CN116009498B - Desktop intelligent factory virtual-real synchronous application system and control method - Google Patents
Desktop intelligent factory virtual-real synchronous application system and control method Download PDFInfo
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- CN116009498B CN116009498B CN202310141129.3A CN202310141129A CN116009498B CN 116009498 B CN116009498 B CN 116009498B CN 202310141129 A CN202310141129 A CN 202310141129A CN 116009498 B CN116009498 B CN 116009498B
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Abstract
The application provides a virtual-real synchronous application system and a control method of a desktop intelligent factory, and relates to the technical field of intelligent factories. The method comprises the steps of obtaining order information and forming an order processing signal; acquiring working state data, and combining an order processing signal to form a production control instruction set; performing production control according to a production control instruction set; monitoring the state of the production process and receiving abnormal state data; and generating a production adjustment instruction according to the state abnormal data, and carrying out production control adjustment. The production control and production monitoring of virtual-real synchronization can be realized, and the normal production efficiency is ensured.
Description
Technical Field
The application relates to the technical field of intelligent factories, in particular to a desktop intelligent factory virtual-real synchronous application system and a control method.
Background
The intelligent factory utilizes various modern technologies to realize the office work, management and production automation of the factory, and achieves the purposes of strengthening and standardizing enterprise management, reducing work errors, blocking various loopholes, improving work efficiency, carrying out safe production, providing decision references, strengthening external connection and widening international markets.
Along with popularization of intelligent factory technology application, the production industry with high process operation integration level can fully utilize the intelligent factory technology to carry out tubular intelligent production control and production monitoring, on one hand, the cost of manually carrying out production control and production monitoring can be reduced, and the conditions of untimely, easy negligence, information flow and inefficient management caused by manually carrying out production control and production monitoring are avoided. On the other hand, because the process integration level is high, the optimization of the whole production process can be realized, even the high integration can be realized by utilizing a lower space occupation ratio, meanwhile, the production operation is efficiently performed, the large-scale control and management of the production operation are greatly facilitated, the production operation efficiency is greatly improved, the management of the production control can be improved, the information reporting and the maintenance can be timely performed, and the production efficiency reduction caused by equipment faults is reduced.
However, for highly integrated production operation, the intelligent factory cannot monitor the production process in real-real synchronization in the application process of intelligent production control and monitoring. Especially in candy canning production, how to adapt and cooperate with production modules of various types and specifications on a highly integrated desktop, and the production control and monitoring of virtual-real synchronization are achieved, so that the normal operation of production is ensured, and the method is a problem faced by the intelligent factory at present.
Therefore, the desktop intelligent factory virtual-real synchronous application system and the control method are designed, so that virtual-real synchronous production control and production monitoring can be realized, normal production efficiency is ensured, and the problem to be solved is urgent at present.
Disclosure of Invention
The embodiment of the application aims to provide a virtual-real synchronous control method for a desktop intelligent factory, which is used for processing orders and forming a real-time production control instruction for production control by combining the working state conditions of equipment, and fully realizing the production control of virtual-real combination from the actual orders to the production control instruction and then to the production control of the equipment. In addition, in the process of production control, the state of the equipment is monitored in real time, and the abnormality in production is adaptively adjusted according to the monitored data, so that the production efficiency is ensured to meet the requirement, and the normal production efficiency is ensured.
The embodiment of the application aims at providing a desktop intelligent factory virtual-real synchronous application system which is beneficial to centralized and efficient management and control of production by integrating the whole production process on a working desktop. And the modularized assembly is carried out by different working procedures, so that the equipment is convenient to install and use according to the production requirement, the control and management of the production are greatly facilitated, meanwhile, a foundation is provided for centralized monitoring and adjustment of the whole production process, and the normal and efficient production is effectively ensured.
In a first aspect, an embodiment of the present application provides a method for synchronously controlling virtual and real states of a desktop intelligent factory, including obtaining order information to form an order processing signal; acquiring working state data, and combining an order processing signal to form a production control instruction set; performing production control according to a production control instruction set; monitoring the state of the production process and receiving abnormal state data; and generating a production adjustment instruction according to the state abnormal data, and carrying out production control adjustment.
In the embodiment of the application, the production control instruction for production control in real time is formed by processing the order and combining the working state condition of the equipment, and the production control is fully realized by carrying out the production control of the equipment from the actual order to the production control instruction and then carrying out the production control of the equipment. In addition, in the process of production control, the state of the equipment is monitored in real time, and the abnormality in production is adaptively adjusted according to the monitored data, so that the production efficiency is ensured to meet the requirement, and the normal production efficiency is ensured.
As one possible implementation, acquiring the working state data and combining the order processing signals to form a production control instruction set includes: acquiring working state data, judging the running state of process equipment, and forming normal operation prompt information of a process; according to the normal operation prompt information of the working procedure and combining with the order processing signal, working procedure task allocation is carried out to form task allocation information; and carrying out process control analysis according to the task allocation information and combining with the process normal operation prompt information to form a production control instruction set.
In the embodiment of the application, the data of the running states of different process equipment are different, and the functions played during working are also different. Therefore, when the working state data is collected, the relevant data information can be collected according to the functions of different process equipment and the working conditions to be completed. The working state of the process equipment is obtained, the process equipment can be determined to normally produce under the next production task, and the distribution and the determination of the production task are required according to the working state data of the process equipment so as to form orderly and efficient production control instructions at the follow-up, and the process equipment is controlled to smoothly produce according to the distributed process task.
