CN116243664A - Equipment safety spot inspection system and control method - Google Patents
Equipment safety spot inspection system and control method Download PDFInfo
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- CN116243664A CN116243664A CN202310000976.8A CN202310000976A CN116243664A CN 116243664 A CN116243664 A CN 116243664A CN 202310000976 A CN202310000976 A CN 202310000976A CN 116243664 A CN116243664 A CN 116243664A
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- spot inspection
- safety
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- control system
- inspection
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—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], computer integrated manufacturing [CIM]
- G05B19/41875—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], computer integrated manufacturing [CIM] characterised by quality surveillance of production
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32368—Quality control
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Abstract
The invention provides a system and a control method for equipment safety spot inspection, which solve the technical problems of low automation degree and multiple inspection steps of the existing spot inspection, and mainly comprise a control system, a field terminal, production equipment and a safety device. The main body of the field terminal is an industrial personal computer and is electrically connected with the production equipment and the safety device. Each production facility is provided with at least one safety device. The control system is integrated in the server and is electrically connected with the field terminal, the production equipment and the safety device respectively. The invention is used for the safety spot inspection of the production equipment in a factory, can realize the manual and/or automatic detection of whether the safety project is available or not through the interaction of the system and the production equipment, ensures that an operator reasonably carries out spot inspection work, does not obviously increase working steps, realizes ordered spot inspection and recording through system guidance in the control method, improves the production safety, improves the spot inspection efficiency, eliminates potential production safety hazards, and can be widely applied to the technical field of safety production.
Description
Technical Field
The invention relates to the technical field of safety production, in particular to a device safety spot inspection system and a control method.
Background
Safety production is a basic guarantee for protecting the safety, health and national property of workers and promoting the development of social productivity. During the production process, the principle of "people oriented" must be adhered to.
In the production and safety relationship, everything is that safety is important, and safety must be arranged in the first place. Therefore, the method has important significance in making safe production work. The dangerous source must be analyzed in advance, so that the accident can be effectively prevented.
In the production process of enterprises at present, the semi-automatic or automatic equipment is provided with a safety device so as to reduce the occurrence of safety accidents, but because the safety device has fault probability, especially the more complex equipment has higher fault probability, most enterprises can coordinate and formulate corresponding equipment safety spot inspection, and the safety device is generally directly detected by operators of the equipment, the detected result is manually input into a safety spot inspection record form, and finally, a record statistics form is transmitted to a safety management department to confirm a signature.
The manually-filled safety spot inspection result has low efficiency and easy item leakage, and operators are sometimes urgent in production, so that the safety spot inspection operation is not performed, only work is conducted, forms are randomly filled, the equipment personnel or the safety personnel are further difficult to timely, accurately and comprehensively know the real condition of the equipment safety device, and the standardization and the accuracy of the safety spot inspection are also difficult to guarantee.
Furthermore, because the spot check plan is issued confusedly or unclear, spot check tasks are frequently missed. In the face of the above situation, part of enterprises adopt a layer-by-layer code adding inspection mode, so that the cost of supervision staff is increased, the spot inspection time is prolonged in the step of breaking, the overall efficiency is also influenced, and the production enthusiasm is hit.
In view of the foregoing, there is a need for further improvements to existing spot check systems and methods.
Disclosure of Invention
The invention aims to solve the defects of the technology and provide a device safety spot inspection system based on automatic design and a control method thereof, wherein the device safety spot inspection system has lower hardware cost.
The invention provides a device safety spot inspection system which is characterized by comprising a control system, a field terminal, production equipment and a safety device;
the main body of the field terminal is an industrial personal computer and is electrically connected with the production equipment and the safety device;
each of said production devices is provided with at least one of said safety devices;
the control system is integrated in the server and is electrically connected with the field terminal, the production equipment and the safety device respectively.
Preferably, the field terminal further comprises a handheld spot inspection instrument, and the handheld spot inspection instrument is in wireless connection with the industrial personal computer or the control system.
Preferably, the handheld spot inspection instrument is provided with a first Bluetooth module, and the safety device is provided with a second Bluetooth module.
