the lower limit of the early warning value of the early warning and alarming range information, adjusting the on-site process parameters according to the automatic adjustment parameter information;
judging whether the field process parameters reach the target range value of the adjustment target range information within the range of the automatic adjustment time T1, if so, finishing adjusting the field process parameters in advance; if the answer is no, the user can select the new type of the product,
the master control system displays abnormal information to remind a person following the cable to intervene in abnormal processing; the abnormal information at least comprises one of abnormal flow per minute of the dosing machine, abnormal flow per minute of the water purification machine, abnormal concentration of raw liquid of the dosing machine, abnormal concentration of raw liquid of the water purification machine and abnormal power of the burner;
judging whether the field process parameters reach the target range value of the adjustment target range information within the range of the exception handling time T2, if so, stopping adjusting the field process parameters; if the answer is no, the user can select the new type of the product,
and (4) continuing to perform exception handling within the space capacity time T3 range by the line following personnel, and within the space capacity time T3 range, ending adjusting the field process parameters if the process parameters reach the target range value of the adjustment target range information, otherwise performing line stop alarm handling.
According to the invention, according to the early warning and warning range information, the position number and the process name of the adjustment target range information, the volume of a liquid medicine pool, the flow rate of a dosing machine and a water purification machine per minute, the concentration value of a raw liquid of the dosing machine and the water purification machine, or according to the early warning and warning range information, the position number and the process name of the adjustment target range information and the power of a burner, the automatic adjustment time T1 and the space capacity time T3 are obtained, before the stop line warning condition is triggered, three time defense lines of the automatic adjustment time T1, the abnormal processing time T2 and the space capacity time T3 are set to adjust the field process parameters to reach the target range value so as to prevent the stop of a metal plate spraying line, the production quality is ensured, the production efficiency is improved, and the problem of high cost caused by frequent stop line adjustment due to the abnormal field process parameters of the spraying line is solved.
In the steps of the invention, except for exception handling T2 and space capacity time T3, a following person is required to intervene exception handling, and other steps are carried out by a machine to intelligently adjust field process parameters, so that the automation degree is high.
Embodiment 2 is the same as embodiment 1 in other technical features, except that the code reader is an infrared code scanning device or other code scanning devices with the same function.
Example 3, other technical features of this example are the same as those of example 1, except that the work order production statistical information further includes,
embodiment 4, other technical features of this embodiment are the same as those of embodiment 1, except that the early warning and warning range information further includes,
embodiment 5, other technical features of this embodiment are the same as those of embodiment 1, except that the adjustment target range information further includes,
embodiment 6 is the same as embodiment 1 in other technical features, except that the automatic adjustment parameter information further includes,
embodiment 7 is the same as embodiment 1 in other technical features, except that as shown in fig. 3, the space capacity time T3 is the longest space capacity time from the lower limit of the warning value to the lower limit of the warning value when the warning and warning range information is reached in the normal operation process on site, and if the longest space capacity time T3 is exceeded and the process parameter does not reach the target range value of the adjustment target range information, the process is stopped and the alarm is issued; the abnormality processing time T2 is set between the automatic adjustment time T1 and the space capacity time T3.
According to the invention, T1-T3 is set to give the person following the line sufficient time for solving the abnormal treatment of the spray line.
Embodiment 8, other technical features of this embodiment are the same as those of embodiment 1, except that, as shown in fig. 1, the main control system at least adopts one of the following detection sensors to acquire the field process parameters in real time: a free alkalinity detection sensor, a washing PH value detection sensor, a phosphating total acidity detection sensor, an electric conductivity detection sensor and a temperature detection sensor;
free alkalinity detects sensor: the system is used for detecting the free alkalinity of the weak base oil removal tank and uploading detection data to a main control system;
washing a pH value detection sensor: the pH value detection device is used for detecting the pH value of the washing pool and uploading detection data to the master control system;
phosphatization pH value detection sensor: the PH value detection device is used for detecting the PH value of the phosphating pool and uploading detection data to a master control system;
sensor for detecting total phosphated acidity: the system is used for detecting the total acidity of the phosphating pool and uploading detection data to a master control system;
conductivity detection sensor: the water washing device is used for detecting the conductivity of the water washing pool and uploading detection data to the main control system;
temperature detection sensor: used for detecting the temperature of the barbecue oven and uploading detection data to the main control system.