As a possible implementation manner, according to the task allocation information, and in combination with the process normal operation prompt information, performing process control analysis to form a production control instruction set, including: acquiring transmission speed range data in the normal operation prompt information of the working procedure, and combining task allocation information to form a transmission control instruction; acquiring the number and position information of process equipment in the process normal operation prompt information, and carrying out process synchronous analysis by combining task allocation information and a transmission control instruction to form a process synchronous control instruction; and combining the transmission control instruction and the procedure synchronous control instruction to form a production control instruction set.
In the embodiment of the application, the production control instruction set mainly comprises instructions for cooperatively controlling each process equipment. In this embodiment, the transmission parameters of the endless conveyor device, which play a role in controlling each process, and the number of unit devices and operation condition data that can perform process operations synchronously in each process are mainly used, and the synchronicity analysis is performed on the basis of fully collecting these parameter data, so that it can be ensured that the control instructions of each formed process device can cooperate with each other, and finally, the effect of efficient production is achieved.
As one possible implementation manner, the method for obtaining the number and the position information of the process equipment in the process normal operation prompt information, and performing process synchronization analysis by combining the task allocation information and the transmission control instruction to form a process synchronization control instruction includes: acquiring a first process time length, a second process time length and a third process time length, and determining a synchronous working time length T according to task allocation information 1 And a second synchronous working time length T 2 The method comprises the steps of carrying out a first treatment on the surface of the Obtaining the number M of first process equipment 1 The sequence of the first process equipment at the transmission position and the synchronous working time length are combined with the task allocation information and the transmission control instruction to form a first process control instruction; obtaining the number M of the second process equipment 2 The order of the second process equipment on the transmission position and the synchronous working time length are combined with the task allocation information, the transmission control instruction and the first process control instruction to form a second process control instruction; obtaining the number M of the third process equipment 3 And the production sequence and the synchronous working time length of the third process equipment are combined with the task allocation information, the transmission control instruction and the second process control instruction to form the third process control instruction.
In an embodiment of the present application, a process operation condition for candy canning is provided. For this job production, it is necessary to confirm the working time length, the number of synchronous operation devices, and the relative positions between the synchronous devices for the three main processes constituting the production process. The setting of the process time length is determined according to the task allocation information and the proper operation time length which can be achieved by the process equipment, so that the process equipment can synchronously operate, and the production efficiency is improved. In addition, the sequence of the working procedures also determines that certain operation association exists among the working procedures, so that when the working time length of each working procedure operation, the number of synchronous operation devices and the relative position relationship among the synchronous devices are fully considered, an efficient working procedure control instruction can be formed, and the punctual and efficient production is ensured.
As one possible implementation, the production control according to the production control instruction set includes: controlling the conveying equipment to operate at a first conveying speed according to the conveying control instruction; according to the first procedure control instruction, control M 1 The first process equipment performs process sequence operation; the sequence operation is M 1 The first working procedure equipment works for a period of time T according to the sequence a The process operations of the c+1 batch are sequentially performed, and the process operations of the c+1 batch include only the first K first process devices that sequentially perform the process operations, wherein: k=m 2 -M 1 * C, wherein c= [ M 2 /M 1 ]Is M 2 And M 1 The quotient is rounded, T a =M 1 *T 1 The method comprises the steps of carrying out a first treatment on the surface of the And after finishing the sequence operation of the working procedures, the interval is K+1 synchronous working time periods T 1 The process sequence operation is performed again.
In the embodiment of the present application, it should be noted that the working durations of the first process equipment, the second process equipment, and the third process equipment, and the working intervals, and the degree of cooperation of the production therebetween, are all determined based on the first conveying speed. The first conveying speed is an important basis for providing the working modes and the working time durations of the three working procedure devices. In addition, for the different quantity of first process equipment, second process equipment and third process equipment, how to form reasonable process collocation and not to cause the confusion of process step is coordinated through the operation mode of the process equipment that control instruction confirmed, fully embodies intelligent factory's high-efficient intelligent production control ability, effectively guarantees the orderly high-efficient operation of production.
As one possible implementation, the production control according to the production control instruction set includes: controlling the working time length T of the second process equipment b Ensure T b =T 1 The method comprises the steps of carrying out a first treatment on the surface of the Controlling the working time length T of the third process equipment c Ensure T c =M 3 *T 1 。
In the embodiment of the present application, it is understood that, due to the coordination of production control between process devices, the coordination may involve the operation duration of each process device and the operation mode and operation sequence of the process devices performing synchronous operation on each process. Therefore, after the working time length, the corresponding working mode and the working sequence of part of the working procedure equipment are determined, the control parameters of all working procedures on the whole production chain, including the working time length, the working mode and the working sequence of the synchronous working procedure equipment, can be accurately determined, an orderly and efficient production process is formed, and the production is ensured to fully meet the requirements.
As one possible implementation manner, generating a production adjustment instruction according to the state anomaly data to perform production control adjustment includes: when the number of faults of the first process equipment is M f1 Then use the remaining M 1 -M f1 The first working process equipment which is working normally continues to perform the working sequence operation.
