CN101625564A

CN101625564A - Method and system for automatic control and automatic warning

Info

Publication number: CN101625564A
Application number: CN200810040266A
Authority: CN
Inventors: 李禄麟; 王金德; 张舒敏; 高孙锋
Original assignee: SHANGHAI XINCE TECHNOLOGY Co Ltd
Current assignee: SHANGHAI ZONTEC INFORMATION TECHNOLOGY CO., LTD.
Priority date: 2008-07-07
Filing date: 2008-07-07
Publication date: 2010-01-13
Anticipated expiration: 2028-07-07
Also published as: CN101625564B

Abstract

The invention discloses a method and a system for automatic control and automatic warning. The system warns operators in various warning ways in real time and carries out prevention in advance on a progress. The invention adopts the technical scheme that the system comprises a data extracting module, an interface export module, a database module, a control limit calculation module, a specification limit setting module, a control state data analysis module, a specification state data analysis module and a command module, wherein the data extracting module is used for acquiring process data and related ID information; the interface export module is used for converting and exporting formats of the data and the information; the database module is used for storing the data and the information; the control limit calculation module is used for calculating a process data control limit through the acquired historical process data; the specification limit setting module is used for setting a process data specification limit; the control state data analysis module is used for comparing the process data with the corresponding control limit so as to output a control state signal depending on whether the process data exceeds the corresponding control limit or not; the specification state data analysis module is used for comparing the process data with the corresponding specification limit so as to output a specification state signal depending on the process data exceeds the corresponding specification limit or not; and the command module is used for outputting a corresponding control command to equipment and outputting a warning instruction according to the control state signal and the specification state signal. The method and the system are applied to the fields of production control and warning.

Description

The method and system of a kind of automatic control and warning

Technical field

The present invention relates to a kind of control and alarm method and system, relate in particular to a kind of based on the automatic control of SPC theory and technology and the method and system of warning.

Background technology

In today of the big production of modernization, automatic control technology is in each large enterprises' widespread use, the mechanization intelligence operation progressively substituted manual operation.These automation equipments realize the automatic control to producing, but this technology never obtain breakthrough progress for many years by the operating process of setting with based on the different standard of declaring of SPEC.

Trace it to its cause, current automatic control technology fully based on the scope of the characteristic index normal value of product judge produce or process whether unusual.Whether unusual feedback signal is carried out work to equipment by obtaining production or process.If the product performance achievement data is in regulating scope, process all belongs to normal condition, and equipment runs well; But if the product performance achievement data exceeds regulating scope, process belongs to up-set condition maybe can not reach the production status requirement, and equipment shuts down or system adjusts according to setting content, sends alerting signal simultaneously and reminds the operator.

In today of the big production of modernization, automated control technology is in each large enterprises' widespread use, the intelligence operation of mechanization progressively substituted manually-operated.These automation equipments are by the operating process set with based on the different standard of declaring of SPEC. control, the automatic control of realization to producing, but this different standard of declaring based on SPEC. control is being used the important breakthrough that just never obtains for many years aspect the theory and technology, this traditional automatic control technology in actual applications, also exist the defective that some need to be improved, mainly show:

One, system can only accomplish process is corrected, and the generation of problem in can not the prevention process, like this, will cause portioned product do over again, scrap or product quality level not high.

They are two years old, can't monitor procedure (or product) and process (or product) between the variation of required controlled variable, thereby the slight change of a lot of crucial details out of control just can not be found in the system, thereby cause the instability of the controlled variable of production run, the instability that causes production run causes the interests loss to enterprise.

Summary of the invention

The object of the present invention is to provide the system of a kind of automatic control and warning, this system is by the mode of group alarm lamp, and the real-time reminding operator is to reach the effect of process being carried out obviate.

Another object of the present invention is to provide the method for a kind of automatic control and warning, this method can be avoided the generation of substandard product in advance and overcome the excessive problem of product variation.

Technical scheme of the present invention is: the present invention has disclosed a kind of automatic control and warning system, and the process data of gathering in the production run is analyzed and by the signal feedback analysis result of warning, this system comprises:

Data extraction module, retrieve processed data and correlation ID information from production run, comprise product direct performance data, process or product indirect performance data and with the closely-related information of data;

Interface is derived module, and process data and correlation ID information that this data extraction module is obtained derive after format conversion;

Database module, process data and correlation ID information that storage is derived;

Control limit computing module, the control limit of the historical process data computation process data of from production run, obtaining by this database module stores;

Standard limit setting module, the standard that is used for the assignment procedure data is limit;

The state of a control data analysis module will be derived process data that module obtains and the control limit of this process data compare from this interface, according to whether exceeding control limit output state of a control signal;

The specification condition data analysis module will be derived process data that module obtains and the standard limit of this process data compare from this interface, according to whether exceeding standard limit output specification condition signal;

Instruction module instructs to corresponding equipment and the corresponding indication of reporting to the police of output according to state of a control signal and specification condition signal output control corresponding.

Above-mentioned automatic control and warning system, wherein, the direct performance data of this product comprises the measurement data of the crucial controlling index of this product, the indirect performance data of this process or product comprises the operational factor of equipment, comprises device numbering and/or technology numbering with the closely-related id information of these data.

Above-mentioned automatic control and warning system, wherein, the control limit that this control limit computing module calculates is divided into the control limit upper limit, control limit lower limit and control limit standard limit, and the standard limit of this standard limit setting module setting is divided into the standard limit upper limit, standard limit lower limit and standard limit standard limit.

Above-mentioned automatic control and warning system, wherein, this system also comprises:

The control chart theory is declared different criterion judge module, judges whether product data violate the different criterion of declaring in the control chart theory, if violate then export one and warn status signal to this instruction module;

The preset standard judge module, judge whether product data violate default standard, if violate then export one and warn status signal, in conjunction with this state of a control signal, this specification condition signal and this status signal of warning, corresponding indication is shown by this instruction module to this alarm module.