Embodiment 9, other technical features of this embodiment are the same as those of embodiment 1, except that as shown in fig. 1, the main control system at least uses one of the following detecting instruments to display abnormal information to remind the following staff to intervene in the abnormal process:
the dosing machine flow detector is arranged on an output pipeline of the dosing machine and used for detecting the flow per minute of the dosing machine and uploading detection data to the main control system;
the flow detector of the water purifier is arranged on an output pipeline of the water purifier and is used for detecting the flow per minute of the water purifier and uploading detection data to the main control system;
the system comprises a dosing machine raw liquid concentration detection sensor, a main control system and a control system, wherein the dosing machine raw liquid concentration detection sensor is arranged in a dosing machine raw liquid container and is used for detecting the concentration of the dosing machine raw liquid and uploading detection data to the main control system;
the water purification machine stock solution concentration detection sensor is arranged in the water purification machine stock solution container and used for detecting the stock solution concentration of the water purification machine and uploading detection data to the master control system.
According to the invention, on-site process parameters such as a plurality of spraying line chemical water tanks, a barbecue oven, a water purification machine, a dosing machine and the like do not need to be checked regularly by a person following the line, the running speed of the spraying line is increased, and the on-site process parameters can be monitored in real time through the cooperation of various detection sensors and on-site process equipment, so that the product performance and the quality of a sprayed sheet metal workpiece can reach the standard.
Example 10, this example is an example of the acquisition process regarding the automatic adjustment time T1, the abnormality processing time T2, and the space capacity time T3, which is designated as weak base degreasing 1 with the position number of 01 in step S4 of example 1.
The following data for the process name weak base degreasing 1, according to the position number of 01:
1) early warning and warning range information: the free alkalinity early warning range is <9 or >13, and the warning (warning stopping) range is <8 or > 14;
2) adjusting target range information: the target range value of the free alkalinity of the corresponding liquid medicine pool is 11-12;
3) automatically adjusting parameter information: the volume of the liquid medicine pool is 6m3The hourly flow rates of the dosing machine and the water purification machine are 6L/h (the total flow rate per minute is 100 ML/min), and the concentration values of the stock solutions (weak base oil removal solution) of the dosing machine and the water purification machine are 700.
The position is numbered 01, the process name is that the stock solution (weak base degreasing liquid) with the concentration value of 700 is automatically added into a corresponding liquid medicine pool for 15 minutes for degreasing by weak base 1, the target range value of the free alkalinity can reach 11-12, and therefore the automatic adjusting time T1 is 15 minutes;
the required time for obtaining the free alkalinity early warning value 9 to the warning value 8 is 60 minutes by combining the production statistical information of the work order and the spraying line running speed, the number of workpieces processed per minute and the workpiece area in the following table, so that the space capacity time T3 is obtained;
based on the knowledge of T1 and T3, the exception handling time T2 is set between the auto-adjustment time T1 and the space capacity time T3, so that the exception handling time T2 is obtained, and the time value of T2 is generally a middle period from T1 to T3 or twice as long as T1.
Example 11, this example is an example of the process of obtaining the automatic adjustment time T1, the abnormality treating time T2, and the space capacity time T3, which are the process names of the water washing 1, with the position number 03, in step S4 of example 1.
The following data for the process name Water Wash 1 according to the position number 03:
1) early warning and warning range information: the early warning range of the PH value is <6.2 or >7.8, and the warning (warning stopping) range is <6 or > 8;
2) adjusting the target range information: the PH value target range value of the corresponding medicine water pool (pure water pool) is 6.8-7.2;
3) automatically adjusting parameter information: the volume of the liquid medicine pool is 6m3The flow rate of the dosing machine and the water purification machine is 14L/min per minute, and the pH value of the stock solution (water) of the dosing machine and the water purification machine is 7.