In this application embodiment, intelligent factory can realize the effective control to production process to the production is carried out to the most efficient mode, fully satisfies the production needs. Meanwhile, the production process can be monitored, so that the production process can be timely reflected and correspondingly adjusted after the situation occurs, and the influence on the production operation is avoided. In this embodiment, the monitored parameters are various, and mainly monitor the working conditions of each process device, so that the operation adjustment can be performed in time when the process device fails. The failure of the first process equipment mainly relates to how to match the subsequent process equipment for production after the synchronous process equipment fails, so that the production is ensured to meet the requirements.
As one possible implementation manner, generating a production adjustment instruction according to the state anomaly data to perform production control adjustment includes: when the number of faults of the second process equipment is M f2 Using the remaining M 1 -M f2 And the first working procedure equipment which works normally continues to conduct working procedure sequence operation.
In this embodiment of the present application, it may be understood that, after the second process equipment fails, the number change of the second process equipment that performs the operation synchronously affects the working mode of the first process equipment and the efficiency of the whole production engineering, so the working mode of the first process equipment and the synchronous working time length of the whole operation need to be adjusted while the actual working number of the second process equipment is adjusted, so that the production efficiency is ensured to be unchanged, and the production needs are satisfied.
As one possible implementation manner, generating a production adjustment instruction according to the state anomaly data to perform production control adjustment includes: when the number of faults of the third working procedure equipment is M f3 For the working time length T of the third working procedure equipment c Adjusting to ensure T c =（M 3 - M f3 ）*T 1 。
In this application embodiment, the trouble of third process equipment is less to whole production process influence, under the unchangeable circumstances of the production control of first process equipment and second process equipment, adjusts the operating time length of third process equipment and can guarantee the efficiency of production.
In a second aspect, an embodiment of the present application provides a virtual-real synchronization application system of a desktop intelligent factory, which adopts the virtual-real synchronization control method of the desktop intelligent factory according to the first aspect, including: the device comprises an operating table top, an annular conveyor belt device, a can pushing device, a first process robot, a material distributing device, a pushing mechanism, a sensor, a second process robot, a cover pushing device and a controller; the annular conveyor belt device is fixed on the operating table top; the first working procedure robot, the can pushing device, the material distributing device, the cover pushing device and the second working procedure robot are arranged on the operating table top along the conveying direction of the annular conveying belt device, and the pushing mechanism and the material distributing device are oppositely arranged on two sides of the annular conveying belt device; the sensor is arranged on the pushing mechanism; the can pushing device comprises a can supplying mechanism, a can pushing cylinder and an RFID reader-writer; the can supplying mechanism is arranged above the RFID reader-writer; the can pushing cylinder is positioned on one side of the can feeding mechanism far away from the annular conveyor belt device, and the controller is respectively connected with the annular conveyor belt device, the can pushing device, the first procedure robot, the material distributing device, the pushing mechanism, the sensor, the second procedure robot and the cap pushing device.
In the embodiment of the application, the system is beneficial to centralized and efficient management and control of production by integrating the whole production process on one working desktop. And the modularized assembly is carried out by different working procedures, so that the equipment is convenient to install and use according to the production requirement, the control and management of the production are greatly facilitated, meanwhile, a foundation is provided for centralized monitoring and adjustment of the whole production process, and the normal and efficient production is effectively ensured.
The desktop intelligent factory virtual-real synchronous application system and the control method provided by the embodiment have the beneficial effects that:
the desktop intelligent factory virtual-real synchronous control method processes orders and combines the working state conditions of equipment to form a real-time production control instruction for production control, and the actual orders are sent to the production control instruction and then to the equipment for production control, so that the production control of virtual-real combination is fully realized. In addition, in the process of production control, the state of the equipment is monitored in real time, and the abnormality in production is adaptively adjusted according to the monitored data, so that the production efficiency is ensured to meet the requirement, and the normal production efficiency is ensured.
The desktop intelligent factory virtual-real synchronous application system is beneficial to centralized and efficient management and control of production by integrating the whole production process on a working desktop. And the modularized assembly is carried out by different working procedures, so that the equipment is convenient to install and use according to the production requirement, the control and management of the production are greatly facilitated, meanwhile, a foundation is provided for centralized monitoring and adjustment of the whole production process, and the normal and efficient production is effectively ensured.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present application, the drawings that are needed in the embodiments of the present application will be briefly described below, it should be understood that the following drawings only illustrate some embodiments of the present application and should not be considered as limiting the scope, and other related drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
Fig. 1 is a step diagram of a desktop intelligent factory virtual-real synchronization control method according to an embodiment of the present application;
fig. 2 is a schematic view of a first view angle structure of a desktop intelligent factory virtual-real synchronization application system according to an embodiment of the present application;
Fig. 3 is a schematic view of a second view angle structure of the desktop intelligent factory virtual-real synchronization application system according to the embodiment of the present application;
fig. 4 is a schematic structural diagram of a can pushing device of the desktop intelligent factory virtual-real synchronous application system according to an embodiment of the present application;
fig. 5 is a diagram of a virtual-real combination control relationship of a desktop intelligent factory virtual-real synchronous application system according to an embodiment of the present application.