The graphic analyses module is showed the data analysis result in the system in the mode of statistical graph.

The alarm lamp module, by the first shape lamp of representing state of a control and represent the second shape lamp of specification condition to form, this first shape lamp all can show first color, second color and the 3rd color with this second shape lamp, its array mode is:

。

The present invention has also disclosed a kind of automatic control and alarm method, and the process data of gathering in the production run is analyzed and by the signal feedback analysis result of warning, this method comprises:

(1) retrieve processed data and correlation ID information from production run, comprise product direct performance data, process or product indirect performance data and with the closely-related id information of data;

(2) process data and the correlation ID information that gets access to is exported to computing machine after format conversion, store database simultaneously into;

(3) limit by the control of stored historical process data computation process data in the database, and the standard of assignment procedure data limit;

(4) process data of current acquisition and the control limit of process data are carried out the data comparison, output state of a control signal carries out the data comparison with the process data of current acquisition and the standard limit of process data, output specification condition signal simultaneously;

(5) according to state of a control signal and the specification condition signal output control corresponding instruction and the indication of reporting to the police.

Above-mentioned automatic control and alarm method, wherein, the direct performance data of this product comprises the measurement data of the crucial controlling index of this product, the indirect performance data of this process or product comprises the operational factor of equipment, comprises device numbering and/or technology numbering with the closely-related id information of these data.

Above-mentioned automatic control and alarm method, wherein, this control limit is divided into the control limit upper limit, control limit lower limit and control limit standard limit, and this standard limit is divided into the standard limit upper limit, standard limit lower limit and standard limit standard limit.

Above-mentioned automatic control and alarm method, wherein, step (4) also comprises:

Judge whether the current production data violate declaring different criterion or violating default standard in the control chart theory, if violate then export the status signal of warning;

Corresponding step (5) further comprises:

On the basis of state of a control signal and specification condition signal, instruct and the corresponding indication of reporting to the police of output in conjunction with this status signal output control corresponding of warning again.

Above-mentioned automatic control and alarm method, wherein, the data analysis result in the step (4) shows in the mode of statistical graph.

Above-mentioned automatic control and alarm method, wherein, this method also comprises:

By the result who warns and indicate by the first shape lamp of representing state of a control and the alarm lamp module of represent the second shape lamp of specification condition to form, this first shape lamp and this second shape lamp all can show first color, second color and the 3rd color, and its array mode is:

。

The present invention contrasts prior art following beneficial effect: the present invention is by introducing the notion of control limit based on the historical process data, simultaneously automatic control system and SPC technological means are organically combined, the Manufacturing Automated process of enterprise is carried out real-time monitoring with SPC technology application mode, and the result of monitoring analysis fed back to opertaing device and panalarm (for example group alarm lamp) in the mode of instruction, automatically produce next step operational order by opertaing device, alarm lamp is informed the production status that the operator is current simultaneously.Contrast prior art, but the generation of obviate unacceptable product and overcome the excessive problem of product variation.

Description of drawings

Fig. 1 is the schematic diagram of first embodiment of automatic control of the present invention and warning system.

Fig. 2 is the schematic diagram of second embodiment of automatic control of the present invention and warning system.

Fig. 3 is the schematic diagram of the 3rd embodiment of automatic control of the present invention and warning system.

Fig. 4 is the schematic diagram of the 4th embodiment of automatic control of the present invention and warning system.

Fig. 5 is the process flow diagram of first embodiment of automatic control of the present invention and alarm method.

Fig. 6 is the process flow diagram of second embodiment of automatic control of the present invention and alarm method.

Fig. 7 is the process flow diagram of the 3rd embodiment of automatic control of the present invention and alarm method.

Fig. 8 is the process flow diagram of the 4th embodiment of automatic control of the present invention and alarm method.

Embodiment

The invention will be further described below in conjunction with method and embodiment.

First embodiment of system

Fig. 1 shows the principle of first embodiment of automatic control of the present invention and warning system.See also Fig. 1, system comprises data extraction module 10, interface derivation module 11, database module 12, control limit computing module 13, state of a control data analysis module 14, standard limit setting module 15, specification condition data analysis module 16, instruction module 17 and alarm lamp module 18.

Wherein data extraction module 10 is obtained current process data and correlation ID information from production run, comprise direct performance data (such as the crucial controlling index of product: length and width, diameter etc.), process or the product of product indirect performance data (such as the operational factor of equipment: electric current, voltage, temperature, pressure intensity etc.) and with the closely-related id information of data (such as the numbering of equipment, technology numbering etc.).Interface derive module 11 with data extraction module 10 procurement process data and correlation ID information after format conversion becomes digital signal or Code Number, derive by RS232, RS485 or RJ45 port.Process data and correlation ID information that database module 12 storages are derived.

Control limit computing module 13 is according to the control limit of the historical process data computation process data of obtaining from production run of database module 12 storages.Standard limit setting module 15 is used for the standard limit of assignment procedure data.The control limit is divided into the control limit upper limit, control limit lower limit and control limit standard limit, and same, the standard limit also is divided into the standard limit upper limit, standard limit lower limit and standard limit standard limit.Understand easily, standard is limit for a fixing process data, and its scope is determined, and the scope of control limit is based on the historical data generation.Compared to standard limit, the range size of control limit is limit less than standard, that is to say since the standard limit cause too greatly the standard limit can't the solution process in the big problem of product variation, can solve by the littler control limit of scope.Same, because the control limit is littler more accurate than the scope of standard limit, the precognition before the product rejection also can be known by whether exceeding the control limit.