Preferably, the safety device comprises one or more of a safety light curtain, a pull-cord switch, a scram button and a safety pedal.
Preferably, the fish eye monitoring system also comprises a monitoring system, wherein the main body is a fish eye camera hoisted in a factory; the fish-eye camera is connected with the control system in a wired or wireless mode.
On the other hand, the invention also provides a control method based on the equipment safety spot inspection system, which comprises the following steps:
s1, the control system automatically compiles a spot inspection plan according to preset rules and acquired information, and records the spot inspection plan in a database after manual auditing;
s2, logging in team information at the field terminal after the spot inspection personnel enter the factory, and downloading a corresponding spot inspection plan;
s3, the spot inspection personnel completes tasks according to the spot inspection plan, feeds back spot inspection conditions at the field terminal, and uploads the spot inspection conditions to the control system;
s4, the control system controls the production equipment to start and stop according to the feedback condition in the S3; if the maintenance condition exists, the notification to be maintained is pushed to maintenance personnel online.
Preferably, the field terminal further comprises a handheld spot inspection instrument, and the spot inspection personnel downloads the spot inspection plan to the handheld spot inspection instrument in S2 and carries the spot inspection plan to the spot inspection position for recording.
Preferably, the handheld spot inspection instrument is provided with a first bluetooth module, the safety device is provided with a second bluetooth module, and the spot inspection process in S3 further comprises:
s31, the second Bluetooth module continuously performs Bluetooth broadcasting and comprises the safety device information and corresponding production equipment information;
s32, the handheld spot inspection instrument displays a current spot inspection task and limits recording option spot selection until the first Bluetooth module receives Bluetooth broadcasting corresponding to the current spot inspection task and automatically releases the limitation after the distance meets the requirement; the recording options comprise qualified options and unqualified options;
and S33, after the spot check personnel finishes spot selecting the recording options, the hand-held spot check instrument automatically displays the next spot check task.
Preferably, the fish eye monitoring system also comprises a monitoring system, wherein the main body is a fish eye camera hoisted in a factory; the fish-eye camera is connected with the control system in a wired or wireless way; the point detection process in S3 further comprises:
after the first Bluetooth module receives Bluetooth broadcasting corresponding to the current spot inspection task, the handheld spot inspection instrument sends an instruction to the control system in an online manner, and the control system starts the fisheye camera to record a video of the current spot inspection area and records the identification to be stored in a database; and the starting and ending time of each video recording is respectively from the start to the interruption of the connection of the first Bluetooth module and the second Bluetooth module.
The beneficial effects of the invention are as follows:
the invention is used for the safety spot inspection of the production equipment in a factory, can realize the manual or automatic detection of whether the safety project is available or not through the interaction of the system and the production equipment, ensures that an operator reasonably performs the spot inspection work, does not obviously increase the working steps, realizes the ordered spot inspection and recording through the system guidance in the control method, improves the spot inspection efficiency while improving the production safety, and eliminates the potential production safety hazard.
Drawings
Fig. 1 is a flow chart of the control method of the present invention.
Detailed Description
The invention will be further described with reference to the drawings and specific examples to aid in understanding the context of the invention. The method used in the invention is a conventional method unless specified otherwise; the raw materials and devices used, unless otherwise specified, are all conventional commercial products.
It should be noted that, the present embodiment is described taking a tire processing factory as an example, but the present embodiment is not limited to this, wherein production equipment includes, but is not limited to, an extrusion line, a calendaring line, a cutting device, a forming machine, a vulcanizing machine, etc., and each production equipment is not limited to one or one safety device.
The invention provides an equipment safety spot inspection system which mainly comprises a control system, a field terminal, production equipment and a safety device.
The main body of the field terminal is an industrial personal computer for industrial use, is internally provided with an operating system, a storage medium, a processor, a communication module and a data acquisition card, is connected with a control system, production equipment, a safety device and the like through an RJ45 port, and is arranged in a factory area together with the production equipment.