Icon:
1. an endless conveyor belt arrangement; 2. a first process robot; 3. a can pushing device; 4. a sensor; 5. a pushing mechanism; 6. a material distributing device; 7. a second step robot; 8. a cap pushing device; 9. a can pushing cylinder; 10. a can supply mechanism; 11. an RFID reader; 12. a candy can; 13. the desktop is operated.
Detailed Description
The technical solutions in the embodiments of the present application will be described below with reference to the drawings in the embodiments of the present application.
The intelligent factory utilizes various modern technologies to realize the office work, management and production automation of the factory, and achieves the purposes of strengthening and standardizing enterprise management, reducing work errors, blocking various loopholes, improving work efficiency, carrying out safe production, providing decision references, strengthening external connection and widening international markets.
Along with popularization of intelligent factory technology application, the production industry with high process operation integration level can fully utilize the intelligent factory technology to carry out tubular intelligent production control and production monitoring, on one hand, the cost of manually carrying out production control and production monitoring can be reduced, and the conditions of untimely, easy negligence, information flow and inefficient management caused by manually carrying out production control and production monitoring are avoided. On the other hand, because the process integration level is high, the optimization of the whole production process can be realized, even the high integration can be realized by utilizing a lower space occupation ratio, meanwhile, the production operation is efficiently performed, the large-scale control and management of the production operation are greatly facilitated, the production operation efficiency is greatly improved, the management of the production control can be improved, the information reporting and the maintenance can be timely performed, and the production efficiency reduction caused by equipment faults is reduced.
However, for highly integrated production operation, the intelligent factory cannot monitor the production process in real-real synchronization in the application process of intelligent production control and monitoring. Especially in the production of the candy cans 12, how to adapt and cooperate with production modules of various types and specifications on a highly integrated desktop to realize the production control and monitoring of virtual-real synchronization and ensure the normal operation of production is a problem faced by the intelligent factory at present.
Referring to fig. 1, an embodiment of the present application provides a virtual-real synchronization control method for a desktop intelligent factory. The method forms a real-time production control instruction for production control by processing orders and combining the working state conditions of equipment, and fully realizes the production control of virtual-real combination from actual orders to the production control instruction and then to the production control of the equipment. In addition, in the process of production control, the state of the equipment is monitored in real time, and the abnormality in production is adaptively adjusted according to the monitored data, so that the production efficiency is ensured to meet the requirement, and the normal production efficiency is ensured.
The desktop intelligent factory virtual-real synchronous control method comprises the following main steps:
s1: order information is acquired to form an order processing signal.
The step mainly comprises the steps of receiving information of an actual demand order, converting the actual order information data into a virtual order processing signal and completing a virtual reality condition access task.
S2: and acquiring working state data, and combining the order processing signals to form a production control instruction set.
The method mainly comprises the following steps:
and acquiring working state data, judging the running state of the process equipment, and forming normal operation prompt information of the process. And according to the normal operation prompt information of the working procedure and combining the order processing signals, carrying out working procedure task allocation to form task allocation information. And carrying out process control analysis according to the task allocation information and combining with the process normal operation prompt information to form a production control instruction set.
The data of the operation states of different process equipment are different, and the functions of the process equipment are different when the process equipment works. Therefore, when the working state data is collected, the relevant data information can be collected according to the functions of different process equipment and the working conditions to be completed. The working state of the process equipment is obtained, the process equipment can be determined to normally produce under the next production task, and the distribution and the determination of the production task are required according to the working state data of the process equipment so as to form orderly and efficient production control instructions at the follow-up, and the process equipment is controlled to smoothly produce according to the distributed process task.
Wherein, according to the task allocation information, and combine the normal operation prompt message of process to carry out process control analysis, form the production control instruction set, include: acquiring transmission speed range data in the normal operation prompt information of the working procedure, and combining task allocation information to form a transmission control instruction; acquiring the number and position information of process equipment in the process normal operation prompt information, and carrying out process synchronous analysis by combining task allocation information and a transmission control instruction to form a process synchronous control instruction; and combining the transmission control instruction and the procedure synchronous control instruction to form a production control instruction set.
The production control instruction set mainly comprises instructions for coordinately controlling all process equipment. In this embodiment, the transmission parameters of the endless conveyor device 1, the number of unit devices capable of synchronously performing the process operations in each process, and the operation condition data are mainly used for connecting the process controls, and the synchronicity analysis is performed on the basis of fully collecting the parameter data, so that the control instructions of the formed process devices can be mutually matched, and finally, the effect of efficient production is achieved.
Specifically, the method comprises the steps of obtaining the number and the position information of the process equipment in the process normal operation prompt information, carrying out process synchronous analysis by combining task allocation information and a transmission control instruction, and forming a process synchronous control instruction, wherein the method comprises the following steps: acquiring a first process time length, a second process time length and a third process time length, and determining a first synchronous working time length T according to task allocation information 1 And a second synchronous working time length T 2 The method comprises the steps of carrying out a first treatment on the surface of the Obtaining the number M of first process equipment 1 The sequence of the first process equipment at the transmission position and the synchronous working time length are combined with the task allocation information and the transmission control instruction to form a first process control instruction; obtaining the number M of the second process equipment 2 The order of the second process equipment on the transmission position and the synchronous working time length are combined with the task allocation information, the transmission control instruction and the first process control instruction to form a second process control instruction; obtaining the number M of the third process equipment 3 And the production sequence and the synchronous working time length of the third process equipment are combined with the task allocation information, the transmission control instruction and the second process control instruction to form the third process control instruction.