Control limit and interface that state of a control data analysis module 14 reception control limit computing modules 13 calculate are derived the active procedure data that module 11 transmits, active procedure data and control limit are carried out the data comparison, whether exceed control limit output state of a control signal to instruction module 17 according to the active procedure data.Meanwhile, specification condition data analysis module 16 receives the active procedure data that standard is limit and interface derivation module 11 transmits that standard limit setting module 15 is provided with, active procedure data and standard limit are carried out the data comparison, whether exceed standard limit output specification condition signal to instruction module 17 according to the active procedure data.For instance, state of a control data analysis module 14 analyzes the active procedure data if specification condition data analysis module 16 analyzes that the active procedure data do not exceed standard limit has exceeded the control limit, illustrates that then current production has the trend that exceeds the standard limit and the possibility of scrapping is arranged in the future.Exceed control limit if state of a control data analysis module 14 analyzes the active procedure data, illustrated that then current production is excessive with the variation of product before this, had consistency problem.

Instruction module 17 illustrates corresponding indication to alarm lamp module 18 according to state of a control signal and specification condition signal.Alarm lamp module 18 can be the composite signal lamp, for state of a control signal and specification condition signal, can take to report to the police respectively or intersect in conjunction with the mode of reporting to the police.For instance, the composite signal light fixture has circular and square two kinds of shapes, and wherein circular signal lamp is represented the judgement of state of a control, and square signal lamp is represented the judgement of specification condition.The color of composite signal lamp is divided into redness and green, and the wherein green active procedure data of representing are not only in the control limit but also in the standard limit, and red representative exceeds the scope of control limit or standard limit.For example, the specification condition signal indicating active procedure data of exporting when specification condition data analysis module 16 do not exceed standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 14 outputs have exceeded control limit scope, and then instruction module 17 can square signal lamp green occur and the state of circular signal lamp redness by the indicator signal Assembled lamp.The specification condition signal indicating active procedure data of exporting when specification condition data analysis module 16 have exceeded standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 14 outputs have exceeded control limit scope, and then the state of square signal lamp redness and circular signal lamp redness appears in instruction module 17 meeting indicator signal Assembled lamps.The specification condition signal indicating active procedure data of exporting when specification condition data analysis module 16 do not exceed standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 14 outputs do not exceed control limit scope yet, and then the state of square signal lamp green and circular signal lamp green appears in instruction module 17 meeting indicator signal Assembled lamps.

It should be noted that instruction module 17 not only has the function of the alerting signal of illustrating, also export the relevant device of steering order to the production run, control these relevant devices automatically, improved on the basis so that follow-up product is manufactured on before this.System can also offer a storage unit, is used for the problem of site operation personnel's storage products appearance, the countermeasure that produces reason and take, and forms a knowledge base, is convenient to the prevention and the processing of follow-up corresponding problem, is convenient to the maintenance and the maintenance of equipment simultaneously.

Second embodiment of system

Fig. 2 shows the principle of second embodiment of automatic control of the present invention and warning system.See also Fig. 2, system comprises data extraction module 20, interface derivation module 21, database module 22, control limit computing module 23, state of a control data analysis module 24, standard limit setting module 25, specification condition data analysis module 26, instruction module 27, graphic analyses module 28 and alarm lamp module 29.

Wherein data extraction module 20 is obtained current process data and correlation ID information from production run, comprise direct performance data (such as the crucial controlling index of product: length and width, diameter etc.), process or the product of product indirect performance data (such as the operational factor of equipment: electric current, voltage, temperature, pressure intensity etc.) and with the closely-related id information of data (such as the numbering of equipment, technology numbering etc.).Interface derive module 21 with data extraction module 20 procurement process data and correlation ID information after format conversion becomes digital signal or Code Number, derive by RS232, RS485 or RJ45 port.Process data and correlation ID information that database module 22 storages are derived.

Control limit computing module 23 is according to the control limit of the historical process data computation process data of obtaining from production run of database module 22 storages.Standard limit setting module 25 is used for the standard limit of assignment procedure data.The control limit is divided into the control limit upper limit, control limit lower limit and control limit standard limit, and same, the standard limit also is divided into the standard limit upper limit, standard limit lower limit and standard limit standard limit.Understand easily, standard is limit for a fixing product, and its scope is determined, and the scope of control limit is based on the historical data generation.Compared to the standard limit, the range size of control limit is limit less than standard, that is to say, because the standard limit causes the standard limit can't solve the big problem of product variation too greatly, can solve by the littler control limit of scope.Same, because the control limit is littler more accurate than the scope of standard limit, the precognition before the product rejection also can be known by whether exceeding the control limit.

Control limit and interface that state of a control data analysis module 24 reception control limit computing modules 23 calculate are derived the active procedure data that module 21 transmits, active procedure data and control limit are carried out the data comparison, whether exceed control limit output state of a control signal to instruction module 27 according to the active procedure data.Meanwhile, specification condition data analysis module 26 receives the active procedure data that standard is limit and interface derivation module 21 transmits that standard limit setting module 25 is provided with, active procedure data and standard limit are carried out the data comparison, whether exceed standard limit output specification condition signal to instruction module 27 according to the current production data.For instance, state of a control data analysis module 24 analyzes the active procedure data if specification condition data analysis module 26 analyzes that the active procedure data do not exceed standard limit has exceeded the control limit, illustrates that then current production has the trend that exceeds the standard limit and the possibility of scrapping is arranged in the future.Exceed control limit if state of a control data analysis module 24 analyzes the active procedure data, illustrated that then current production is excessive with the variation of product before this, had consistency problem.

Graphic analyses module 28 with the data analysis result in the system (mainly being the data analysis result of state of a control data analysis module 24 and specification condition data analysis module 26) for example to be that the mode of the statistical graph of average range chart etc. displays, so that the operator utilizes control diagram to carry out process analysis procedure analysis.

