CN115202304A - Material frame tracking method in forging production process - Google Patents
Material frame tracking method in forging production process Download PDFInfo
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- G05B19/4185—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by the network communication
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Abstract
The invention provides a material frame tracking method in the production process of a forge piece, wherein a node monitoring module, a metal bar code of a material frame, a data storage module, an application terminal and a network server are linked, the network server receives a work order containing information of product name, yield and batch number sent by an application terminal of a manager, and the network server also receives data transmitted by the node monitoring module, records forge piece information provided by each workshop in a database and provides the forge piece information for the application terminal to access; the material frame tracking management is realized, and the problems that manual management and operation are adopted in the traditional manufacturing process, and a material circulation process is adopted, a black box is adopted, and the like are solved. The method and the device realize effective scheduling of the forge pieces and the material frames, improve the tracking management efficiency of a workshop and reduce the production cost.
Description
Technical Field
The invention belongs to the field of production and manufacturing of forgings, and particularly relates to a material frame tracking method in a production process.
Background
The forging is widely applied to strategic industrial equipment in the power industry, the metallurgy industry, the ship industry, the military industry, heavy mining machinery, aerospace and the like. The production and the manufacture of the forging reflect the industrial level of a country to a certain extent, and have important significance for the development and the construction of the country. However, many forging production lines at present are manually regulated and controlled, manual management and operation are adopted for tracking and managing material frames, fatigue is easily generated by long-time repeated heavy physical labor of operators, and states and information of forgings and material frames in the conveying process cannot be obtained in real time, so that lean management and control of the whole production process are directly influenced.
The material frame that the black case of material circulation process leads to tracks inefficiency, manufacturing information is incomplete, can't preserve the complete archives of formation batch, material frame transfer speed leads to in process of work in progress a large amount of overstocks scheduling problem to make the production efficiency and the product quality greatly reduced of forging. When the traditional material frame tracking management method is used for transporting the forged piece, the forged piece can be lost in the transportation process, even serious safety accidents are caused, and the reliability is low.
Therefore, how to provide a material frame tracking management method in the forging production process is necessary.
Disclosure of Invention
In order to solve the problems of low production efficiency and low product quality of the forge piece, the invention provides the material frame tracking method in the forge piece production process, so that the material frame is effectively tracked, the tracking management efficiency of the forge piece is improved, and the accuracy and the real-time performance of the material frame tracking process are ensured.
The technical scheme of the invention is as follows: a material frame tracking method in the production process of a forged piece is characterized in that a network server receives a work order containing product name, yield and batch number information sent by a manager application terminal, receives data transmitted by a node monitoring module, records forged piece information provided by each workshop in a database and provides the forged piece information for the application terminal to access;
each workshop arranged according to the processing flow of the forge piece is provided with a node monitoring module, and each node monitoring module comprises an electronic scale, two material frame monitoring node code scanners and a networking control device; the two material frame monitoring nodes of each workshop are a material frame monitoring node No. 1 and a material frame monitoring node No. 2, a code scanner of each material frame monitoring node scans a metal bar code arranged on a material frame to obtain material frame information, the material frame monitoring node No. 1 is an entry node, the material frame monitoring node No. 2 is an exit node, and an electronic scale arranged at a discharge port of each workshop obtains weighing data; the networked control equipment takes an STM32F103 core board as a core control module, can acquire real-time data weighed by an electronic scale and display the data on a display screen, and transmits the data to a network server through an HTTP protocol, the network server calculates the quantity of forgings at the discharge port according to the single weight of the forgings and current weighing data, and the measured and calculated data and the forgings, the information of the networked control equipment, the current workshop information of a material frame, the scheduling time and the single number information are stored in a database together so as to facilitate the material management at the later stage of a factory.
An ESP8266 (namely a WIFI chip) is adopted as a wireless communication module in the equipment networking part of the networking control equipment, and data communication between an STM32F103 core board and the ESP8266 is realized through a serial port; the wireless communication module is externally connected with an antenna rod and adopts an AT instruction to realize a wireless communication function; when the network is networked for the first time, the wireless communication module connection test and the networking mode configuration are carried out; and if the network is disconnected subsequently, the wireless communication module can automatically connect the wireless network and acquire the connection of the network server according to the last configured route.
Networking controlgear passes through the mode of the external antenna of wireless communication module, strengthens signal identification sensitivity, ensures the wiFi signal intensity of operation in-process, and external antenna rod working frequency channel contains the wiFi frequency channel, can satisfy equipment wiFi communication requirement.