The position is numbered as 03, the process name of washing 1 is that stock solution (water) with the pH value of 7 needs to be automatically added into a corresponding liquid medicine pool for 7 minutes to reach the pH value of 6.8-7.2, and therefore the automatic adjustment time T1 is 7 minutes;
the required time from the pH early warning value 6.2 of water washing to the warning value 6 is 28 minutes by combining the production statistical information of the work order and the spraying line running speed, the number of workpieces processed per minute and the area of the workpieces, and therefore the space capacity time T3 is obtained;
based on the knowledge of T1 and T3, the exception handling time T2 is set between the auto-adjustment time T1 and the space capacity time T3, so that the exception handling time T2 is obtained, and the time value of T2 is generally a middle period from T1 to T3 or twice as long as T1.
Example 12, this example is an example of the obtaining process regarding the automatic adjusting time T1, the abnormality treating time T2, and the space capacity time T3, which is designated as baking 1 by the process name of position number 10 in step S4 of example 1.
The following data for the process designation bake 1, according to the position number 10:
1) early warning and warning range information: the early warning range of the temperature of the baking furnace is <125 or >148 ℃, and the warning (warning stopping) range is <120 or >151 ℃;
2) adjusting the target range information: the temperature target range value corresponding to the baking furnace is 135-140 ℃;
3) combined spatial capacity time T3;
obtaining that the position number is 10, the process name is baking 1, and the burner needs to automatically apply 5 minutes of heating to the corresponding baking furnace to enable the temperature of the corresponding baking furnace to reach 135-140 ℃, so as to obtain the automatic adjustment time T1 of 5 minutes;
combining with the statistical information of the production of the work order, the running speed of a spraying line, the number of processing workpieces per minute, the area of the workpieces, the power of a burner and the capacity of a baking oven, and obtaining the required time from the temperature early warning value of the baking oven to the alarm value of 125 ℃ for 20 minutes, thereby obtaining the space capacity time T3;
it should be noted that the burner provides heat to the oven;
based on the knowledge of T1 and T3, the exception handling time T2 is set between the auto-adjustment time T1 and the space capacity time T3, so that the exception handling time T2 is obtained, and the time value of T2 is generally a middle period from T1 to T3 or twice as long as T1.
In the above embodiments 10-12, there are cases where the consumption of the stock solution is abnormal due to abnormality of the transmission chain as statistical information of the production of the work order, and the capacity time T3 from the temperature warning value 125 degrees to the warning value 120 degrees of the baking oven may be less than the automatic adjustment time T1, and when this occurs, the wire-off warning process is performed.
In embodiments 1 to 12 of the present invention, when the field process parameter reaches the lower limit of the warning value of the warning and warning range information, the field process parameter is adjusted, which is an additive adjustment using the consumed raw material as the process basis, and in the specific implementation process, the field process parameter may also reach the upper limit of the warning value, and when such a situation occurs, similarly, the field process parameter may be adjusted by dilution or subtraction with reference to the technical scheme in the embodiments of the present invention, and details are not repeated here.