Instruction module 27 illustrates corresponding indication to alarm lamp module 29 according to state of a control signal and specification condition signal.Alarm lamp module 29 can be the composite signal lamp, for state of a control signal and specification condition signal, can take to report to the police respectively or intersect in conjunction with the mode of reporting to the police.For instance, the composite signal light fixture has circular and square two kinds of shapes, and wherein circular signal lamp is represented the judgement of state of a control, and square signal lamp is represented the judgement of specification condition.The color of composite signal lamp is divided into redness and green, and the wherein green active procedure data of representing are not only in the control limit but also in the standard limit, and red representative exceeds the scope of control limit or standard limit.For example, the specification condition signal indicating active procedure data of exporting when specification condition data analysis module 26 do not exceed standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 24 outputs have exceeded control limit scope, and then instruction module 27 can square signal lamp green occur and the state of circular signal lamp redness by the indicator signal Assembled lamp.The specification condition signal indicating active procedure data of exporting when specification condition data analysis module 26 have exceeded standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 24 outputs have exceeded control limit scope, and then the state of square signal lamp redness and circular signal lamp redness appears in instruction module 27 meeting indicator signal Assembled lamps.The specification condition signal indicating active procedure data of exporting when specification condition data analysis module 26 do not exceed standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 24 outputs do not exceed control limit scope yet, and then the state of square signal lamp green and circular signal lamp green appears in instruction module 27 meeting indicator signal Assembled lamps.

It should be noted that instruction module 27 not only has the function of the alerting signal of illustrating, also export the relevant device of steering order to the production run, control these relevant devices automatically, improved on the basis so that follow-up product is manufactured on before this.System can also offer a storage unit, is used for the problem of site operation personnel's storage products appearance, the countermeasure that produces reason and take, and forms a knowledge base, is convenient to the prevention and the processing of follow-up corresponding problem, is convenient to the maintenance and the maintenance of equipment simultaneously.

The 3rd embodiment of system

Fig. 3 shows the principle of the 3rd embodiment of automatic control of the present invention and warning system.See also Fig. 3, system comprises data extraction module 300, interface derivation module 301, database module 302, controls and limit computing module 303, state of a control data analysis module 304, standard limit setting module 305, specification condition data analysis module 306, control chart theory to declare different criterion judge module 307, preset standard judge module 308, instruction module 309 and alarm lamp module 310.

Wherein data extraction module 300 is obtained active procedure data and correlation ID information from production run, comprise direct performance data (such as the crucial controlling index of product: length and width, diameter etc.), process or the product of product indirect performance data (such as the operational factor of equipment: electric current, voltage, temperature, pressure intensity etc.) and with the closely-related id information of data (such as the numbering of equipment, technology numbering etc.).Interface derive module 301 with data extraction module 300 procurement process data and correlation ID information after format conversion becomes digital signal or Code Number, derive by RS232, RS485 or RJ45 port.Process data and correlation ID information that database module 302 storages are derived.

Control limit computing module 303 is according to the control limit of the historical process data computation product that obtains from production run of database module 302 storages.Standard limit setting module 305 is used for the standard limit of assignment procedure data.The control limit is divided into the control limit upper limit, control limit lower limit and control limit standard limit, and same, the standard limit also is divided into the standard limit upper limit, standard limit lower limit and standard limit standard limit.Understand easily, standard is limit for a fixing product, and its scope is determined, and the scope of control limit is based on the historical data generation.Compared to the standard limit, the range size of control limit is limit less than standard, that is to say, because the standard limit causes the standard limit can't solve the big problem of product variation too greatly, can solve by the littler control limit of scope.Same, because the control limit is littler more accurate than the scope of standard limit, the precognition before the product rejection also can be known by whether exceeding the control limit.

Control limit and interface that state of a control data analysis module 304 reception control limit computing modules 303 calculate are derived the active procedure data that module 301 transmits, active procedure data and control limit are carried out the data comparison, whether exceed control limit output state of a control signal to instruction module 309 according to the active procedure data.Meanwhile, specification condition data analysis module 306 receives the active procedure data that standard is limit and interface derivation module 301 transmits that standard limit setting module 305 is provided with, active procedure data and standard limit are carried out the data comparison, whether exceed standard limit output specification condition signal to instruction module 309 according to the active procedure data.For instance, state of a control data analysis module 304 analyzes the active procedure data if specification condition data analysis module 306 analyzes that the active procedure data do not exceed standard limit has exceeded the control limit, illustrates that then active procedure has the trend that exceeds the standard limit and the possibility of scrapping is arranged in the future.Exceed control limit if state of a control data analysis module 304 analyzes the active procedure data, illustrated that then current production is excessive with the variation of product before this, had consistency problem.

The control chart theory is declared the active procedure data that different criterion judge module 307 receiving interfaces are derived module 301, and whether judgment data violates the different criterion of declaring in the control chart theory, if violate then output is warned signal to instruction module 309.These are declared different criterion and comprise that in the control chart theory some declare different criterion, if for example module 307 is judged continuous 6 risings or continuous 6 declines, then judge current production and have ascendant trend or downtrending, the possibility that exceeds the control limit is arranged, and output is warned status signal accordingly to instruction module 309.

Preset standard judge module 308 receiving interfaces are derived the active procedure data of module 301, and whether judgment data violates preset standard, if violate then output is warned status signal to instruction module 309.For example set in advance a numerical range as preset standard, if the current production data exceed whole default numerical range, then output is warned status signal accordingly to instruction module 309.