When the wireless communication module is connected with a power supply, the power supply indicator lamp can be lightened, and the lightening state is kept during the working period of the wireless communication module; when the wireless communication module is successfully accessed to the network and the server, the networking indicator lamp flashes twice and the buzzer buzzes to prompt the wireless communication module to be successfully networked, and the networking indicator lamp is always kept in a lighting state under the condition that the network is connected; the wireless communication module controls whether the weighing data is uploaded or not through a key, and when a start key is pressed down to indicate that the data uploading starts, and an end key is pressed down to indicate that the data uploading is stopped; the OLED display screen of the wireless communication module can display basic information of the wireless communication module, the current time and the networking state of the wireless communication module, and the display screen can refresh the electronic scale to weigh the weight once every 0.5s, so that the real-time performance of data display is ensured.
The metal bar codes used for identifying the material frame are arranged on 4 side faces of the material frame, the 4 metal bar codes are the same in size and code and are scanned and identified in aspects.
When measurement data measured by a gravity sensor on the electronic scale changes and data received by a data input interface of the electronic scale fluctuates and can be stably kept for a period of time, the total weight of the material frames starts to be measured, the obtained data are packaged, the data are uploaded to an EMQX MQTT message agent of a network server through a wireless communication module and are stored in a database, data are issued to a theme corresponding to a node monitoring module based on an MQTT protocol of TCP, the network server subscribes the theme to acquire weighing data to realize tracking of the discharging condition of a discharging port, and the network server calculates the number of forgings of the discharging port according to the acquired weighing data;
when the measurement data measured by the gravity sensor on the electronic scale is unchanged, the data cannot be continuously uploaded.
When the electronic scale data input interface continuously receives N frames of same data, judging that the data received by the electronic scale data input interface can be stably maintained after fluctuating, and uploading data when N = 10;
when an input interface of the electronic scale continuously receives N + N frames of same data, the data are not uploaded, wherein N is any positive integer; therefore, each time of data uploading exists under the condition of continuously receiving 10 frames of the same data after data change; the data uploaded each time are data after one-time weighing stabilization, and the data are not changed for more than 10 frames, which indicates that the weight of the forge piece is kept at the current stable value, namely the state of the forge piece in the forge piece frame is not changed, and the forge piece is not newly added or reduced, so that the data do not need to be uploaded. The 10 frames are determined by the stabilization time of a part of electronic scales on the market, and the data collected by the electronic scales are kept unchanged for 1s to judge that the weighing is stabilized at the moment. The baud rate of serial port data transmission of the electronic scale sensor connected with the MCU can be set to 1200 at the lowest, 120 bytes can be transmitted uninterruptedly every second, namely 10 data frames, a current weighing result can be output every 0.1s, data acquisition is dense, uploading is a result which can continuously stabilize a plurality of frames and is not a process quantity, and the final effect of data acquisition cannot be influenced by discarding one frame of data due to byte errors occasionally.
Each frame of data of the electronic scale data input interface consists of 12 bytes, wherein the 1 st byte is a start bit, the 2 nd byte is a sign bit, the 3 rd to 8 th bytes are weighing data bits, the 9 th byte is a decimal point bit, the 10 th to 11 th bytes are exclusive-or check bits, and the 12 th byte is an end bit.
The application terminal is a handheld industrial PDA and is provided with a camera, a touch screen, a keyboard and a wifi module, an Android operating system runs in the application terminal, a material frame tracking APP runs in the Android operating system, the material frame tracking APP scans a metal bar code on a material frame through the camera to obtain a bar code number, a network access network server inquires a record corresponding to the bar code number and displays related information of the material frame in the material frame tracking APP, information of the material frame in the network server and current monitoring nodes or production information are bound through an operating interface of the material frame tracking APP and updated to the network server for storage, and the storage information comprises material frame state change, built-in forging number and model information; when the number and the type of the forge pieces in the material frame change, the information is modified in an operation interface provided by the material frame tracking APP, and the information is updated to the network server through the wifi module.