In this embodiment, the candy canning operation is taken as an example, and for this operation production, it is necessary to confirm the working time length, the number of synchronous operation devices, and the relative positions between the synchronous devices for the three main processes that constitute the production process. The setting of the process time length is determined according to the task allocation information and the proper operation time length which can be achieved by the process equipment, so that the process equipment can synchronously operate, and the production efficiency is improved. In addition, the sequence of the working procedures also determines that certain operation association exists among the working procedures, so that when the working time length of each working procedure operation, the number of synchronous operation devices and the relative position relationship among the synchronous devices are fully considered, an efficient working procedure control instruction can be formed, and the punctual and efficient production is ensured.
Naturally, according to the production control instruction setPerforming production control, comprising: controlling the conveying equipment to operate at a first conveying speed according to the conveying control instruction; according to the first procedure control instruction, control M 1 The first process equipment performs process sequence operation; the sequence operation is M 1 The first working procedure equipment works for a period of time T according to the sequence a The process operations of the c+1 batch are sequentially performed, and the process operations of the c+1 batch include only the first K first process devices that sequentially perform the process operations, wherein:
K=M 2 -M 1 *[M 2 /M 1 ]wherein C= [ M ] 2 /M 1 ]Is M 2 And M 1 The quotient is rounded off and the result is that,
T a =M 1 *T 1 ；
and after finishing the sequence operation of the working procedures, the interval is K+1 first synchronous working time periods T 1 The process sequence operation is performed again.
The working time period and the working interval of the first, second and third process equipment are determined based on the first conveying speed. The first conveying speed is an important basis for providing the working modes and the working time durations of the three working procedure devices. In addition, for the different quantity of first process equipment, second process equipment and third process equipment, how to form reasonable process collocation and not to cause the confusion of process step is coordinated through the operation mode of the process equipment that control instruction confirmed, fully embodies intelligent factory's high-efficient intelligent production control ability, effectively guarantees the orderly high-efficient operation of production.
S3: and carrying out production control according to the production control instruction set.
The various operating parameters are determined to form an instruction set to control production. There is a correlation between process equipment, and therefore, when the operating parameters of a first process equipment are determined, the operating parameters of subsequent process equipment are determined one after the other. Performing production control according to a production control instruction set, comprising: controlling the working time length T of the second process equipment b Ensure T b =T 1 The method comprises the steps of carrying out a first treatment on the surface of the Controlling the working time length T of the third process equipment c Ensure T c =M 3 *T 1。
It will be appreciated that the coordination of the process equipment may involve the length of time each process equipment is operated and the mode and sequence of operation of the process equipment that is operated synchronously for each process, as a result of the need for production control between the process equipment. Therefore, after the working time length, the corresponding working mode and the working sequence of part of the working procedure equipment are determined, the control parameters of all working procedures on the whole production chain, including the working time length, the working mode and the working sequence of the synchronous working procedure equipment, can be accurately determined, an orderly and efficient production process is formed, and the production is ensured to fully meet the requirements.
S4: and monitoring the state of the production process and receiving abnormal state data.
The method mainly monitors the state of the production process after the intelligent control of the production process is realized. The object to be monitored is mainly process equipment. Therefore, the measures taken to monitor anomalies are different for different process plants. Specifically:
when the number of faults of the first process equipment is M f1 Then use the remaining M 1 -M f The first working process equipment which is working normally continues to perform the working sequence operation. The intelligent factory can realize the effective control of the production process, and the production is carried out in the most efficient mode, so that the production needs are fully satisfied. Meanwhile, the production process can be monitored, so that the production process can be timely reflected and correspondingly adjusted after the situation occurs, and the influence on the production operation is avoided. In this embodiment, the monitored parameters are various, and mainly monitor the working conditions of each process device, so that the operation adjustment can be performed in time when the process device fails. The failure of the first process equipment mainly relates to how to match the subsequent process equipment for production after the synchronous process equipment fails, so that the production is ensured to meet the requirements.
Correspondingly, when the second process equipment fails by the quantity M f2 Using the remaining M 1 -M f2 And the first working procedure equipment which works normally continues to conduct working procedure sequence operation.
It can be understood that when the second process equipment fails, the working mode of the first process equipment and the efficiency of the whole production engineering are affected by the number change of the second process equipment for synchronous operation, so that the working mode of the first process equipment and the synchronous working time of the whole operation are required to be adjusted while the actual working number of the second process equipment is adjusted, the production efficiency is ensured to be unchanged, and the production requirement is met.
It can be understood that when the second process equipment fails, the working mode of the first process equipment and the efficiency of the whole production engineering are affected by the number change of the second process equipment for synchronous operation, so that the working mode of the first process equipment and the synchronous working time of the whole operation are required to be adjusted while the actual working number of the second process equipment is adjusted, the production efficiency is ensured to be unchanged, and the production requirement is met.
When the number of faults of the third working procedure equipment is M f3 For the working time length T of the third working procedure equipment c Adjusting to ensure T c =（M 3 - M f3 ）*T 1 . The failure of the third process equipment has small influence on the whole production process, and the production efficiency can be ensured by adjusting the working time length of the third process equipment under the condition that the production control of the first process equipment and the second process equipment is unchanged.
