CN117311238A - Central control system and control method for commercial vehicle assembly workshop - Google Patents
Central control system and control method for commercial vehicle assembly workshop Download PDFInfo
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- G—PHYSICS
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- 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
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
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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
- G05B2219/20—Pc systems
- G05B2219/25—Pc structure of the system
- G05B2219/25257—Microcontroller
Abstract
The invention discloses a central control system and a control method for a commercial vehicle assembly workshop. The scheduling control and timing monitoring module is connected with a control system of at least one station device, and the data acquisition unit is used for acquiring arrival information, identification information and PLC data of the station device; the data management unit is used for storing production plan queue information of the assembly workshop; the monitoring unit is respectively connected with the data acquisition unit and the data management unit and is used for reading the production plan queue information, comparing the production plan queue information with the identification information, and if the comparison is consistent, feeding back the comparison consistency information of the point passing data to the control system of the station equipment; the analysis module is at least connected with the scheduling control and timing monitoring module and is used for analyzing and calculating the data output by the scheduling control and timing monitoring module. The embodiment of the invention can manage and monitor the real-time conditions of all links such as process equipment, quality and the like, and ensure the low cost and high efficiency operation of the production line of the final assembly workshop.
Description
Technical Field
The embodiment of the invention relates to the technical field of intelligent automobile manufacturing, in particular to a central control system and a control method for a commercial vehicle assembly workshop.
Background
With the deep development of high-end equipment and intelligent manufacturing, the automobile manufacturing production line realizes intelligent scheduling of products based on automatic information and real material flows, and the creation of data-driven twin monitoring of production equipment becomes urgent.
However, the conventional central control system can only provide limited planning management functions, generate production sequence tasks, and cannot meet the requirements of comprehensive monitoring, analysis and intelligent control of the production process in a low cost and high efficiency manner.
Disclosure of Invention
The embodiment of the invention provides a central control system and a control method for a commercial vehicle assembly workshop, which realize intelligent management and optimal control of the commercial vehicle production process and improve the production efficiency and quality stability by integrating the central control system and station equipment data of the commercial vehicle assembly workshop.
In a first aspect, an embodiment of the present invention provides a central control system for a commercial vehicle assembly shop, including: the system comprises a scheduling control and timing monitoring module and an analysis module, wherein the scheduling control and timing monitoring module is connected with a control system of at least one station device, and the control system of the station device is used for controlling the corresponding station device to process according to the information output by the scheduling control and timing monitoring module;
the scheduling control and timing monitoring module comprises:
the data acquisition unit is used for acquiring arrival information and identification information of the station equipment and PLC data of the station equipment;
the data management unit is connected with the data acquisition unit and is used for storing production plan queue information of the assembly workshop;
the monitoring unit is respectively connected with the data acquisition unit and the data management unit, and is used for reading the production plan queue information, comparing the production plan queue information with the identification information, and if the comparison is consistent, feeding back the comparison consistency information of the point passing data to the control system of the station equipment;
the analysis module is at least connected with the scheduling control and timing monitoring module, and is used for analyzing and calculating the data output by the scheduling control and timing monitoring module and displaying the analysis result.
Optionally, the scheduling control and timing monitoring module further comprises a data forwarding unit and a quality management unit;
the data forwarding unit is respectively connected with the upper computer system and the quality management unit of the station equipment and is used for transmitting the identification information and the processing quality data output by the upper computer system to the quality management unit;
the data acquisition unit is also used for acquiring the quality data receiving success information fed back by the quality management unit and feeding back a success signal to the upper computer system;
the analysis module is also connected with the upper computer system.
Optionally, the station equipment comprises a frame assembly EMS, an outlet lifting device, an interior decoration transmission line, an engine assembly, a chassis surface paint line, a tire transmission line, a filling device and a tightening device.
Optionally, the analysis module comprises a data modeling unit and an application development unit;
the data modeling unit is respectively connected with the data acquisition unit and the upper computer system and is used for establishing a data model according to the identification information acquired by the data acquisition unit, the PLC data of the station equipment and the process parameter data in the upper computer system;
the application development unit is connected with the data modeling unit and is used for carrying out visualization processing on corresponding data according to the data model.
Optionally, the data model includes a plant static data model, a planning data model, a process parameter data model, an energy data model, a fault data model, and an eastern data model;
the process parameter data includes temperature, tightening parameters, and filling parameters.
Optionally, the application development unit is further configured to produce the early warning information when the visualized data does not meet the preset threshold range.
Optionally, the analysis module further includes a system integration unit, the system integration unit is connected with the application development unit, and the system integration unit is used for sending the early warning information to the user.