The network server receives a work order containing product name, yield and batch number information sent by the application terminal of a manager, receives data transmitted by the node monitoring module, records forging information provided by each workshop in a database and provides the forging information for the application terminal to access;
each workshop which is arranged according to the processing flow of the forge piece is provided with a node monitoring module, and each node monitoring module comprises an electronic scale, two material frame monitoring nodes and networking control equipment; the two material frame monitoring nodes of each workshop are a material frame monitoring node No. 1 and a material frame monitoring node No. 2, a code scanner of each material frame monitoring node scans a metal bar code arranged on a material frame to obtain material frame information, the material frame monitoring node No. 1 is an entry node, the material frame monitoring node No. 2 is an exit node, and an electronic scale arranged at a discharge port of each workshop obtains weighing data; the networked control equipment takes an STM32F103 core board as a core control module, can acquire real-time data weighed by an electronic scale and display the real-time data on a display screen, and transmits the real-time data to a network server through an HTTP (hyper text transport protocol), the network server calculates the number of forgings at the discharge port according to the single weight of the forgings and current weighing data, and the measured and calculated data and the forgings, the information of the networked control equipment, the current workshop information of a material frame, the scheduling time and the single number information are stored in a database together so as to facilitate the later-stage material management of a factory.
An ESP8266 (namely a WIFI chip) is adopted as a wireless communication module in the equipment networking part of the networking control equipment, and data communication between an STM32F103 core board and the ESP8266 is realized through a serial port; the wireless communication module is externally connected with an antenna rod and adopts an AT instruction to realize a wireless communication function; when the network is networked for the first time, the wireless communication module connection test and the networking mode configuration are carried out; if the network is disconnected subsequently, the wireless communication module can automatically connect to the wireless network and acquire the connection of the network server according to the last configured route.
The networking controlgear passes through the mode of the external antenna of wireless communication module, strengthens signal identification sensitivity, ensures the wiFi signal strength of operation in-process, and external antenna stick working frequency channel contains the wiFi frequency channel, can satisfy equipment wiFi communication requirement.
When the wireless communication module is connected with the power supply, the power indicator lamp can be lightened, and the lightening state is kept during the working period of the wireless communication module; when the wireless communication module is successfully accessed to the network and the server, the networking indicator lamp flashes twice and the buzzer buzzes to prompt the wireless communication module to be successfully networked, and the networking indicator lamp is always kept in a lighting state under the condition that the network is connected; the wireless communication module controls whether the weighing data is uploaded or not through the key, when the start key is pressed down to indicate that the data uploading starts, and the end key is pressed down to indicate that the data uploading is stopped; the OLED display screen of the wireless communication module can display basic information of the wireless communication module, the current time and the networking state of the wireless communication module, and the display screen can refresh the electronic scale to weigh the weight once every 0.5s, so that the real-time performance of data display is ensured.
The metal bar codes used for identifying the material frame are arranged on 4 side faces of the material frame, the 4 metal bar codes are the same in size and code and are scanned and identified in aspects.
When measurement data measured by a gravity sensor on the electronic scale changes and data received by a data input interface of the electronic scale fluctuates and can be stably kept for a period of time, the total weight of the material frames starts to be measured, the obtained data are packaged, the data are uploaded to an EMQX MQTT message agent of a network server through a wireless communication module (ESP 8266 WIFI module) and are stored in a database, data are issued to a theme corresponding to a node monitoring module based on an MQTT protocol of TCP, the network server subscribes the theme to obtain weighing data so as to track the discharging condition of a discharging port, and the network server calculates the number of forgings of the discharging port according to the obtained weighing data;
when the measurement data measured by the gravity sensor on the electronic scale is unchanged, the data cannot be continuously uploaded.
When the electronic scale data input interface continuously receives N frames of same data, judging that the data received by the electronic scale data input interface can be stably maintained after fluctuating, and uploading data when N = 10;
when an input interface of the electronic scale continuously receives N + N frames of same data, the data are not uploaded, wherein N is any positive integer; therefore, each time of data uploading exists under the condition that 10 frames of same data are continuously received after the data are changed;
the data uploaded each time are data after one-time weighing stabilization, and the data are not changed for more than 10 frames, which indicates that the weight of the forging piece is kept at the current stable value, namely the state of the forging piece in the forging piece frame is not changed, and the forging piece is not newly added or reduced, so that the data do not need to be uploaded. The 10 frames are determined by the stabilization time of a part of electronic scales on the market, and the data collected by the electronic scales are kept unchanged for 1s to judge that the weighing is stabilized at the moment. The lowest baud rate of serial port data transmission of the electronic scale sensor and the MCU can be set to 1200, 120 bytes can be transmitted continuously every second, namely 10 data frames, a current weighing result can be output every 0.1s, data acquisition is still dense, uploading is a result which can continuously stabilize a plurality of frames and is not changed, a process quantity is not required, and the final effect of data acquisition cannot be influenced by discarding one frame of data due to byte errors occasionally.