Preferably, in order to realize paperless inspection and reduce working steps, the design field terminal further comprises at least one handheld spot inspection instrument, specifically a mobile platform with an android or linux system, and the mobile platform is provided with a wireless communication module, can send and receive information online, and is in wireless connection with an industrial personal computer and a control system.
Each production facility is provided with at least one safety device; preferably, the safety device comprises one or more of a safety light curtain, a pull-cord switch, an emergency stop button and a safety pedal, and is particularly selected according to equipment requirements.
The control system is integrated in a server, wherein a database is also built in the server and used for storing corresponding records and rules. Specifically, the server is installed in the control room and interacts with an operator through a human-computer interaction interface, such as a display screen, a keyboard, a mouse, a control panel, and the like. The server is electrically connected with the field terminal, the production equipment and the safety device in a wired or wireless mode respectively and is used for controlling the operation of the equipment.
Preferably, the handheld spot inspection instrument is also provided with a first Bluetooth module, and each safety device is provided with a second Bluetooth module. Furthermore, the whole system also comprises a monitoring system, and the main body of the monitoring system is a fish-eye camera for hoisting the roof in the factory, and the 360-degree shooting can be carried out by adopting the fish-eye camera, so that only one monitoring system is needed to be hoisted in the middle area of the roof, and cameras are not needed to be independently installed in each equipment area or erected at a plurality of places in the factory. The fisheye camera is wirelessly connected with the control system.
Based on the above-mentioned equipment security spot inspection system, the present embodiment also provides a corresponding control method, as shown in fig. 1, mainly including the following steps:
s1, manually setting preset rules in a control system, such as the upper limit of the number of spot inspection devices in a single period, the allowable range of the spot inspection period duration, the minimum spot inspection interval period and the like; combining the collected data, such as the total number of the devices, supporting the maximum point detection period by each device (including a safety device), automatically compiling point detection plans, such as a shift detection plan, a daily detection plan, a weekly detection plan, a monthly detection plan and the like, by a task allocation algorithm or a self-built neural network model, and then manually checking by a safety responsible person at a sending display end, and recording in a corresponding database after passing through the points detection plans;
s2, logging in team information of the spot inspection at a field terminal (an industrial personal computer) after the spot inspection personnel enter a factory, specifically, a user name and a password which are applied for recording in advance, or face information of a responsible person, downloading a corresponding spot inspection plan, directly transmitting the spot inspection plan to a handheld spot inspection instrument, and carrying the spot inspection plan to each spot inspection position for recording;
s3, the spot inspection personnel completes tasks according to the spot inspection plan; the spot inspection body is divided into an automatic part and a manual part, wherein a control system automatically performs data interaction with the equipment point location through OPC software, and automatically judges whether the safety device is qualified or not according to a predefined protocol;
the manual part is divided into two parts, one is that a spot inspection personnel is required to manually operate the safety device, the system detects the state of the safety device through OPC software, and the system automatically judges whether the safety device is qualified or not according to the state change; the other type is visual and touch detection, which requires a spot inspection person to record and upload the spot inspection person nearby a point location through a handheld spot inspection instrument, so that in order to avoid multi-channel inspection programs, the embodiment is designed to realize low-power-consumption near-field identification by using a Bluetooth technology, so that automatic limitation and release are performed through a system, no additional personnel monitoring is needed, and the spot inspection person is guaranteed to work in place, and the method further comprises the following specific steps:
s31, the second Bluetooth module of each safety device continuously carries out Bluetooth broadcasting, and the broadcasting information comprises safety device information and corresponding production equipment information;
s32, displaying a current spot inspection task by a handheld spot inspection instrument of a spot inspection person, limiting the recording option spot selection of the current task before the spot inspection person approaches to corresponding equipment, and automatically removing the limitation by the handheld spot inspection instrument system after a first Bluetooth module in the handheld spot inspection instrument receives Bluetooth broadcasting corresponding to the current spot inspection task and the calculated distance meets the requirement until the person reaches the vicinity of the equipment, wherein the recording option comprises a qualified option and an unqualified option according to the corresponding spot selection recording option of a visual or touch detection result by the spot inspection person;