In a second aspect, an embodiment of the present invention provides a control method for a central control system of a commercial vehicle assembly shop, where the central control system includes a scheduling control and timing monitoring module and an analysis module, and the scheduling control and timing monitoring module is connected with a control system of at least one station device; the scheduling control and timing monitoring module comprises: the system comprises a data acquisition unit, a data management unit and a monitoring unit;
the control method comprises the following steps:
the control data acquisition unit acquires arrival information and identification information of the station equipment and PLC data of the station equipment;
the control monitoring unit acquires the arrival information and the identification information of the station equipment, acquires the production plan queue information stored in the data management unit, compares the production plan queue information with the arrival information and the identification information of the station equipment, and if the comparison is consistent, feeds back the comparison consistency information of the point passing data to the control system of the station equipment so that the control system of the station equipment carries out processing operation on the station equipment according to the corresponding process parameter data;
the control analysis module is used for analyzing and calculating the data output by the scheduling control and timing monitoring module and displaying the analysis result.
Optionally, the scheduling control and timing monitoring module further comprises a data forwarding unit and a quality management unit, wherein the data forwarding unit is respectively connected with the upper computer system and the quality management unit of the station equipment; after finishing the processing operation, the control method further comprises:
the control data acquisition unit acquires request leaving information sent by a control system of the station equipment;
the control data forwarding unit sends the processing quality data transmitted by the upper computer system, the arrival signals of the station equipment and the identification information to the quality management unit;
if the quality management unit receives the quality data successfully, the control monitoring unit receives the quality data successfully received information fed back by the quality management unit, and sends the quality data successfully received information to the data acquisition unit, and the control data acquisition unit feeds back successful signals to the upper computer system and the station equipment, so that the control system of the station equipment feeds back permission release information to the data acquisition unit.
Optionally, the analysis module comprises a data modeling unit, an application development unit and a system integration unit;
the control analysis module analyzes and calculates the data output by the scheduling control and timing monitoring module, and displays the analysis result, wherein the analysis result comprises:
the control data modeling unit establishes a data model according to the station equipment arrival information, the identification information and the process parameter data in the upper system acquired by the acquisition unit;
the control application development unit performs visualization processing on the corresponding data according to the data model, and when the data after the visualization processing does not meet the preset threshold range, early warning information is produced;
the control system integrated unit sends the early warning information to the user.
The embodiment of the invention provides a central control system for a commercial vehicle assembly workshop, which comprises the following components: the system comprises a scheduling control and timing monitoring module and an analysis module, wherein the scheduling control and timing monitoring module is connected with a control system of at least one station device, and the control system of the station device is used for controlling the corresponding station device to process according to the information output by the scheduling control and timing monitoring module. The scheduling control and timing monitoring module comprises: the data acquisition unit is used for acquiring arrival information, identification information and PLC data of the station equipment. The data management unit is connected with the data acquisition unit and is used for storing production plan queue information of the assembly workshop. The monitoring unit is respectively connected with the data acquisition unit and the data management unit, and is used for reading the production plan queue information, comparing the production plan queue information with the identification information, and if the comparison is consistent, feeding back the comparison consistency information of the point passing data to the control system of the station equipment. The analysis module is at least connected with the scheduling control and timing monitoring module, and is used for analyzing and calculating the data output by the scheduling control and timing monitoring module and displaying the analysis result. In the technical scheme provided by the embodiment, the scheduling control and time sequence monitoring module automatically schedules production tasks based on the information flow of the production site, provides real-time production monitoring and guidance, does not transmit the information flow of the production product, and performs time sequence monitoring according to the transmission action time sequence, thereby providing support for production and operation and maintenance, realizing action time sequence monitoring and optimization control on the production process of the assembly workshop, and improving the man-machine interaction efficiency. The monitoring unit compares the station equipment arrival information and the identification information acquired by the data acquisition unit with the station equipment arrival information and the identification information in the data management unit, if the data are consistent, the control system of the station equipment controls the corresponding station equipment to process according to the data information output by the monitoring unit, the monitoring unit monitors the production execution plan data, the energy consumption data, the process parameter data and the processing quality data in the processing process in real time, and the data acquisition unit acquires the production execution plan data, the energy consumption data, the process parameter data and the processing quality data in the processing process, transmits the production execution plan data, the energy consumption data and the process parameter data to the analysis module for analysis and calculation, and displays the analysis result. The technical scheme of the embodiment of the invention can manage and monitor the real-time conditions of all links such as station equipment, quality and the like, ensures the low cost and high efficiency operation of the assembly workshop production line, and is beneficial to improving the production efficiency and the quality stability.
It should be understood that the description in this section is not intended to identify key or critical features of the embodiments of the invention or to delineate the scope of the invention. Other features of the present invention will become apparent from the description that follows.
Drawings
In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the drawings required for the description of the embodiments will be briefly described below, and it is apparent that the drawings in the following description are only some embodiments of the present invention, and other drawings may be obtained according to these drawings without inventive effort for a person skilled in the art.