Instruction module 309 illustrates corresponding indication to alarm lamp module 310 according to state of a control signal and specification condition signal.Alarm lamp module 310 can be the composite signal lamp, for state of a control signal, specification condition signal and the status signal of warning, can take to report to the police respectively or intersect in conjunction with the mode of reporting to the police.For instance, the composite signal light fixture has circular and square two kinds of shapes, and wherein circular signal lamp is represented the judgement of state of a control, and square signal lamp is represented the judgement of specification condition.The color of composite signal lamp is divided into redness, green and yellow, the wherein green active procedure data of representing are not only in the control limit but also in the standard limit, red representative exceeds the scope of control limit or standard limit, and yellow representative has been violated the control chart theory and declared different criterion or violated preset standard in advance but do not exceed the standard limit.For example, the specification condition signal indicating active procedure data of exporting when specification condition data analysis module 306 do not exceed standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 304 outputs have exceeded control limit scope, and then instruction module 309 can square signal lamp green occur and the state of circular signal lamp redness by the indicator signal Assembled lamp.The specification condition signal indicating active procedure data of exporting when specification condition data analysis module 306 have exceeded standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 304 outputs have exceeded control limit scope, and then the state of square signal lamp redness and circular signal lamp redness appears in instruction module 309 meeting indicator signal Assembled lamps.The specification condition signal indicating active procedure data of exporting when specification condition data analysis module 306 do not exceed standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 304 outputs do not exceed control limit scope yet, and then the state of square signal lamp green and circular signal lamp green appears in instruction module 309 meeting indicator signal Assembled lamps.Declare different criterion judge module 307 or preset standard judge module 308 when the control chart theory and judge the active procedure data and violated the control chart theory and declare different criterion or violated preset standard, then instruction module 309 can yellow state occur showing by the indicator signal Assembled lamps.

It should be noted that instruction module 309 not only has the function of the alerting signal of illustrating, also export the relevant device of steering order to the production run, control these relevant devices automatically, improved on the basis so that follow-up product is manufactured on before this.System can also offer a storage unit, is used for the problem of site operation personnel's storage products appearance, the countermeasure that produces reason and take, and forms a knowledge base, is convenient to the prevention and the processing of follow-up corresponding problem, is convenient to the maintenance and the maintenance of equipment simultaneously.

The 4th embodiment of system

Fig. 4 shows the principle of the 4th embodiment of automatic control of the present invention and warning system.See also Fig. 4, system comprises data extraction module 400, interface derivation module 401, database module 402, controls and limit computing module 403, state of a control data analysis module 404, standard limit setting module 405, specification condition data analysis module 406, control chart theory to declare different criterion judge module 407, preset standard judge module 408, instruction module 409, graphic analyses module 410 and alarm lamp module 411.

Wherein data extraction module 400 is obtained active procedure data and correlation ID information from production run, comprise direct performance data (such as the crucial controlling index of product: length and width, diameter etc.), process or the product of product indirect performance data (such as the operational factor of equipment: electric current, voltage, temperature, pressure intensity etc.) and with the closely-related id information of data (such as the numbering of equipment, technology numbering etc.).Interface is derived module 401 data extraction module 400 is obtained data and correlation ID information after format conversion becomes digital signal or Code Number, derives by RS232, RS485 or RJ45 port.Data and correlation ID information that database module 402 storages are derived.

Control limit computing module 403 is according to the control limit of the historical process data computation process data of obtaining from production run of database module 402 storages.Standard limit setting module 405 is used for the standard limit of assignment procedure data.The control limit is divided into the control limit upper limit, control limit lower limit and control limit standard limit, and same, the standard limit also is divided into the standard limit upper limit, standard limit lower limit and standard limit standard limit.Understand easily, standard is limit for a fixing product, and its scope is determined, and the scope of control limit is based on the historical data generation.Compared to the standard limit, the range size of control limit is limit less than standard, that is to say, because the standard limit causes the standard limit can't solve the big problem of product variation too greatly, can solve by the littler control limit of scope.Same, because the control limit is littler more accurate than the scope of standard limit, the precognition before the product rejection also can be known by whether exceeding the control limit.

Control limit and interface that state of a control data analysis module 404 reception control limit computing modules 403 calculate are derived the active procedure data that module 401 transmits, active procedure data and control limit are carried out the data comparison, whether exceed control limit output state of a control signal to instruction module 409 according to the active procedure data.Meanwhile, specification condition data analysis module 406 receives the active procedure data that standard is limit and interface derivation module 401 transmits that standard limit setting module 405 is provided with, active procedure data and standard limit are carried out the data comparison, whether exceed standard limit output specification condition signal to instruction module 409 according to the active procedure data.For instance, state of a control data analysis module 404 analyzes the active procedure data if specification condition data analysis module 406 analyzes that the active procedure data do not exceed standard limit has exceeded the control limit, illustrates that then current production has the trend that exceeds the standard limit and the possibility of scrapping is arranged in the future.Exceed control limit if state of a control data analysis module 404 analyzes the current production data, illustrated that then current production is excessive with the variation of product before this, had consistency problem.

The control chart theory is declared the current production data that different criterion judge module 407 receiving interfaces are derived module 401, and whether judgment data violates the different criterion of declaring in the control chart theory, if violate then output is warned signal to instruction module 409.These are declared different criterion and comprise that in the control chart theory some declare different criterion, if for example module 407 is judged continuous 6 risings or continuous 6 declines, then judge current production and have ascendant trend or downtrending, the possibility that exceeds the control limit is arranged, and output is warned status signal accordingly to instruction module 409.

Preset standard judge module 408 receiving interfaces are derived the current production data of module 401, and whether judgment data violates preset standard, if violate then output is warned status signal to instruction module 409.For example set in advance a numerical range as preset standard, if the current production data exceed whole default numerical range, then output is warned status signal accordingly to instruction module 409.

Graphic analyses module 410 with the data analysis result in the system (mainly being the data analysis result that state of a control data analysis module 407, specification condition data analysis module 406, control chart theory are declared different criterion judge module 407 and preset standard judge module 408) for example to be that the mode of the statistical graph of average range chart etc. displays, so that the operator utilizes control diagram to carry out process analysis procedure analysis.