S5: and generating a production adjustment instruction according to the state abnormal data, and carrying out production control adjustment.
Different adjustment instructions are generated according to the abnormality of different process equipment, and the operation can be effectively ensured to be normally carried out and the production efficiency can be ensured by accurately adjusting according to the instructions.
Referring to fig. 2-5, the embodiment of the application further provides a desktop intelligent factory virtual-real synchronization application system. The system adopts the desktop intelligent factory virtual-real synchronous control method of the embodiment of the application. The device comprises an operation table top 13, an annular conveyor belt device 1, a can pushing device 3, a first process robot 2, a material distributing device 6, a pushing mechanism 5, a sensor 4, a second process robot 7, a cover pushing device 8 and a controller; the endless conveyor belt device 1 is fixed on an operating table top 13; the first process robot 2, the can pushing device 3, the material distributing device 6, the cover pushing device 8 and the second process robot 7 are arranged on the operating table top 13 along the conveying direction of the annular conveying belt device 1, and the pushing mechanism 5 and the material distributing device 6 are oppositely arranged on two sides of the annular conveying belt device 1; the sensor 4 is arranged on the pushing mechanism 5; the can pushing device 3 comprises a can supplying mechanism 10, a can pushing cylinder 9 and an RFID reader-writer 11; the can supply mechanism 10 is arranged above the RFID reader-writer 11; the can pushing cylinder 9 is located on one side of the can supplying mechanism 10 far away from the annular conveyor belt device 1, and the controller is respectively connected with the annular conveyor belt device 1, the can pushing device 3, the first process robot 2, the material distributing device 6, the pushing mechanism 5, the sensor 4, the second process robot 7 and the cap pushing device 8.
The system is beneficial to centralized and efficient management and control of production by integrating the whole production process on a working desktop. And the modularized assembly is carried out by different working procedures, so that the equipment is convenient to install and use according to the production requirement, the control and management of the production are greatly facilitated, meanwhile, a foundation is provided for centralized monitoring and adjustment of the whole production process, and the normal and efficient production is effectively ensured.
Specifically, the hardware devices in the system are uniformly controlled and managed through the controller. In the embodiment of the application, the controller mainly comprises a PLC control module, a virtual actual corresponding module, an RFID read-write module, an infrared sensor module and a conveyor belt assembly module. The order information can be obtained from the server through the virtual actual corresponding module and converted into a required order processing signal, and then the PLC control module is used for forming a production control instruction set to carry out production control under the condition that the RFID read-write module, the conveyor belt assembly module and the infrared sensor module are subjected to working state data acquisition. And in the production process, the RFID read-write module, the conveyor belt assembly module and the infrared sensor 4 module are subjected to state monitoring and timely control and adjustment.
The embodiment provides a specific implementation mode, so as to display the virtual-real synchronous control method and the application system of the desktop intelligent factory in detail.
Take the candy canning operation as an example. The upper server adopts a non-x 86 server to analyze data, the central control end adopts an Intel server CPU and a Windows/NetWare network operating system, and the CPU is more than 2GHZ; the virtual reality corresponding module adopts network, wireless and wired to transmit information; the RFID read-write module reads and writes order information by adopting radio frequency information; the PLC control module adopts virtual software OCTOUZ to carry out integral intelligent control; the conveyor belt assembly module mainly performs command execution on each operation hardware.
The first process robot 2 is a six-axis robot; the can pushing devices 3 are arranged in parallel in the conveying direction of the endless conveyor belt device 1, namely M 1 The material dividing devices 6 are arranged in parallel 6 along the conveying direction of the endless conveyor device 1, i.e. M =3 2 =6; naturally, the number of pushing mechanisms 5 and sensors 4 is also 6; the number of the cap pushing devices 8 is 3, namely M 3 =3, and are arranged side by side; the second step robot 7 is a four-axis robot.
And according to the working state data of each process equipment, the canning work of 60 candy cans 12 is completed in 1 hour by combining task allocation information. The completion time for each candy was 1/min. The working time of each process device can be adjusted according to the completion time of each candy. And consider the gap time transferred between each procedure, and synchronously process the operation time length, so as to obtain the synchronous operation time length T 1 T is not considered in the interval time of transmission between the processes 1 =20s. This allows the following setting parameters to be determined:
K=0，C=2，T a =60 s; namely, after the 3 can pushing devices 3 finish the can pushing action at the same time, waiting for 60 seconds to finish the 3 can pushing devices 3 to push cans at the same time again, and then, after waiting for 20 seconds, continuing to perform continuous two times of simultaneous can pushing actions, so that the circulating operation is always performed.
Ensure T for the second process equipment b =T 1 =20s；
In the third process equipment, since there are 3 cap pushing devices 8 that are performed simultaneously,after one cap pushing device 8 is put into the candy can 12 to push the caps, the first put candy can 12 is taken out after the other two cap pushing devices 8 are put in sequence, so that the actual cap pushing time T of the candy can 12 c =M 3 *T 1 =60s。
The entire candy can 12 filling operation operates in accordance with the production control described above. When the fault of the process equipment is monitored, the process equipment needs to be adjusted according to the process equipment:
in the event of failure of the first process equipment, e.g. failure of one of the push-cans 3, i.e. M f1 =1, at this time, M 1 =2. According to M 1 For adjustment by =2, then k=0, c=3, t a =40s. Specifically, after 2 normal can pushing devices 3 complete can pushing actions at the same time, waiting 40s to complete 2 can pushing devices 3 to push cans at the same time again, and then waiting 20s to continue to perform continuous two times of simultaneous can pushing actions, so that circulating operation is always performed. The subsequent equipment working modes are unchanged.