Each frame of data of the electronic scale data input interface consists of 12 bytes, wherein the 1 st byte is a start bit, the 2 nd byte is a sign bit, the 3 rd to 8 th bytes are weighing data bits, the 9 th byte is a decimal point bit, the 10 th to 11 th bytes are exclusive-or check bits, and the 12 th byte is an end bit.
The application terminal is a handheld industrial PDA and is provided with a camera, a touch screen, a keyboard and a wifi module, an Android operating system runs in the application terminal, a material frame tracking APP runs in the Android operating system, the material frame tracking APP scans a metal bar code on a material frame through the camera to obtain a bar code number, a network access server inquires a record corresponding to the number and displays related information of the material frame in the material frame tracking APP, and the information of the material frame in the network server and current monitoring nodes or production information can be bound and updated to the network server for storage through an operating interface of the material frame tracking APP, wherein the information comprises the state change of the material frame, the number of built-in forgings and model information; when the quantity and the model of the built-in forging of material frame change, can modify information in the interface that this APP provided to in network server is updated through the wifi module.
The method is based on the existing forging production line, combines with field equipment, and utilizes a node monitoring module, a material frame marking module, a data storage module and an application terminal to realize material frame tracking management in the production and manufacturing process of the forge piece. In the intelligent material frame tracking management method, network connection is established with a network server to realize material frame tracking management, and the problems of manual management and operation, black box in the material circulation process and the like in the traditional manufacturing process are solved.
The node monitoring module comprises a material frame monitoring node No. 1, a code scanner of a material frame monitoring node No. 2 and an electronic scale, wherein the material frame monitoring node No. 1 and the code scanner of the material frame monitoring node No. 2 are arranged in each workshop; a gravity sensor and a vibration sensor are arranged on the electronic scales of each workshop; the node monitoring module is connected with the networking control equipment, the networking control equipment is connected with a network server through the forge piece frame falling times and the total weight data of the material frames, which are obtained by the vibration sensor and the gravity sensor in the electronic scale, and the forge piece number and the total weight of the material frames are uploaded.
The material frame marking module comprises a metal bar code. The metal bar codes are used for identifying the material frame, the metal bar codes are arranged on 4 side faces of the material frame, the 4 metal bar codes are the same in size and code and are scanned and identified in aspects.
The networking control equipment uses an STM32F103 core board (also called an STM32F103 single chip microcomputer and an STM32F103 development board) as a core control module, can acquire real-time data weighed by an electronic scale and display the real-time data on a display screen, and transmits the real-time data to a network server through an HTTP (hyper text transport protocol), and the server end calculates the quantity of the forge piece at the discharge port according to the singleness of the forge piece and the current weighing data. The networked control device is referred to as a device for short. The measured data is stored into a factory production information base (namely a database) together with time and equipment information so as to facilitate the material management in the later period of the factory. When the equipment is connected with a power supply, the power supply indicator lamp can be lightened, and the lightening state is kept during the working period of the equipment; when the equipment is successfully accessed to the network and the server, the networking indicator lamp flashes twice and the buzzer buzzes to prompt the equipment to be successfully networked, and the networking indicator lamp is always kept in a lighting state in a network connection state; the equipment needs to control the uploading of the weighing data through the keys, when the start key is pressed down to indicate that the data uploading starts, and when the end key is pressed down to indicate that the data uploading is stopped. The OLED display screen of the equipment can display basic information of the equipment, the current time and the networking state of the equipment, and the display screen can refresh the electronic scale to weigh the weight once every 0.5s, so that the real-time performance of data display is ensured.
Networking control equipment's equipment networking part adopts ESP8266 (WIFI chip promptly) as the WiFi module (the wireless communication module promptly), realizes STM32F103 development board and ESP 8266's data communication through the serial ports. The WiFi module is externally connected with an antenna rod, and the wireless communication function is realized by adopting an AT instruction. When networking is carried out for the first time, module connection testing and networking mode configuration are required; and if the network is disconnected subsequently, the WiFi module can automatically connect the wireless network and acquire the connection of the server according to the last configured route. In order to ensure the WiFi signal strength in the operation process, the equipment strengthens the signal identification sensitivity in a mode of externally connecting the WiFi module with an antenna. The external antenna rod working frequency band contains the WiFi frequency band, and the WiFi communication requirement of the equipment can be met.