Instruction module 409 illustrates corresponding indication to alarm lamp module 411 according to state of a control signal and specification condition signal.Alarm lamp module 411 can be the composite signal lamp, for state of a control signal, specification condition signal and the status signal of warning, can take to report to the police respectively or intersect in conjunction with the mode of reporting to the police.For instance, the composite signal light fixture has circular and square two kinds of shapes, and wherein circular signal lamp is represented the judgement of state of a control, and square signal lamp is represented the judgement of specification condition.The color of composite signal lamp is divided into redness, green and yellow, the wherein green active procedure data of representing are not only in the control limit but also in the standard limit, red representative exceeds the scope of control limit or standard limit, and yellow representative has been violated the control chart theory and declared different criterion or violated preset standard in advance but do not exceed the standard limit.For example, the specification condition signal indicating active procedure data of exporting when specification condition data analysis module 406 do not exceed standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 404 outputs have exceeded control limit scope, and then instruction module 409 can square signal lamp green occur and the state of circular signal lamp redness by the indicator signal Assembled lamp.The specification condition signal indicating active procedure data of exporting when specification condition data analysis module 406 have exceeded standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 404 outputs have exceeded control limit scope, and then the state of square signal lamp redness and circular signal lamp redness appears in instruction module 409 meeting indicator signal Assembled lamps.The specification condition signal indicating active procedure data of exporting when specification condition data analysis module 406 do not exceed standard limit scope, and the state of a control signal indicating active procedure data of state of a control data analysis module 404 outputs do not exceed control limit scope yet, and then the state of square signal lamp green and circular signal lamp green appears in instruction module 409 meeting indicator signal Assembled lamps.Declare different criterion judge module 407 or preset standard judge module 408 when the control chart theory and judge the current production data and violated the control chart theory and declare different criterion or violated preset standard, then instruction module 409 can yellow state occur showing by the indicator signal Assembled lamps.

It should be noted that instruction module 409 not only has the function of the alerting signal of illustrating, also export the relevant device of steering order to the production run, control these relevant devices automatically, improved on the basis so that follow-up product is manufactured on before this.System can also offer a storage unit, is used for the problem of site operation personnel's storage products appearance, the countermeasure that produces reason and take, and forms a knowledge base, is convenient to the prevention and the processing of follow-up corresponding problem, is convenient to the maintenance and the maintenance of equipment simultaneously.

Method first embodiment

Fig. 5 shows the process flow diagram of first embodiment of automatic control of the present invention and alarm method.Seeing also Fig. 5, is the detailed description to each step in this method below.

Step S100: from production run, obtain active procedure data and correlation ID information, comprise direct performance data (such as the crucial controlling index of product: length and width, diameter etc.), process or the product of product indirect performance data (such as the operational factor of equipment: electric current, voltage, temperature, pressure intensity etc.) and with the closely-related id information of data (such as the numbering of equipment, technology numbering etc.).

Step S101: the process data that gets access to and correlation ID information after format conversion becomes digital signal or Code Number, are exported to computing machine by RS232, RS485 or RJ45 port, store in the database simultaneously.

Step S102: by the control limit of stored historical process data computation process data in the database, the standard of assignment procedure data limit simultaneously.

The control limit is divided into the control limit upper limit, control limit lower limit and control limit standard limit, and same, the standard limit also is divided into the standard limit upper limit, standard limit lower limit and standard limit standard limit.Understand easily, standard is limit for a fixing product, and its scope is determined, and the scope of control limit is based on the historical data generation.Compared to the standard limit, the range size of control limit is limit less than standard, that is to say, because the standard limit causes the standard limit can't solve the big problem of product variation too greatly, can solve by the littler control limit of scope.Same, because the control limit is littler more accurate than the scope of standard limit, the precognition before the product rejection also can be known by whether exceeding the control limit.

Step S103: the process data of current acquisition and the control limit of process data are carried out the data comparison, and output state of a control signal carries out the data comparison with the process data of current acquisition and the standard limit of process data, output specification condition signal simultaneously.

For instance, do not exceed standard limit but exceeded the control limit, illustrate that then active procedure has the trend that exceeds the standard limit and the possibility of scrapping is arranged in the future if analyze the active procedure data.Exceed control limit if analyze the current production data, illustrated that then current production is excessive with the variation of product before this, had consistency problem.

Step S104: instruct to the production equipment of correspondence and corresponding indicating signals to the alarm lamp module according to state of a control signal and specification condition signal output control corresponding.

It should be noted that not only have the alerting signal of illustrating among the step S104, also export the relevant device of steering order to the production run, control these relevant devices automatically, improved on the basis so that follow-up product is manufactured on before this.Method can also increase a step: offer a storage unit, be used for the problem of site operation personnel's storage products appearance, the countermeasure that produces reason and take, form a knowledge base, be convenient to the prevention and the processing of follow-up corresponding problem, be convenient to the maintenance and the maintenance of equipment simultaneously.

Step S105: the alarm lamp module is according to the different state of indicator signal caution.

The alarm lamp module can be the composite signal lamp, for state of a control signal and specification condition signal, can take to report to the police respectively or intersect in conjunction with the mode of reporting to the police.For instance, the composite signal light fixture has circular and square two kinds of shapes, and wherein circular signal lamp is represented the judgement of state of a control, and square signal lamp is represented the judgement of specification condition.The color of composite signal lamp is divided into redness and green, and the wherein green active procedure data of representing are not only in the control limit but also in the standard limit, and red representative exceeds the scope of control limit or standard limit.For example, limit scope when specification condition signal indicating active procedure data exceed standard, and state of a control signal indicating active procedure data have exceeded control limit scope, then the state of circular signal lamp redness square signal lamp green appears and in the indicator signal Assembled lamp.When specification condition signal indicating active procedure data have exceeded standard limit scope, and state of a control signal indicating active procedure data have exceeded control limit scope, and then the state of the red and circular signal lamp redness of square signal lamp appears in the indicator signal Assembled lamp.When specification condition signal indicating active procedure data exceed standard limit scope, and state of a control signal indicating active procedure data do not exceed control limit scope yet, and then the state of the green and circular signal lamp green of square signal lamp appears in the indicator signal Assembled lamp.