In the event of a failure of the second process equipment, e.g. of a separating device 6, or of a pushing mechanism 5, i.e. M f2 =1，M 2 =5. K=2 and c=1. Production control of the first process equipment is performed according to the parameter.
In the event of a failure of third process equipment, e.g. of a cap-pushing device 8, i.e. M f3 The operation time period T of the cap pushing device 8 is set to be =1 c Adjusted to T c =（M 3 - M f3 ）*T 1 =40s。
In summary, the desktop intelligent factory virtual-real synchronous application system and the control method provided by the embodiment of the application have the beneficial effects that:
the desktop intelligent factory virtual-real synchronous control method processes orders and combines the working state conditions of equipment to form a real-time production control instruction for production control, and the actual orders are sent to the production control instruction and then to the equipment for production control, so that the production control of virtual-real combination is fully realized. In addition, in the process of production control, the state of the equipment is monitored in real time, and the abnormality in production is adaptively adjusted according to the monitored data, so that the production efficiency is ensured to meet the requirement, and the normal production efficiency is ensured.
The desktop intelligent factory virtual-real synchronous application system is beneficial to centralized and efficient management and control of production by integrating the whole production process on a working desktop. And the modularized assembly is carried out by different working procedures, so that the equipment is convenient to install and use according to the production requirement, the control and management of the production are greatly facilitated, meanwhile, a foundation is provided for centralized monitoring and adjustment of the whole production process, and the normal and efficient production is effectively ensured.
In the present application, "at least one" means one or more, and "a plurality" means two or more. "at least one of" or the like means any combination of these items, including any combination of single item(s) or plural items(s). For example, at least one (one) of a, b, or c may represent: a, b, c, a-b, a-c, b-c, or a-b-c, wherein a, b, c may be single or plural.
It should be understood that, in various embodiments of the present application, the sequence numbers of the foregoing processes do not mean the order of execution, and the order of execution of the processes should be determined by the functions and internal logic thereof, and should not constitute any limitation on the implementation process of the embodiments of the present application.
Those of ordinary skill in the art will appreciate that the various illustrative elements and algorithm steps described in connection with the embodiments disclosed herein may be implemented as electronic hardware, or combinations of computer software and electronic hardware. Whether such functionality is implemented as hardware or software depends upon the particular application and design constraints imposed on the solution. Skilled artisans may implement the described functionality in varying ways for each particular application, but such implementation decisions should not be interpreted as causing a departure from the scope of the present application.
It will be clear to those skilled in the art that, for convenience and brevity of description, specific working procedures of the above-described systems, apparatuses and units may refer to corresponding procedures in the foregoing method embodiments, and are not repeated herein.
In the several embodiments provided in this application, it should be understood that the disclosed systems, devices, and methods may be implemented in other manners. For example, the apparatus embodiments described above are merely illustrative, e.g., the division of the units is merely a logical function division, and there may be additional divisions when actually implemented, e.g., multiple units or components may be combined or integrated into another system, or some features may be omitted or not performed. Alternatively, the coupling or direct coupling or communication connection shown or discussed with each other may be an indirect coupling or communication connection via some interfaces, devices or units, which may be in electrical, mechanical or other form.
The units described as separate units may or may not be physically separate, and units shown as units may or may not be physical units, may be located in one place, or may be distributed on a plurality of network units. Some or all of the units may be selected according to actual needs to achieve the purpose of the solution of this embodiment.
In addition, each functional unit in each embodiment of the present application may be integrated in one processing unit, or each unit may exist alone physically, or two or more units may be integrated in one unit.
The functions, if implemented in the form of software functional units and sold or used as a stand-alone product, may be stored in a computer-readable storage medium. Based on such understanding, the technical solution of the present application may be embodied essentially or in a part contributing to the prior art or in a part of the technical solution, in the form of a software product stored in a storage medium, including several instructions for causing a computer device (which may be a personal computer, a server, or a network device, etc.) to perform all or part of the steps of the methods described in the embodiments of the present application. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a read-only memory (ROM), a random access memory (random access memory, RAM), a magnetic disk, or an optical disk, or other various media capable of storing program codes.
The technical features of the above embodiments may be arbitrarily combined, and all possible combinations of the technical features in the above embodiments are not described for brevity of description, however, as long as there is no contradiction between the combinations of the technical features, they should be considered as the scope of the description.
The foregoing examples illustrate only a few embodiments of the invention, which are described in detail and are not to be construed as limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of protection of the present invention is to be determined by the appended claims.