Each workshop is provided with two material frame monitoring nodes, transmits data to the data storage module and provides the data for the application terminal to access.
The data storage module comprises a database software. And the database software is used for creating an identification database and storing binding information of the material frame, the forging and the workshop in the production and manufacturing process of the forging. The network server can receive a work order containing information of product names, yield and batch numbers sent by the management personnel application terminal PDA, can also receive data transmitted by the material frame node monitoring module, records the forging information provided by each workshop in the database, and provides the forging information for the application terminal to access.
Drawings
FIG. 1 is a schematic diagram of a process flow for producing a forging;
FIG. 2 is a structural explanatory diagram of the present invention;
FIG. 3 is a schematic diagram of a networked control device;
FIG. 4 is a schematic view of a networked control device;
fig. 5 is a data parsing flow diagram for a networked control device.
Detailed Description
In the figures 1-4, an STM32F103 core board is used as a core control module, networking control equipment (equipment for short) is designed, the equipment can acquire real-time data weighed by an electronic scale and display the data on an OLED display screen, the real-time data is transmitted to a network server through WiFi, and the network server calculates the quantity of forgings at the discharge port according to the single weight of the forgings and the current weighing data. The measured historical data is stored into a factory production information base together with time and equipment information so as to facilitate factory production management. When the equipment is connected with a power supply, the power supply indicator lamp can be lightened, and the lightening state is kept during the working period of the equipment; when the equipment is successfully accessed to the network and the network server, the networking indicator lamp flashes twice, the buzzer sends out a prompt sound to prompt the equipment to be successfully networked, and the networking indicator lamp is always kept in a lighting state under the condition that the network is connected; the device needs to control the uploading of the weighing data through the keys, when the start key is pressed to indicate that the uploading is ready to be started, and when the end key is pressed to indicate that the uploading of the data is terminated.
Networking controlgear adopts the low pressure power supply, and the supply voltage scope: 2V to 3.6V, and the highest working voltage is 3.6V. By adopting a micro USB power interface, when the 220V alternating current is connected, voltage modulation needs to be carried out through a converter.
The electronic scale data acquisition part adopts serial port communication, and STM32F103 nuclear core plate passes through the RS232 interface of serial port connection electronic scale, receives the incessant data frame of coming from the electronic scale to analyze it immediately, extract the forging weight data that the electronic scale weighed at present according to the structure of data frame. After data fluctuation, if the development board obtains 10 times of same data frames and the current equipment is in a data uploading state, the weighing data, time and equipment information are uploaded to a network server through a WiFi module.
And the equipment networking part adopts the ESP8266 as a WiFi module, and also realizes data communication between the STM32F103 development board and the ESP8266 through a serial port. ESP8266 WiFi module external antenna stick adopts AT instruction to realize wireless communication function. When networking is carried out for the first time, module connection testing and networking mode configuration are required; and if the network is disconnected subsequently, the WiFi module can automatically connect the wireless network and acquire the connection of the network server according to the last configured route.
The status indication part is used for continuously lighting the power indicator lamp after the equipment is electrified; the networking indicator light flashes when the network state of the equipment changes and is continuously lightened in the networking state; the buzzer can prompt when the network connection state changes, and the buzzing sound is used as the prompt sound of the key state change.
The appearance diagram of the networking control equipment is shown in fig. 4, a PCB circuit board which takes STM32F103 as a core and controls peripheral functions is arranged in an equipment packaging box, a micro USB power interface and an electronic scale RS232 interface are connected to the PCB circuit board, and a data uploading and uploading ending key, a power supply and a network state indicator lamp are led out at the same time. When the data uploading key is pressed down, the equipment starts to transmit data which are acquired from the current time to the cloud server; when the upload ending button is pressed, the data upload is immediately ended. The power indicator lamp keeps on lighting when the equipment is powered on; the network state indicator lights twinkle for a moment when the network state of the equipment changes, the status is continuously lighted up when the equipment is normally networked, and the status is kept extinguished when no network connection exists. The connected OLED display screen can display basic information of the equipment, the current time and the networking state of the equipment, and the display screen can refresh the electronic scale to weigh the weight once every 0.5s, so that the real-time performance of data display is ensured. STM32F103 core development board contains three communication serial ports of USART1, USART2, USART3, and USART1 is as debugging information output interface, USART2 is as wiFi module communication interface, and USART3 is as electronic scale data input interface.