further, considering the condition of checking the bottom, an economic monitoring means is required to be added, the work enthusiasm of the spot inspection personnel can not be influenced, and the cost can not be obviously increased, so the embodiment designs and utilizes the hoisted fisheye camera, and as the fisheye camera has the capability of shooting without dead angles, the panoramic picture in the factory can be shot only by hoisting 1 camera in a proper area, and meanwhile, in order to further save the monitoring cost, the spot inspection personnel can work without sense, and the Bluetooth module application is selected to be combined for shooting. Specifically, after the first bluetooth module receives bluetooth broadcast corresponding to the current spot inspection task, the handheld spot inspection instrument simultaneously sends an instruction to the control system, the control system starts the fisheye camera to record the current spot inspection area, as more data are generated by shooting the panoramic picture, the storage is not facilitated, the image in the designated area of the recorded panoramic image is manually segmented and marked by design, the control system keeps the image in the designated area of the recorded panoramic image according to the sending instruction, the rest of the image is deleted, the recorded video is recorded and marked, the renaming operation can be carried out according to shooting time and the corresponding equipment name, and then the recorded video is stored in the database for backtracking and reading at any time. The starting and ending time of each video recording is respectively from the start to the interruption of the connection of the first Bluetooth module and the second Bluetooth module.
And S33, after the spot check personnel finishes the spot check record option, the hand-held spot check instrument automatically displays the next spot check task.
The above is described by taking the spot inspection of the forming machine as an example, the spot inspection task includes visual inspection of the position of the safety light curtain in the tire forming machine, when the spot inspection personnel holds the spot inspection machine to display the task, the recording option is a gray option block (which can not be selected), after that, the system picture stays on the current task and does not display the content of the next task, the spot inspection personnel is required to move to the forming machine, when the hand held spot inspection machine receives the broadcast sent by the second Bluetooth module of the safety light curtain, and the Bluetooth module automatically judges that the spot inspection personnel reaches the spot inspection position under the condition that the calculated distance of the Bluetooth module accords with the threshold value according to the intensity of the signal, and sends a command of 'forming machine-safety light curtain-video recording start' to the control system, and starts the fish eye camera after receiving the command, and cuts off the area outside the mounting position of the forming machine in the picture synchronously. Meanwhile, the hand-held spot inspection instrument releases the non-spot-selectable state of the task recording option, after the spot inspection personnel check that the safety light curtain is free of problems, the qualified option is selected, then the hand-held spot inspection instrument displays the next task, the spot inspection personnel leave to go to the next equipment area, after the Bluetooth connection is disconnected due to the distance, the hand-held spot inspection instrument sends a 'forming machine-safety light curtain-video recording stop' instruction to the control system, thereby completing the monitoring record of a point position, and in the whole process, the system limits and ensures that the spot inspection personnel carry out according to the working procedure, and no extra step is added or the spot inspection personnel are monitored in the visible range, so that the non-sensing spot inspection is realized.
After the whole inspection is finished, the point inspection personnel return to the checking point inspection condition of the industrial personal computer and upload the checking point inspection condition to the control system;
s4, the control system controls the production equipment to start and stop according to the feedback condition in the S3; specifically, the field terminal can display whether each safety device is qualified or not, if the safety device is unqualified, a maintainer is informed to stop and maintain, meanwhile, the system control equipment is produced until all the maintenance is qualified, if all the maintenance is qualified after the maintenance is finished, an operator can generate a safety spot inspection record in the control system after submitting the safety spot inspection record, and a spot inspection task is finished.
In the description of the present invention, it should be understood that the terms "left", "right", "upper", "lower", "top", "bottom", "front", "rear", "inner", "outer", "back", "middle", etc. indicate orientations or positional relationships based on the orientations or positional relationships shown in the drawings, are merely for convenience in describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must be provided with specific orientations, be configured and operated in specific orientations, and thus are not to be construed as limiting the present invention.
However, the foregoing description is only illustrative of the present invention and is not intended to limit the scope of the invention, so that the substitution of equivalent elements or equivalent variations and modifications within the scope of the invention are intended to fall within the scope of the claims.