Method second embodiment

Fig. 6 shows the process flow diagram of second embodiment of automatic control of the present invention and alarm method.Seeing also Fig. 6, is the detailed description to each step in this method below.

Step S200: from production run, obtain active procedure data and correlation ID information, comprise direct performance data (such as the crucial controlling index of product: length and width, diameter etc.), process or the product of product indirect performance data (such as the operational factor of equipment: electric current, voltage, temperature, pressure intensity etc.) and with the closely-related id information of data (such as the numbering of equipment, technology numbering etc.).

Step S201: the process data that gets access to and correlation ID information after format conversion becomes digital signal or Code Number, are exported to computing machine by RS232, RS485 or RJ45 port, store in the database simultaneously.

Step S202: by the control limit of stored historical process data computation process data in the database, the standard of assignment procedure data limit simultaneously.

The control limit is divided into the control limit upper limit, control limit lower limit and control limit standard limit, and same, the standard limit also is divided into the standard limit upper limit, standard limit lower limit and standard limit standard limit.Understand easily, standard is limit for a fixing product, and its scope is determined, and the scope of control limit is based on the generation of historical process data.Compared to the standard limit, the range size of control limit is limit less than standard, that is to say, because the standard limit causes the standard limit can't solve the big problem of product variation too greatly, can solve by the littler control limit of scope.Same, because the control limit is littler more accurate than the scope of standard limit, the precognition before the product rejection also can be known by whether exceeding the control limit.

Step S203: the process data of current acquisition and the control limit of process data are carried out the data comparison, and output state of a control signal carries out the data comparison with the process data of current acquisition and the standard limit of process data, output specification condition signal simultaneously.

Step S204: the data analysis result among the step S203 is showed in the mode of statistical graph.

For example, show the data analysis result in the mode of the statistical graph of average range chart etc., so that the operator utilizes control diagram to carry out process analysis procedure analysis.

Step S205: instruct to the production equipment of correspondence and corresponding indicating signals to the alarm lamp module according to state of a control signal and specification condition signal output control corresponding.

It should be noted that not only have the alerting signal of illustrating among the step S205, also export the relevant device of steering order to the production run, control these relevant devices automatically, improved on the basis so that follow-up product is manufactured on before this.Method can also increase a step: offer a storage unit, be used for the problem of site operation personnel's storage products appearance, the countermeasure that produces reason and take, form a knowledge base, be convenient to the prevention and the processing of follow-up corresponding problem, be convenient to the maintenance and the maintenance of equipment simultaneously.

Step S206: the alarm lamp module is according to the different state of indicator signal caution.

Method the 3rd embodiment

Fig. 7 shows the process flow diagram of the 3rd embodiment of automatic control of the present invention and alarm method.Seeing also Fig. 7, is the detailed description to each step in this method below.

Step S300: from production run, obtain active procedure data and correlation ID information, comprise direct performance data (such as the crucial controlling index of product: length and width, diameter etc.), process or the product of product indirect performance data (such as the operational factor of equipment: electric current, voltage, temperature, pressure intensity etc.) and with the closely-related id information of data (such as the numbering of equipment, technology numbering etc.).

Step S301: the process data that gets access to and correlation ID information after format conversion becomes digital signal or Code Number, are exported to computing machine by RS232, RS485 or RJ45 port, store in the database simultaneously.

Step S302: by the control limit of stored historical process data computation process data in the database, the standard of assignment procedure data limit simultaneously.

Step S303: the process data of current acquisition and the control limit of process data are carried out the data comparison, and output state of a control signal carries out the data comparison with the process data of current acquisition and the standard limit of process data, output specification condition signal simultaneously.Judge whether the active procedure data violate declaring different criterion or violating default standard in the control chart theory, if violate status signal then output is warned.

For instance, do not exceed standard limit but exceeded the control limit, illustrate that then active procedure has the trend that exceeds the standard limit and the possibility of scrapping is arranged in the future if analyze the active procedure data.Exceed control limit if analyze the active procedure data, illustrated that then current production is excessive with the variation of product before this, had consistency problem.

These control chart theories are declared different criterion and are comprised that in the control chart theory some declare different criterion, if for example continuous 6 are risen or continuous 6 declines, then judge current production and have ascendant trend or downtrending, the possibility that exceeds the control limit is arranged, export the status signal of warning accordingly.If the current production data exceed whole default numerical range, then export the status signal of warning accordingly.

Step S304: instruct to the production equipment of correspondence and corresponding indicating signals to the alarm lamp module according to state of a control signal, specification condition signal and the status signal of warning output control corresponding.

It should be noted that not only have the alerting signal of illustrating among the step S304, also export the relevant device of steering order to the production run, control these relevant devices automatically, improved on the basis so that follow-up product is manufactured on before this.Method can also increase a step: offer a storage unit, be used for the problem of site operation personnel's storage products appearance, the countermeasure that produces reason and take, form a knowledge base, be convenient to the prevention and the processing of follow-up corresponding problem, be convenient to the maintenance and the maintenance of equipment simultaneously.

Step S305: the alarm lamp module is according to the different state of indicator signal caution.