FIG. 1 is a diagram of a central control system scheduling control and timing monitoring module architecture according to an embodiment of the present invention;
FIG. 2 is a flow diagram of queue information in a data management unit provided by an embodiment of the present invention;
FIG. 3 is a schematic diagram of a timing monitoring module and a scheduling control system of a central control system according to an embodiment of the present invention;
fig. 4 is a schematic diagram of an analysis module of a central control system according to an embodiment of the present invention.
Detailed Description
In order that those skilled in the art will better understand the present invention, a technical solution in the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings in which it is apparent that the described embodiments are only some embodiments of the present invention, not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the present invention without making any inventive effort, shall fall within the scope of the present invention.
It should be noted that the terms "first," "second," and the like in the description and the claims of the present invention and the above figures are used for distinguishing between similar objects and not necessarily for describing a particular sequential or chronological order. It is to be understood that the data so used may be interchanged where appropriate such that the embodiments of the invention described herein may be implemented in sequences other than those illustrated or otherwise described herein. Furthermore, the terms "comprises," "comprising," and "having," and any variations thereof, are intended to cover a non-exclusive inclusion, such that a process, method, system, article, or apparatus that comprises a list of steps or elements is not necessarily limited to those steps or elements expressly listed but may include other steps or elements not expressly listed or inherent to such process, method, article, or apparatus.
Fig. 1 is a schematic diagram of a central control system scheduling control and timing monitoring module according to an embodiment of the present invention. Fig. 2 is a queue information flow chart in a data management unit provided in an embodiment of the present invention, referring to fig. 1 and fig. 2, a central control system of the commercial vehicle assembly shop includes: the system comprises a scheduling control and timing monitoring module 10 and an analysis module 30, wherein the scheduling control and timing monitoring module 10 is connected with a control system 12 of at least one station device, and the control system 12 of the station device is used for controlling the corresponding station device 11 to process according to the information output by the scheduling control and timing monitoring module 10. The scheduling control and timing monitoring module 10 includes: the data acquisition unit 101 is used for acquiring arrival information and identification information of the station equipment and PLC data of the station equipment 11; and the data management unit 103 is connected with the data acquisition unit 101, and the data management unit 103 is used for storing production plan queue information of the assembly shop. The monitoring unit 102 is respectively connected with the data acquisition unit 101 and the data management unit 103, the monitoring unit 102 is used for reading the production plan queue information, comparing the production plan queue information with the identification information, and if the comparison is consistent, feeding back the comparison consistency information 1-2 of the data of the passing points to the control system of the station equipment 11. The analysis module 30 is at least connected with the scheduling control and timing monitoring module 10, and the analysis module 30 is configured to analyze and calculate the data output by the scheduling control and timing monitoring module 10, and display the analysis result.
The station devices 11 are devices for processing products in a commercial vehicle assembly shop, and the number of the station devices 11 is a plurality. The PLC data includes production execution plan data and energy consumption data. The production schedule queue information includes: arrival information and identification information 1-1 of the station equipment, passing point data comparison coincidence information 1-2, process parameter data 1-3, request leaving information 1-4, processing quality data 1-5, processing quality data receiving success information 1-6 and permission release information 1-7.
Specifically, when the production line operates, the data acquisition unit 11 may acquire the arrival information and the identification information 1-1 of each station device 11 based on an OPC (OLE forProcess Contro, object linking and embedded process control) protocol, and transmit the acquired arrival information and identification information of the station device 11 to the monitoring unit 102 in the scheduling control and timing monitoring module 10, the monitoring unit 102 reads the production plan queue information stored in the data management unit 103, and compares the production plan queue information with the arrival information and the identification information 1-1 of the station device 11 acquired by the data acquisition unit 101, if the data is consistent, the monitoring unit 102 transmits the point passing data comparison consistent information 1-2 to the control system 12 of the station device through the OPC protocol, and the control system 12 of the station device controls the corresponding station device 11 to perform the processing operation according to the data information output by the scheduling control and timing monitoring module 10 (e.g., the monitoring unit 102). At this time, the monitoring unit 102 may monitor the production execution plan data and the energy consumption data in real time during the processing. Optionally, the monitoring unit 102 may also monitor the process parameter data 1-3 and the process quality data 1-5 in real time during the process.
The analysis module 40 is connected with the data acquisition unit 101 in the scheduling control and timing monitoring module 10, and the analysis module 40 acquires the production execution plan data and the energy consumption data in the data acquisition unit 101, performs analysis and calculation on the acquired production execution plan data and energy consumption data, and displays analysis results so as to better identify abnormal conditions in the production process.