In order to ensure the WiFi signal strength in the operation process, the device strengthens the signal identification sensitivity in a mode of externally connecting an ESP8266 WiFi module with an antenna. The external antenna rod working frequency band contains the WiFi frequency band, and the WiFi communication requirement of the equipment can be met.
The Baud rate of the USART3 interface of the wireless communication module is matched with the output Baud rate of the electronic scale sensor and is set to 2400 and 8 bit data bits and 1 bit stop bit. The electronic scale serial communication uses a continuous mode 4, each frame of the communication mode comprises 12 bytes, and the specific rule is as follows:
the transmitted data is the current weight (gross weight) data displayed by the meter (weight value at overload is 999999). Each frame data consists of 12 groups of data. The format is shown in the following table: (xor =2 · 3 · 8230; \8230; 8 # 9)
And continuously detecting the data receiving condition of the USART3, if any byte of one frame of data is not qualified, re-detecting from the first byte received later, and directly discarding the byte data with errors.
When the data received by the serial port can be stably maintained after fluctuating (10 frames of same data are continuously received), the data is uploaded to a network server, namely, the data is issued to a theme corresponding to the electronic scale, if the data is kept unchanged subsequently, the data cannot be continuously uploaded, so that each time the data is uploaded, the situation that 10 frames of same data are continuously received after the data are changed exists.
Fig. 5 is a flow chart of data parsing of a serial port, where each frame of data includes 12 bytes, and receives data and updates a serial port state through a switch-case statement. When the serial port state is set to 0, the analysis is started when the received byte is 0x02, otherwise, the starting byte is continuously waited. If the received start byte is 0x02, the serial port state is set to 1, the data of the sign bit is received, the sign is positive when the received data byte of the sign bit is 0x2B, and the sign is negative when the received data byte of the sign bit is 0x 2D. And when the data of the sign bit is neither 0x2B nor 0x2D, judging that the data does not meet the requirement, setting the serial port state to be 0, and restarting to detect the start byte. If the symbol bit data is correct, the serial port state is set to 2, weighing data is received, and the weighing data consists of 6 bytes. And only if the weighing data is within 0x 30-0 x39 and is composed of 6 bytes, the limited data is formed, and when the weighing data does not meet the requirement, the serial port state is set to be 0, and the detection of the start byte is restarted. If the weighing data is correct, the serial port state is set to be 3, and decimal point position data are received. And (3) only the decimal point position data is limited data within 0x 30-0 x34, and when the decimal point position data does not meet the requirement, the serial port state is set to be 0, and the detection of the starting byte is restarted. If the weighing data is correct, the serial port state is set to 4, and high 4-bit check data are received. And when the high-order 4-bit check data are incorrect, setting the serial port state to be 0, and restarting to detect the start byte. If the high 4-bit check data is correct, the serial port state is set to 5, and the low 4-bit check data is received. And when the lower 4-bit check data are incorrect, setting the serial port state to be 0, and restarting to detect the start byte. If the lower 4 bits of check data are correct, the serial port state is set to 6, and the end data is received. And when the ending data byte is not 0x03, setting the serial port state to be 0, and restarting to detect the starting byte. If the received byte is 0x03, extracting the valid data of the frame and analyzing. After extracting effective data of one frame, setting the serial port state to 0 to receive the data of the next frame, and forming a set of complete serial port data analysis flow.
The following description will be made of a material frame tracking method in the production process of a forged piece, taking a forging workshop with the processing flow of the forged piece as an example:
the raw materials are firstly sent to a forging workshop for processing, after forging is completed, the batch of forgings are generated and transferred to a heat treatment workshop for task, binding information between the forgings and the forging workshop is generated, and scheduling time and single number information are recorded. The transfer transportation task comprises the total amount and weight of single-batch forge pieces, the batch number of the forge pieces, whether a single forge piece is a large one, a transportation starting point and a transportation end point, when the network server receives the transfer transportation task of the forging shop, the network server generates a transportation instruction aiming at the transfer transportation task, gives priority to the transportation instruction, obtains a metal bar code in an idle state between the vehicles according to the transportation instruction, and compares the transportation task with the load capacity limit of a material frame in the idle state between the vehicles.