Claims (9)
1. The equipment safety spot inspection system is characterized by comprising a control system, a field terminal, production equipment and a safety device;
the main body of the field terminal is an industrial personal computer and is electrically connected with the production equipment and the safety device;
each of said production devices is provided with at least one of said safety devices;
the control system is integrated in the server and is electrically connected with the field terminal, the production equipment and the safety device respectively.
2. The system of claim 1, wherein the field terminal further comprises a handheld spot check meter, the handheld spot check meter being wirelessly connected to the industrial personal computer or the control system.
3. The system of claim 2, wherein the handheld spot check device is provided with a first bluetooth module and the security device is provided with a second bluetooth module.
4. A device safety spot inspection system according to any one of claims 1-3, wherein the safety means comprises, but is not limited to, one or more of a safety light curtain, a pull-cord switch, a scram button, a safety foot rest.
5. A system for equipment safety spot inspection according to any one of claims 1-3, further comprising a monitoring system, the main body being a fish-eye camera hoisted in a factory; the fish-eye camera is connected with the control system in a wired or wireless mode.
6. A control method of an equipment security spot check system according to any one of claims 1 to 5, comprising the steps of:
s1, the control system automatically compiles a spot inspection plan according to preset rules and acquired information, and records the spot inspection plan in a database after manual auditing;
s2, logging in team information at the field terminal after the spot inspection personnel enter the factory, and downloading a corresponding spot inspection plan;
s3, the spot inspection personnel completes tasks according to the spot inspection plan, feeds back spot inspection conditions at the field terminal, and uploads the spot inspection conditions to the control system;
s4, the control system controls the production equipment to start and stop according to the feedback condition in the S3; if the maintenance condition exists, the notification to be maintained is pushed to maintenance personnel online.
7. The method according to claim 6, wherein the field terminal further comprises a handheld spot inspection device, and the spot inspection personnel downloads the spot inspection plan to the handheld spot inspection device and carries the spot inspection plan to the spot inspection location for recording.
8. The method for controlling a system for checking a security point of a device according to claim 7, wherein the handheld checking instrument is provided with a first bluetooth module, the security device is provided with a second bluetooth module, and the step S3 of checking the security point further comprises:
s31, the second Bluetooth module continuously performs Bluetooth broadcasting and comprises the safety device information and corresponding production equipment information;
s32, the handheld spot inspection instrument displays a current spot inspection task and limits recording option spot selection until the first Bluetooth module receives Bluetooth broadcasting corresponding to the current spot inspection task and automatically releases the limitation after the distance meets the requirement; the recording options comprise qualified options and unqualified options;
and S33, after the spot check personnel finishes spot selecting the recording options, the hand-held spot check instrument automatically displays the next spot check task.
9. The control method of a safety spot inspection system of claim 8, further comprising a monitoring system, wherein the main body is a fish-eye camera hoisted in a factory; the fish-eye camera is connected with the control system in a wired or wireless way; the point detection process in S3 further comprises:
after the first Bluetooth module receives Bluetooth broadcasting corresponding to the current spot inspection task, the handheld spot inspection instrument sends an instruction to the control system in an online manner, and the control system starts the fisheye camera to record a video of the current spot inspection area and records the identification to be stored in a database; and the starting and ending time of each video recording is respectively from the start to the interruption of the connection of the first Bluetooth module and the second Bluetooth module.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310000976.8A CN116243664A (en) | 2023-01-03 | 2023-01-03 | Equipment safety spot inspection system and control method |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202310000976.8A CN116243664A (en) | 2023-01-03 | 2023-01-03 | Equipment safety spot inspection system and control method |
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| Publication Number | Publication Date |
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| CN116243664A true CN116243664A (en) | 2023-06-09 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202310000976.8A Pending CN116243664A (en) | 2023-01-03 | 2023-01-03 | Equipment safety spot inspection system and control method |
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| CN (1) | CN116243664A (en) |
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2023
- 2023-01-03 CN CN202310000976.8A patent/CN116243664A/en active Pending
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