In the technical scheme provided by the embodiment, the scheduling control and timing monitoring module 10 automatically schedules production tasks based on the information flow of the production site, provides real-time production monitoring and guidance, does not transmit the information flow of the production product, and performs timing monitoring according to the transmission action timing sequence, thereby providing support for production and operation and maintenance, realizing action timing monitoring and optimizing control on the production process of the assembly shop, and improving the man-machine interaction efficiency. The monitoring unit 102 compares the arrival information and the identification information 1-1 of the station equipment 11 acquired by the data acquisition unit 101 with the arrival information and the identification information 1-1 of the station equipment 101 in the data management unit 103, if the data are consistent, the control system 12 of the station equipment controls the corresponding station equipment 11 to process according to the data information output by the monitoring unit, the monitoring unit 102 monitors the production execution plan data, the energy consumption data, the process parameter data 1-3 and the process quality data 1-5 in real time in the process, the data acquisition unit 101 acquires the production execution plan data, the energy consumption data, the process parameter data 1-3 and the process quality data 1-5 in the process, and transmits the production execution plan data, the energy consumption data and the process parameter data 1-3 to the analysis module 40 for analysis and calculation, and displays the analysis result. The technical scheme of the embodiment of the invention can manage and monitor the real-time conditions of all links such as the station equipment 11, the quality and the like, ensure the low cost and high efficiency operation of the production line of the assembly workshop, and is beneficial to improving the production efficiency and the quality stability.
Fig. 3 is a schematic diagram of a central control system scheduling control and timing monitoring module according to an embodiment of the present invention, referring to fig. 2 and fig. 3, and optionally, the scheduling control and timing monitoring module 10 further includes a data forwarding unit 104 and a quality management unit 105 based on the above embodiment. The data forwarding unit 104 is respectively connected with the upper computer system 13 and the quality management unit 105 of the station device 11, and the data forwarding unit 104 is used for transmitting the station device arrival signal, the identification information 1-1 and the processing quality data 1-5 output by the upper computer system 13 to the quality management unit 105. The quality management unit 105 is used to store the process quality data 1-5. The data acquisition unit 101 is further configured to acquire the processing quality data reception success information 1-6 fed back by the quality management unit 105, and feed back a success signal to the upper computer system 13. The analysis module 40 is also connected to a host computer system.
The upper computer system 13 is used for transmitting the arrival information and the identification information 1-1 of the station equipment 11 and the processing quality data 1-5 to the data forwarding unit 104, and is also used for receiving the information of successful reception fed back by the quality management unit 105. The upper computer system 13 includes a filler upper computer 131 and a tightening device upper computer 132.
Specifically, after the monitoring unit 102 transmits the passing point data comparison consistency information 1-2 to the control system 12 of the station equipment, the control system 12 of the station equipment reads the process parameter data 1-3 of the product in the upper computer system 13, and the control system 12 of the station equipment controls the corresponding station equipment 11 to carry out processing operation according to the passing point data comparison consistency information 1-2 fed back by the scheduling control and timing monitoring module 10. At this time, the data collection unit 101 collects the production execution plan data, the energy consumption data, the process parameter data 1-3, and the process quality data 1-5 during the process, and transfers the production execution plan data and the energy consumption data to the analysis module 40.
After the processing operation is finished, the request leaving information 1-4 is fed back to the data acquisition unit 101, the data acquisition unit 101 feeds back the process parameter data 1-3, the processing quality data 1-5 and the arrival information and the identification information 1-1 of the station equipment to the control system 12 of the station equipment, the control system 12 of the station equipment is transmitted to the upper computer system 13, the upper computer system 13 transmits the arrival information and the identification information 1-1 of the station equipment 11 and the processing quality data 1-5 to the data forwarding unit 104 based on the WEBSERVICE protocol, the data forwarding unit 104 transmits the arrival information and the identification information 1-1 of the station equipment 11 and the processing quality data 1-5 to the quality management unit 105, the quality management unit 105 feeds back the processing quality data receiving success information 1-6 to the monitoring unit 102 after receiving success, the monitoring unit 102 transmits the information to the data acquisition unit 101, the information fed back success by the data acquisition unit 101 to the upper computer system 13 and the station equipment 11, and the upper computer system 13 starts to clear the cached process parameter data 1-3. After receiving the information of successful feedback, the control system 12 of the station equipment feeds back the permission release information 1-7 to the data acquisition unit 101, and the station flow is ended. In this process, the scheduling control and timing monitoring module 10 of the central control system monitors the timing process, establishes a monitoring-allowed block diagram, and realizes man-machine interaction by means of signal flow. For example, different colors may be used to represent the transmission process of the signal stream, green represents the node data transmission, and yellow represents the node data to be transmitted next.
The monitoring unit 102 also monitors the in-process production execution plan data, the energy consumption data, the process parameter data 1-3, and the process quality data 1-5 in real time for the manager to make decisions and optimize the production organization.