Claims (7)
1. A desktop intelligent factory virtual-real synchronous control method is characterized by comprising the following steps:
acquiring order information to form an order processing signal;
acquiring working state data, and combining the order processing signals to form a production control instruction set;
performing production control according to the production control instruction set;
monitoring the state of the production process and receiving abnormal state data;
generating a production adjustment instruction according to the state abnormal data, and carrying out production control adjustment;
wherein: acquiring working state data and combining the order processing signals to form a production control instruction set, wherein the method comprises the following steps: acquiring the working state data, judging the operation state of the process equipment, and forming normal operation prompt information of the process; according to the normal operation prompt information of the working procedure and the order processing signal, working procedure task allocation is carried out to form task allocation information; according to the task allocation information, and combining the normal operation prompt information of the working procedure, carrying out working procedure control analysis to form a production control instruction set;
And performing process control analysis according to the task allocation information and in combination with the process normal operation prompt information to form a production control instruction set, wherein the process control instruction set comprises: acquiring transmission speed range data in the normal operation prompt information of the working procedure, and combining the task allocation information to form a transmission control instruction; acquiring the number and position information of process equipment in the process normal operation prompt information, and performing process synchronous analysis by combining the task allocation information and the transmission control instruction to form a process synchronous control instruction; combining the transmission control instruction and the procedure synchronization control instruction to form the production control instruction set;
the step of obtaining the number and the position information of the step equipment in the step normal operation prompt information, and combining the task allocation information and the transmission control instruction to perform step synchronous analysis to form a step synchronous control instruction comprises the following steps: acquiring a first process time length, a second process time length and a third process time length, and determining a synchronous working time length T according to the task allocation information 1 The method comprises the steps of carrying out a first treatment on the surface of the Obtaining the number M of first process equipment 1 The order of the first process equipment in the transfer position and the synchronous working time length T 1 Combining the task allocation information and the transmission control instruction to form a first procedure control instruction; obtaining the number M of the second process equipment 2 The order of the second process equipment in the transfer position and the synchronous working time length T 1 Combining the task allocation information, the transmission control instruction and the first procedure control instruction to form a second procedure control instruction; obtaining the number M of the third process equipment 3 Production sequence of third process equipment and the synchronous working time length T 1 And combining the task allocation information, the transmission control instruction and the second process control instruction to form a third process control instruction.
2. The method for synchronously controlling the virtual and actual states of a desktop intelligent factory according to claim 1, wherein the production control according to the production control instruction set comprises:
controlling the conveying equipment to operate at a first conveying speed according to the conveying control instruction;
according to the first procedure control instruction, controlling M 1 The first process equipment performs process sequence operation; the process sequence is operated as M 1 The first working procedure equipment works for a period of time T according to the sequence a Sequentially performing the process operations of the c+1 batch, and the process operations of the c+1 batch only include the first K first process devices sequentially performing the process operations, wherein:
K=M 2 -M 1 * C, wherein c= [ M 2 /M 1 ]Is M 2 And M 1 The quotient is rounded off and the result is that,
T a =M 1 *T 1 ；
and after finishing the sequence operation of the working procedures, the interval is K+1 the synchronous working time length T 1 The process sequence operation is performed again.
3. The method for synchronously controlling the virtual and actual states of a desktop intelligent factory according to claim 2, wherein the performing production control according to the production control instruction set comprises:
controlling the working time length T of the second process equipment b Ensure T b =T 1 ；
Controlling the working time length T of the third process equipment c Ensure T c =M 3 *T 1 。
4. The method for synchronously controlling the virtual and the actual states of a desktop intelligent factory according to claim 3, wherein the generating the production adjustment command according to the state anomaly data to perform production control adjustment comprises the following steps:
when the number of faults of the first working procedure equipment is M f1 Then use the remaining M 1 -M f1 And the first working procedure equipment which works normally continues to conduct working procedure sequence operation.
5. The method for synchronously controlling the virtual and the actual states of a desktop intelligent factory according to claim 3, wherein the generating the production adjustment command according to the state anomaly data to perform production control adjustment comprises the following steps:
when the number of faults of the second working procedure equipment is M f2 Using the remaining M 1 -M f2 And the first working procedure equipment which works normally continues to conduct working procedure sequence operation.
6. The method for synchronously controlling the virtual and actual states of a desktop intelligent factory according to claim 5, wherein the generating the production adjustment command according to the state anomaly data to perform production control adjustment comprises:
when the number of faults of the third working procedure equipment is M f3 For the working time length T of the third working procedure equipment c Adjusting to ensure T c =（M 3 - M f3 ）*T 1 。
7. A desktop intelligent factory virtual-real synchronization application system, characterized in that the desktop intelligent factory virtual-real synchronization control method according to any one of claims 1-6 is adopted, comprising:
the device comprises an operating table top, an annular conveyor belt device, a can pushing device, a first process robot, a material distributing device, a pushing mechanism, a sensor, a second process robot, a cover pushing device and a controller; the annular conveyor belt device is fixed on the operating table top; the first working procedure robot, the can pushing device, the material distributing device, the cover pushing device and the second working procedure robot are arranged on the operating table top along the conveying direction of the annular conveying belt device, and the pushing mechanism and the material distributing device are oppositely arranged on two sides of the annular conveying belt device; the sensor is arranged on the pushing mechanism; the can pushing mechanism comprises a can feeding mechanism, a can pushing cylinder and an RFID reader-writer; the tank supplying mechanism is arranged above the RFID reader-writer; the can pushing cylinder is positioned on one side of the can supplying mechanism, which is far away from the annular conveyor belt device; the controller is respectively connected with the annular conveyor belt device, the can pushing device, the first process robot, the material distributing device, the pushing mechanism, the sensor, the second process robot and the cover pushing device.
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