When the total weight of a single batch of forgings in a forging workshop is larger than the load capacity limit of the material frames in the idle state in the workshop, the transportation efficiency of the batch of forgings is reduced, and at the moment, the network server sends a carrying instruction to other workshops and selects the material frames in the idle state in the other workshops. The network server selects idle state material frames of other workshops nearby according to the priority of the carrying instruction and transfers the idle state material frames to the forging workshop, and selects the heat treatment workshop with the shortest path from the forging workshop as much as possible to transfer.
Due to the fact that the total weight and the number of the forgings in different batches are different and the types of the forgings are different, the load capacity limits of material frames of different types are also different. When a single batch of forged pieces are large forged pieces, the network server generates a carrying instruction aiming at the large forged piece transfer and transportation task, gives priority to the carrying instruction, acquires a large metal bar code in an idle state according to the carrying instruction, and compares the load capacity limit of a large material frame in the idle state in the workshop. When the weight of a single batch of heavy forged pieces is larger than the load capacity limit of the heavy material frames in the idle state in the workshop, the network server sends the carrying instruction to other workshops at the moment, and the carrying instruction is selected from the heavy material frames in the idle state in other workshops. The network server can reasonably distribute the material frames according to the carrying instructions with different priorities and preferentially select the large material frames of the nearby workshops for transfer.
When idle state material frames of other workshops are transferred to a forging workshop, the total weight of the forging of the batch is equal to or less than the load capacity limit of the material frame in the idle state in the current workshop, the material frame is scanned and uploaded to a network server at a material frame monitoring node No. 1 in the forging workshop, the network server uploads a database to create a new identification entry, the material frame is written in to bind forging workshop information, and scheduling time and single number information are recorded.
The method comprises the steps that a material frame reaches a production line through a conveyor belt to receive a forge piece, the forge piece falls into the production line in uninterrupted time, a vibration sensor of an electronic scale judges whether the weight is within a reasonable weight range of a single forge piece or not through the newly increased weight generated by the falling of the forge piece each time, if so, the number of the newly increased forge piece is counted, a gravity sensor on the electronic scale judges whether the material frame is filled with the newly increased forge piece or not through the continuously increased weight, a networking control device connects the number of times of falling of the forge piece and total weight data of the material frame, which are obtained by the vibration sensor and the gravity sensor in the electronic scale, with a network server, uploads the number and the total weight of the forge piece falling into the material frame, the network server calculates the number of the forge piece at a discharge port according to the single weight of the forge piece and current weighing data, historical data after measurement and calculation and node monitoring module information are used for binding the forge piece, the material frame and forging workshop information, and recording scheduling time and the single number information.
After a batch of forgings in the forging shop are framed, reach No. 2 material frame monitoring nodes through the conveyer belt, roll out the forging shop through No. 2 material frame monitoring nodes bar code scanner, send to next workshop and carry out next round of processing. And simultaneously, the network server uploads the database modification identification items, erases the material frame binding forging workshop information, retains the binding records of the batch of forgings and the forging workshop, and waits for the network server to issue a processing task instruction for transferring the batch of forgings to the next workshop.
Claims (8)
1. A material frame tracking method in the production process of a forge piece is characterized by comprising the following steps: the network server receives a work order containing product name, yield and batch number information sent by the application terminal of a manager, receives data transmitted by the node monitoring module, records forging information provided by each workshop in a database, and provides the forging information for the application terminal to access;
each workshop arranged according to the processing flow of the forge piece is provided with a node monitoring module, and each node monitoring module comprises an electronic scale, two material frame monitoring node code scanners and a networking control device; the two material frame monitoring nodes of each workshop are a material frame monitoring node No. 1 and a material frame monitoring node No. 2, a code scanner of each material frame monitoring node scans a metal bar code arranged on a material frame to obtain material frame information, the material frame monitoring node No. 1 is an entry node, the material frame monitoring node No. 2 is an exit node, and an electronic scale arranged at a discharge port of each workshop obtains weighing data; the networked control equipment takes an STM32F103 core board as a core control module, can acquire real-time data weighed by an electronic scale and display the data on a display screen, and transmits the data to a network server through an HTTP protocol, the network server calculates the quantity of forgings at the discharge port according to the single weight of the forgings and current weighing data, and the measured and calculated data and the forgings, the information of the networked control equipment, the current workshop information of a material frame, the scheduling time and the single number information are stored in a database together so as to facilitate the material management at the later stage of a factory.