In the technical scheme provided by the embodiment of the invention, the processing quality data 1-5 are transmitted to the quality management unit 105 through the data forwarding unit 104 and the upper computer system 13, the processing quality data 1-5 are stored, the data acquisition unit 101 transmits the process parameter data 1-3 to the upper computer system 13, and after the upper computer system 13 receives the feedback information of successful reception of the quality management unit 105, the buffer process parameter data 1-3 is cleared.
Referring to fig. 3, the station apparatus may optionally include a carriage assembly EMS, an outlet lifting apparatus, an interior trim transfer line, an engine assembly, a chassis face paint line, a tire transfer line, a filling apparatus, and a tightening apparatus, in accordance with the above-described embodiments.
The scheduling control and timing monitoring module 10 is connected with at least one control system in station equipment such as a frame assembly EMS, outlet lifting equipment, an interior decoration transmission line, an engine assembly, a chassis surface paint line, a tire transmission line, filling equipment, screwing equipment and the like.
Fig. 4 is a schematic diagram of an analysis module of a central control system according to an embodiment of the present invention, referring to fig. 2 and fig. 4, and, optionally, the analysis module 40 includes a data modeling unit 401 and an application development unit 402 based on the foregoing embodiments. The data modeling unit 401 is respectively connected with the data acquisition unit 101 and the upper computer system, and the data modeling unit 401 is used for establishing a data model according to the identification information of the station equipment, the PLC data of the station equipment and the process parameter data 1-3 of 13 in the upper computer system, which are acquired by the data acquisition unit 101; the application development unit 402 is connected with the data modeling unit 401, and the application development unit 402 is used for performing visualization processing on corresponding data according to the data model.
The station equipment PLC comprises a frame assembly EMSPLC-121, an outlet lifting equipment PLC-122, an interior decoration conveying line PLC-123, an engine assembly PLC-124, a chassis finishing line PLC-125, a tire conveying line PLC-126, a filling equipment PLC-127 and a tightening equipment PLC-128. The frame assembly EMSPLC controls the frame assembly EMS to process, the outlet lifting device PLC-122 controls the outlet lifting device to process, the interior trim conveying line PLC-123, the engine assembly PLC-124 controls the engine assembly to process, the chassis finishing line PLC-125 controls the chassis finishing line to process, the tire conveying line PLC-126 controls the tire conveying line to process, the filling device PLC-127 controls the filling device to process and the tightening device PLC-128 controls the tightening device to process.
Specifically, when the data acquisition unit 101 acquires the production execution plan data and the energy consumption data of the station devices 11 such as the frame assembly EMS, the outlet lifting device, the interior trim transmission line, the engine assembly, the chassis finish, the tire transmission line, the filling device, the tightening device and the like, the production execution plan data and the energy consumption data of each station device 11 are transmitted to the data modeling unit 401 in the analysis module 30, the data modeling unit 401 acquires the process parameter data 1-3 of the filling device and the tightening device from the upper computer system 13, and the data modeling unit 401 establishes a data model according to the acquired production execution plan data, the energy consumption data and the process parameter data 1-3 of the filling device and the tightening device. The application development unit 402 reads the data received by the data modeling unit 401, and performs a visual process on the read production plan data and energy consumption data and process parameter data 1-3 in a graphical programming manner.
In the technical solution of the present embodiment, the data modeling unit 401 models the production execution plan data, the energy consumption data, and the process parameter data 1-3 of each station device, and the application development unit 402 performs the visualization processing on the production execution plan data, the energy consumption data, and the process parameter data 1-3, so as to provide a production plan, an energy consumption, a process parameter, a multidimensional report, and a trend analysis, which is favorable for making a decision and optimizing a production organization for a manager.
Optionally, the data model includes a plant static data model, a planning data model, a process parameter data model, an energy data model, a fault data model, and an eastern data model.
Wherein the static data model comprises a model constructed by factory-workshop-single station equipment. The plan data model is based on a static data model, and machining plan data of each station device are added. The process parameter data model is a model constructed by temperature, tightening parameters and filling parameter data of each station device. The energy data model comprises a model constructed by meter data, wherein the meter data comprises electric energy data, compressed air consumption data and natural gas consumption data. The fault data model comprises a fault type model, wherein the fault type is divided into mechanical faults, electrical faults and thermal faults, and the fault type model comprises fault data such as overtime, overrun and scram of each station device; the data acquisition unit 101 acquires equipment alarm data of the station equipment 11 in the production process, and transmits the equipment alarm data of each station equipment 11 to the data modeling unit 401, and the data modeling unit 401 establishes a fault data model according to the equipment alarm data. The safe data are data of the operation states of each station device, and comprise an automatic operation mode, a manual mode and a standby mode.
The technical scheme provided by the embodiment provides multidimensional reports and trend analysis of production plans, energy consumption, process parameters, equipment faults and the like, and is beneficial to making decisions and optimizing production organization for management staff.