The alarm lamp module can be the composite signal lamp, for state of a control signal, specification condition signal and the status signal of warning, can take to report to the police respectively or intersect in conjunction with the mode of reporting to the police.For instance, the composite signal light fixture has circular and square two kinds of shapes, and wherein circular signal lamp is represented the judgement of state of a control, and square signal lamp is represented the judgement of specification condition.The color of composite signal lamp is divided into redness, green and yellow, the wherein green active procedure data of representing are not only in the control limit but also in the standard limit, red representative exceeds the scope of control limit or standard limit, and yellow representative has been violated the control chart theory and declared different criterion or violated preset standard in advance but do not exceed the standard limit.For example, limit scope when specification condition signal indicating active procedure data exceed standard, and state of a control signal indicating active procedure data have exceeded control limit scope, then the state of circular signal lamp redness square signal lamp green appears and in the indicator signal Assembled lamp.When specification condition signal indicating active procedure data have exceeded standard limit scope, and state of a control signal indicating active procedure data have exceeded control limit scope, and then the state of the red and circular signal lamp redness of square signal lamp appears in the indicator signal Assembled lamp.When specification condition signal indicating active procedure data exceed standard limit scope, and state of a control signal indicating active procedure data do not exceed control limit scope yet, and then the state of the green and circular signal lamp green of square signal lamp appears in the indicator signal Assembled lamp.Violated the control chart theory and declare different criterion or violated preset standard when judging the current production data, then yellow state appears showing in the indicator signal Assembled lamp.

Method the 4th embodiment

Fig. 8 shows the process flow diagram of the 4th embodiment of automatic control of the present invention and alarm method.Seeing also Fig. 8, is the detailed description to each step in this method below.

Step S400: from production run, obtain active procedure data and correlation ID information, comprise direct performance data (such as the crucial controlling index of product: length and width, diameter etc.), process or the product of product indirect performance data (such as the operational factor of equipment: electric current, voltage, temperature, pressure intensity etc.) and with the closely-related id information of data (such as the numbering of equipment, technology numbering etc.).

Step S401: the process data that gets access to and correlation ID information after format conversion becomes digital signal or Code Number, are exported to computing machine by RS232, RS485 or RJ45 port, store in the database simultaneously.

Step S402: by the control limit of stored historical process data computation process data in the database, the standard of assignment procedure data limit simultaneously.

Step S403: the process data of current acquisition and the control limit of process data are carried out the data comparison, and output state of a control signal carries out the data comparison with the process data of current acquisition and the standard limit of process data, output specification condition signal simultaneously.Judge whether the active procedure data violate declaring different criterion or violating default standard in the control chart theory, if violate status signal then output is warned.

These control chart theories are declared different criterion and are comprised that in the control chart theory some declare different criterion, if for example continuous 6 are risen or continuous 6 declines, then judge current production and have ascendant trend or downtrending, the possibility that exceeds the control limit is arranged, export the status signal of warning accordingly.If the active procedure data exceed whole default numerical range, then export the status signal of warning accordingly.

Step S404: the data analysis result among the step S403 is showed in the mode of statistical graph.

Step S405: instruct to the production equipment of correspondence and corresponding indicating signals to the alarm lamp module according to state of a control signal, specification condition signal and the status signal of warning output control corresponding.

It should be noted that not only have the alerting signal of illustrating among the step S405, also export the relevant device of steering order to the production run, control these relevant devices automatically, improved on the basis so that follow-up product is manufactured on before this.Method can also increase a step: offer a storage unit, be used for the problem of site operation personnel's storage products appearance, the countermeasure that produces reason and take, form a knowledge base, be convenient to the prevention and the processing of follow-up corresponding problem, be convenient to the maintenance and the maintenance of equipment simultaneously.

Step S406: the alarm lamp module is according to the different state of indicator signal caution.

The foregoing description provides to those of ordinary skills and realizes or use of the present invention; those of ordinary skills can be under the situation that does not break away from invention thought of the present invention; the foregoing description is made various modifications or variation; thereby protection scope of the present invention do not limit by the foregoing description, and should be the maximum magnitude that meets the inventive features that claims mention.

Claims

1, a kind of automatic control and warning system, the process data of gathering in the production run is analyzed and by the signal feedback analysis result of warning, this system comprises:

2, automatic control according to claim 1 and warning system, it is characterized in that, the direct performance data of this product comprises the measurement data of the crucial controlling index of this product, the indirect performance data of this process or product comprises the operational factor of equipment, comprises device numbering and/or technology numbering with the closely-related id information of these data.

3, automatic control according to claim 1 and warning system, it is characterized in that, the control limit that this control limit computing module calculates is divided into the control limit upper limit, control limit lower limit and control limit standard limit, and the standard limit of this standard limit setting module setting is divided into the standard limit upper limit, standard limit lower limit and standard limit standard limit.

4, automatic control according to claim 1 and warning system is characterized in that, this system also comprises:

5, according to each described automatic control and warning system in the claim 1～4, it is characterized in that this system also comprises:

6, automatic control according to claim 4 and warning system is characterized in that, this system also comprises:

。

7, a kind of automatic control and alarm method, the process data of gathering in the production run is analyzed and by the signal feedback analysis result of warning, this method comprises:

8, automatic control according to claim 7 and alarm method, it is characterized in that, the direct performance data of this product comprises the measurement data of the crucial controlling index of this product, the indirect performance data of this process or product comprises the operational factor of equipment, comprises device numbering and/or technology numbering with the closely-related id information of these data.

9, automatic control according to claim 7 and alarm method is characterized in that, this control limit is divided into the control limit upper limit, control limit lower limit and control limit standard limit, and this standard limit is divided into the standard limit upper limit, standard limit lower limit and standard limit standard limit.

10, automatic control according to claim 7 and alarm method is characterized in that, step (4) also comprises:

Corresponding step (5) further comprises:

11, according to each described automatic control and alarm method in the claim 7～10, it is characterized in that the data analysis result in the step (4) shows in the mode of statistical graph.

12, automatic control according to claim 10 and alarm method is characterized in that, this method also comprises:

。