2. The material frame tracking method in the forging production process according to claim 1, characterized in that: an ESP8266 is adopted as a wireless communication module in the equipment networking part of the networking control equipment, and data communication between an STM32F103 core board and the ESP8266 is realized through a serial port; the wireless communication module is externally connected with an antenna rod and adopts an AT instruction to realize a wireless communication function; when the network is networked for the first time, the wireless communication module connection test and the networking mode configuration are carried out; and if the network is disconnected subsequently, the wireless communication module can automatically connect the wireless network and acquire the connection of the network server according to the last configured route.
3. The material frame tracking method in the forging production process according to claim 1, characterized in that: networking controlgear passes through the mode of the external antenna of wireless communication module, strengthens signal identification sensitivity, ensures the wiFi signal intensity of operation in-process, and external antenna rod working frequency channel contains the wiFi frequency channel, can satisfy equipment wiFi communication requirement.
4. The material frame tracking method in the forging production process according to claim 1, wherein: when the wireless communication module is connected with a power supply, the power supply indicator lamp can be lightened, and the lightening state is kept during the working period of the wireless communication module; when the wireless communication module is successfully accessed to the network and the server, the networking indicator lamp flashes twice and the buzzer buzzes to prompt the wireless communication module to be successfully networked, and the networking indicator lamp is always kept in a lighting state under the condition that the network is connected; the wireless communication module controls whether the weighing data is uploaded or not through the key, when the start key is pressed down to indicate that the data uploading starts, and the end key is pressed down to indicate that the data uploading is stopped; wherein the OLED display screen of wireless communication module can show wireless communication module basic information, current time and wireless communication module networking state to every 0.5s can the display screen can refresh once electronic scale and weigh weight, ensure data display's real-time.
5. The material frame tracking method in the forging production process according to claim 1, wherein: the metal bar codes used for identifying the material frame are arranged on 4 side faces of the material frame, the 4 metal bar codes are the same in size and code and are scanned and identified in aspects.
6. The material frame tracking method in the forging production process according to claim 1, wherein: when measurement data measured by a gravity sensor on the electronic scale changes and data received by a data input interface of the electronic scale fluctuates and can be stably kept for a period of time, the total weight of the material frames starts to be measured, the obtained data are packaged, the data are uploaded to an EMQX MQTT message agent of a network server through a wireless communication module and are stored in a database, data are issued to a theme corresponding to a node monitoring module based on an MQTT protocol of TCP, the network server subscribes the theme to acquire weighing data to realize tracking of the discharging condition of a discharging port, and the network server calculates the number of forgings of the discharging port according to the acquired weighing data;
when the measurement data measured by the gravity sensor on the electronic scale is unchanged, the data cannot be continuously uploaded.
7. The material frame tracking method in the forging production process according to claim 1, wherein: when the electronic scale data input interface continuously receives N frames of same data, judging that the data received by the electronic scale data input interface can be stably maintained after fluctuating, and uploading the data;
when an input interface of the electronic scale continuously receives N + N frames of same data, the data are not uploaded, wherein N is any positive integer;
each frame of data of the electronic scale data input interface consists of 12 bytes, wherein the 1 st byte is a start bit, the 2 nd byte is a sign bit, the 3 rd to 8 th bytes are weighing data bits, the 9 th byte is a decimal point bit, the 10 th to 11 th bytes are exclusive-or check bits, and the 12 th byte is an end bit.
8. The material frame tracking method in the forging production process according to claim 1, wherein: the application terminal is a handheld industrial PDA and is provided with a camera, a touch screen, a keyboard and a wifi module, an Android operating system runs in the Android operating system, a material frame tracking APP runs in the Android operating system, the material frame tracking APP scans a metal bar code on a material frame through the camera to obtain a bar code number, a network server is accessed through a network to inquire a record corresponding to the bar code number and display related information of the material frame in the material frame tracking APP, the information of the material frame in the network server and a current monitoring node or production information are bound through an operating interface of the material frame tracking APP and are updated into the network server for storage, and the storage information comprises the state change of the material frame, the number of built-in forgings and model information; when the number and the type of the forge pieces in the material frame change, the information is modified in an operation interface provided by the material frame tracking APP, and the information is updated to the network server through the wifi module.
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