With continued reference to fig. 4, the application development unit 402 is further configured to generate the early warning information when the visualized data does not satisfy the preset threshold range, if necessary.
Specifically, the application development unit 402 is configured to respectively calculate the static data model, the planning data model, the process parameter data model, the energy data model, the fault data model and the safe data model to generate a production plan execution trend chart, a process parameter graph, an energy consumption trend chart, each fault time duty ratio chart and an safe slice analysis chart in a graphical programming manner, and complete early warning reminding through threshold comparison. Illustratively, the early warning operation includes: and when the real-time plan completion rate is less than 98%, early warning is carried out, when the temperature is less than 175 ℃ or greater than 220 ℃, early warning is carried out when the consumption of each energy hour is greater than the accumulated consumption of the instrument at the same time period/the number of production days/24, and early warning is carried out when the automatic operation safe mode duration of each station device is less than 95% of the total operation duration of the daily device.
The technical scheme of the embodiment can detect the running state of the equipment in real time, record alarm information, production plan information, energy consumption information and process information in real time, provide multidimensional reports and trend analysis of production plans, processes, equipment faults, safety, energy sources and the like, and facilitate management staff to make decisions and optimize production organization.
With continued reference to fig. 4, the analysis module 40 may further include a system integration unit 403, where the system integration unit 403 is connected to the application development unit 402, and the system integration unit 403 is configured to send the early warning information to the user.
The application development unit 402 is further configured to store production execution plan index data, energy consumption index data, equipment alarm index data, and safe index data, among others. The production execution plan index data, the energy consumption index data, the equipment alarm index data, and the safe index data are input to the central control system application development unit 402 by the manager before the start of the machining operation.
Specifically, when the application development unit 402 compares the read production execution plan data, energy consumption data, device alarm data and safe data of the station device with the production execution plan index data, energy consumption index data, device alarm index data and safe index data, if an abnormality is found, the system integration unit 403 carries out early warning reminding and sends abnormality information to the system integration unit 403, the system integration unit 403 obtains a group chat ID based on a PYTHON definition screenshot function, and the screenshot application development unit 402 corresponds to an abnormal interface and sends the group chat ID. The production execution plan index data, the energy consumption index data, the equipment alarm index data and the safe index data can be set according to actual production requirements.
In other embodiments, the system integration unit 403 may also perform a short message reminder, an audible and visual alarm on the production site, and so on according to the received abnormal information.
In this embodiment, the early warning is performed by the application development unit 402, the early warning information is transmitted to the system integration unit 403, the abnormal information is sent to the group chat ID by the system integration unit 403, and the alarm information is recorded in real time, so that the problem can be found and solved in time.
The embodiment of the invention provides a control method for a central control system of a commercial vehicle assembly workshop, referring to fig. 1 and 2, the embodiment is further optimized and expanded based on the embodiments and can be combined with various optional technical schemes in the embodiment, the central control system comprises a scheduling control and timing monitoring module 10 and an analysis module 40, and the scheduling control and timing monitoring module 10 is connected with a control system 12 of at least one station device; the scheduling control and timing monitoring module 10 includes: a data acquisition unit 101, a data management unit 103 and a monitoring unit 102.
The control method comprises the following steps:
the control data acquisition unit 101 acquires arrival information of the station apparatus 11, identification information 1-1, and PLC data of the station apparatus 11.
The control monitoring unit 102 acquires the arrival information and the identification information 1-1 of the station equipment, acquires the production plan queue information stored in the data management unit 105, compares the production plan queue information with the arrival information and the identification information 1-1 of the station equipment, and if the comparison is consistent, feeds back the point passing data comparison consistent information 1-2 to the control system 12 of the station equipment, so that the control system 12 of the station equipment performs processing operation on the station equipment 11 according to the corresponding process parameter data 1-3.
The control analysis module 40 performs analysis and calculation on the data output by the schedule control and timing monitoring module 10, and displays the analysis result.
In the technical solution provided in this embodiment, the monitoring unit 102 compares the arrival information and the identification information 1-1 of the station apparatus 11 acquired by the data acquisition unit 101 with the arrival information and the identification information 1-1 of the station apparatus 11 in the data management unit 103, and if the data are consistent, the control system 12 of the station apparatus controls the corresponding station apparatus 11 to perform the processing operation according to the output data information, the monitoring unit 102 monitors the production execution plan data, the energy consumption data, the process parameter data 1-3 and the processing quality data 1-5 in real time during the processing, the data acquisition unit 101 transmits the production execution plan data, the energy consumption data, the process parameter data 1-3 and the processing quality data 1-5 acquired during the processing to the analysis module 40 for analysis calculation, and displays the analysis result. The technical scheme of the embodiment of the invention can manage and monitor the real-time conditions of all links such as the station equipment 11, the quality and the like, ensure the low cost and high efficiency operation of the production line of the assembly workshop, and is beneficial to improving the production efficiency and the quality stability.