Claims (7)
1. A pre-warning adjusting and controlling method for preventing a metal plate spraying line from stopping is characterized by comprising the following steps:
s1, the code reader scans or the person who follows the line inputs the work order bar code, and the bar code is uploaded to the MES server through the master control system and the MES network interface to match the work order information of the corresponding work order bar code, and the work order information is fed back to the master control system;
the work order information at least comprises one of spray line number, material type, total number of workpieces and chain running speed;
s2, automatically adding the work order information to the work order production statistical information, wherein the work order production statistical information at least comprises one of a spraying line number, a work order number, a material type, a total number of workpieces, a chain running speed, a spraying starting time, a hung workpiece number, a line stop state and a spraying state;
s3, the main control system calls an MES server through an MES network interface to obtain early warning and warning range information according to the material type corresponding to the work order number, and the early warning and warning range information is fed back to the main control system and updated; the early warning and warning range information at least comprises one early warning value and warning value of free alkalinity, pH value, total acidity, conductivity and temperature corresponding to each position number and process name;
meanwhile, the MES server obtains the adjustment target range information according to the material type of the early warning and alarm range information, wherein the adjustment target range information comprises:
each position number, each process name, corresponding to each dosing machine, and one target range value of free alkalinity, phosphorization PH value and phosphorization total acidity,
each position number, each process name, one of the target range values of the washing PH value and the washing conductivity corresponding to each water purifier,
each position number, each process name and a temperature target range value corresponding to each combustor; s4, according to the early warning and warning range information, the position number and the process name of the adjustment target range information, combining the volume of the liquid medicine pool, the flow rate of the medicine adding machine and the water purification machine per minute, the concentration value of the raw liquid of the medicine adding machine and the water purification machine, or,
according to the early warning and warning range information, the position number and the process name of the adjustment target range information and the power of the burner,
obtaining automatic adjustment time T1, exception handling time T2 and space capacity time T3;
forming automatic adjustment parameter information by using the position number, the process name, the volume of the liquid medicine tank, the flow rates of the dosing machine and the water purification machine per minute, the concentration values of the stock solutions of the dosing machine and the water purification machine, the power of the burner, the automatic adjustment time T1, the exception handling time T2 and the space volume time T3, and feeding back the information to the master control system;
s5, the main control system collects field process parameters in real time through a detection sensor, wherein the field process parameters at least comprise one of parameters of a liquid medicine pool of oil removal alkalinity of a weak base oil removal pool, a water washing PH value of a water washing pool, a phosphorization PH value of a phosphorization pool, conductivity of the water washing pool, phosphorization acidity of the phosphorization pool, and temperature parameters of a baking oven;
s6, when the on-site process parameter reaches the lower limit of the early warning value of the early warning and warning range information, adjusting the on-site process parameter according to the automatic adjustment parameter information;
judging whether the field process parameters reach the target range value of the adjustment target range information within the range of the automatic adjustment time T1, if so, ending the adjustment of the field process parameters in advance; if the answer is no, the user can select the new type of the product,
the main control system displays abnormal information to remind a person following the cable to intervene in abnormal processing; the abnormal information at least comprises one of abnormal flow per minute of the dosing machine, abnormal flow per minute of the water purification machine, abnormal concentration of raw liquid of the dosing machine, abnormal concentration of raw liquid of the water purification machine and abnormal power of the burner;
judging whether the field process parameters reach the target range value of the adjustment target range information within the range of the exception handling time T2, if so, stopping adjusting the field process parameters; if the answer is no, the user can select the new type of the product,
and (4) continuing to perform exception handling within the space capacity time T3 by the line following personnel, and within the space capacity time T3, if the process parameters reach the target range value of the adjustment target range information, ending the adjustment of the field process parameters, otherwise, performing line stop alarm processing.
2. The early warning regulation and control method for preventing the stop of the sheet metal spraying line as claimed in claim 1, wherein the code reader is an infrared code scanning device.
3. The early warning regulation and control method for preventing the wire stop of the sheet metal spraying line according to claim 1, wherein the work order production statistical information further comprises,
4. the early warning regulation and control method for preventing the wire stop of the sheet metal spraying line according to claim 3, wherein the early warning and warning range information further comprises,
5. the early warning regulation and control method for preventing the stop of the sheet metal spraying line as claimed in claim 4, wherein the information of the regulation target range further comprises,
6. the early warning regulation and control method for preventing the stop of the sheet metal spraying line as claimed in claim 5, wherein the automatic parameter regulation information further comprises,
7. the early warning regulation and control method for preventing the wire stop of the sheet metal spraying line as claimed in claim 6, wherein the space capacity time T3 is the longest space capacity time from the lower limit of the early warning value to the lower limit of the warning value when the early warning and warning range information is reached in the normal operation process on site, and the wire stop warning processing is performed when the longest space capacity time T3 is exceeded and the process parameter does not reach the target range value of the regulation target range information; the abnormality processing time T2 is set between the automatic adjustment time T1 and the space capacity time T3.
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