With continued reference to fig. 2 and 3, the scheduling control and timing monitoring module 10 further includes a data forwarding unit 104 and a quality management unit 105, where the data forwarding unit 104 is connected to the upper computer system 12 and the quality management unit 105 of the station apparatus 11, respectively. After finishing the processing operation, the control method further comprises:
the control data acquisition unit 101 acquires the request leaving information 1-4 sent by the control system 12 of the station apparatus, and the control data transfer unit 104 sends the processing quality data 1-5 transmitted by the upper computer system 13, and the arrival information and identification information 1-1 of the station apparatus to the quality management unit 105. If the quality management unit 105 receives the processing quality data successfully, the control monitoring unit 102 sends processing quality data receiving success information 1-6 to the data acquisition unit 101, and the control data acquisition unit 101 feeds back success signals to the upper computer system 13 and the station equipment 11, so that the control system 12 of the station equipment feeds back permission release information 1-7 to the data acquisition unit 101.
In the technical scheme provided by the embodiment of the invention, the processing quality data 1-5 are transmitted to the quality management unit 105 by controlling the data forwarding unit 104 and the upper computer system 13, the processing quality data 1-5 are stored, the process parameter data 1-3 are transmitted to the upper computer system 13 by controlling the data acquisition unit 101, and the upper computer system 13 starts to clear the cached process parameter data 1-3 after receiving the feedback information of successful reception of the quality management unit 105. The embodiment of the invention can record the change of the processing quality data 1-5 and the process parameter data 1-3 in real time, and is convenient for a manager to make decisions and optimize production organization.
Referring to fig. 2 and 4, the analysis module 40 may optionally include a data modeling unit 401, an application development unit 402, and a system integration unit 403; the control analysis module 40 performs analysis and calculation on the data output by the schedule control and timing monitoring module 10, and displays analysis results including: the control data modeling unit 401 establishes a data model according to the station equipment arrival signals, the identification information 1-1 and the process parameter data 1-3 in the upper system acquired by the data acquisition unit 101; the control application development unit 402 performs visualization processing on corresponding data according to the data model, and when the data after the visualization processing does not meet a preset threshold range, early warning information is produced; the control system integrated unit sends the early warning information to the user.
Specifically, after the station flow is finished, the control data modeling unit 401 acquires the production execution plan data, the energy consumption data, the arrival information and the identification information 1-1 of the station equipment and the process parameter data 1-3 of the upper computer system of the data acquisition unit 101, controls the data modeling unit 401 to build a data model according to the production execution plan data, the energy consumption data and the process parameter data 1-3, controls the application development unit 402 to read the data of the data modeling unit 401, and generates a production plan execution trend graph, a process parameter graph, an energy consumption trend graph, each fault time duty graph and an Andong slice analysis graph on the corresponding data in a graphical programming mode. The application development unit 402 is also controlled to compare the read production execution plan data, energy consumption data, equipment alarm data and safe data of the station equipment with production execution plan index data, energy consumption index data, equipment alarm index data and safe index data, and perform early warning and reminding after the comparison is completed, the control system integration unit 403 obtains group chat IDs based on PYTHON definition screenshot functions, and the screenshot application development unit 402 corresponds to an abnormal interface and sends the group chat IDs.
In the technical scheme of the embodiment of the invention, the data modeling unit 401, the application development unit 402 and the system integration unit 403 are used for intelligently analyzing and predicting the data of the station equipment 11, so that abnormal conditions in the production process can be identified, and real-time alarming and early warning functions are provided, thereby being beneficial to preventing faults and solving problems in time, and facilitating management personnel to make decisions and optimize production organization.
It should be appreciated that various forms of the flows shown above may be used to reorder, add, or delete steps. For example, the steps described in the present invention may be performed in parallel, sequentially, or in a different order, so long as the desired results of the technical solution of the present invention are achieved, and the present invention is not limited herein.
The above embodiments do not limit the scope of the present invention. It will be apparent to those skilled in the art that various modifications, combinations, sub-combinations and alternatives are possible, depending on design requirements and other factors. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the scope of the present invention.
Claims (10)
1. A central control system for a commercial vehicle assembly plant, comprising: the system comprises a scheduling control and timing monitoring module and an analysis module, wherein the scheduling control and timing monitoring module is connected with a control system of at least one station device, and the control system of the station device is used for controlling the corresponding station device to carry out processing operation according to the information output by the scheduling control and timing monitoring module;
the scheduling control and timing monitoring module comprises:
the data acquisition unit is used for acquiring arrival information and identification information of the station equipment and PLC data of the station equipment;
the data management unit is connected with the data acquisition unit and is used for storing production plan queue information of the assembly workshop;
the monitoring unit is respectively connected with the data acquisition unit and the data management unit, and is used for reading the production plan queue information, comparing the production plan queue information with the identification information, and if the comparison is consistent, feeding back the comparison consistency information of the past points to a control system of the station equipment;
the analysis module is at least connected with the scheduling control and timing monitoring module, and is used for analyzing and calculating the data output by the scheduling control and timing monitoring module and displaying the analysis result.
2. The central control system for a commercial vehicle assembly shop according to claim 1, wherein the scheduling control and timing monitoring module further comprises a data forwarding unit and a quality management unit;
the data forwarding unit is respectively connected with the upper computer system of the station equipment and the quality management unit, and is used for transmitting the identification information and the processing quality data output by the upper computer system to the quality management unit;
the data acquisition unit is also used for acquiring the quality data receiving success information fed back by the quality management unit and feeding back a success signal to the upper computer system;
the analysis module is also connected with the upper computer system.
3. The central control system for a commercial vehicle assembly plant according to claim 1, wherein the station apparatus comprises a carriage assembly EMS, an exit hoist apparatus, an interior trim transfer line, an engine assembly, a chassis finish line, a tire transfer line, a filling apparatus, and a tightening apparatus.
4. The central control system for a commercial vehicle assembly plant according to claim 2, wherein the analysis module comprises a data modeling unit and an application development unit;
the data modeling unit is respectively connected with the data acquisition unit and the upper computer system, and is used for establishing a data model according to the identification information acquired by the data acquisition unit, the PLC data of the station equipment and the process parameter data in the upper computer system;
the application development unit is connected with the data modeling unit and is used for carrying out visualization processing on corresponding data according to the data model.
5. The central control system for a commercial vehicle assembly plant of claim 4, wherein the data models include a plant static data model, a planning data model, a process parameter data model, an energy data model, a fault data model, and an eastern data model;
the process parameter data includes temperature, tightening parameters, and filling parameters.
6. The central control system for a commercial vehicle assembly shop according to claim 4, wherein the application development unit is further configured to produce the early warning information when the visualized data does not satisfy the preset threshold range.
7. The center control system for a commercial vehicle assembly plant according to claim 6, wherein,
the analysis module further comprises a system integration unit, the system integration unit is connected with the application development unit, and the system integration unit is used for sending the early warning information to a user.
8. The control method of the central control system for the commercial vehicle assembly workshop is characterized in that the central control system comprises a scheduling control and timing monitoring module and an analysis module, and the scheduling control and timing monitoring module is connected with a control system of at least one station device; the scheduling control and timing monitoring module comprises: the system comprises a data acquisition unit, a data management unit and a monitoring unit;
the control method comprises the following steps:
the data acquisition unit is controlled to acquire arrival information and identification information of the station equipment and PLC data of the station equipment;
the monitoring unit is controlled to acquire the arrival information and the identification information of the station equipment, acquire the production plan queue information stored in the data management unit, compare the production plan queue information with the arrival information and the identification information of the station equipment, and if the comparison is consistent, feed back the comparison consistency information of the past data to the control system of the station equipment so that the control system of the station equipment carries out processing operation on the station equipment according to the corresponding process parameter data;
and controlling the analysis module to analyze and calculate the data output by the scheduling control and timing monitoring module, and displaying the analysis result.
9. The control method for the central control system of the commercial vehicle assembly shop according to claim 8, wherein the scheduling control and timing monitoring module further comprises a data forwarding unit and a quality management unit, the data forwarding unit is respectively connected with an upper computer system of the station equipment and the quality management unit; after the machining operation is completed, the control method further includes:
the data acquisition unit is controlled to acquire the request leaving information sent by the control system of the station equipment;
the data forwarding unit is controlled to send the processing quality data transmitted by the upper computer system, the arrival information and the identification information of the station equipment to the quality management unit;
and if the quality management unit receives the quality data successfully, controlling the monitoring unit to receive the quality data successfully received information fed back by the quality management unit, sending the quality data successfully received information to the data acquisition unit, and controlling the data acquisition unit to feed back successful signals to the upper computer system and the station equipment so that the control system of the station equipment feeds back permission release information to the data acquisition unit.
10. The control method for a central control system of a commercial vehicle assembly shop according to claim 8, wherein the analysis module comprises a data modeling unit, an application development unit and a system integration unit;
the control the analysis module to analyze and calculate the data output by the scheduling control and timing monitoring module, and display the analysis result comprises the following steps:
the data modeling unit is controlled to establish a data model according to the arrival information, the identification information and the technological parameter data in the upper system of the station equipment acquired by the acquisition unit;
controlling the application development unit to perform visualization processing on corresponding data according to the data model, and producing early warning information when the visualized data do not meet a preset threshold range;
and controlling the system integration unit to send the early warning information to a user.
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