CN103529799B - Metal cover production line information service method and system - Google Patents
Metal cover production line information service method and system Download PDFInfo
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P80/00—Climate change mitigation technologies for sector-wide applications
- Y02P80/10—Efficient use of energy, e.g. using compressed air or pressurized fluid as energy carrier
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
The present invention discloses a kind of metal cover production line information service method and system, first metal lid production line information service system is set up, then data communication between each equipment is realized in system, the collection of following settling signal, the automatic generation of process and information, to the automatic alarm of exception, the automatic generation of form, and remote maintenance.The present invention replaces the work such as manual record calculating by automatic acquisition process state and data, decreases a large amount of workloads, improves the real-time of data, accuracy; By each equipment of remote guide maintenance maintenance, improve the promptness of equipment repair, decrease the hard work and transport cost of hurrying back and forth in strange land; By unit exception calling system, improve the rapid reaction of production, improve efficiency of operation etc.; By the production information resource sharing of Nei Ge company of group, facilitate carrying out of centralized supervisory and optimal enforcement.
Description
Technical field
The present invention relates to field of industrial automation control and communication field, be specifically related to a kind of metal cover production line information service method and system.
Background technology
Metal lid production line is package member--the equipment of bottle cap for the manufacture of food, beverage, can, flavouring, beer, dairy products, cosmetics of everyday use etc., made bottle cap is normally made up of tinplate, comprise metal twist-off cap, crown plug, aluminium matter pilferproof closure etc., the making of these bottle caps generally will through multiple working procedures such as punch press, rolling, lid processed, drying room, countings, and the product made must meet Chinese bottle cap industry standard or international standard, therefore metal lid production line has the accurate main equipment compared with high technology content.
In recent years along with manufacturing industry produces the proposition of quantitative management, equipment control, rapid reaction, energy ZOOM analysis, each situation such as equipment operation, production, product quality, energy resource consumption and each abnormal needs of each production line of Zhi Gai enterprise are controlled and information interchange in real time.Because metal lid production line workshop noise is comparatively large and production line is longer, various exception often can not Timeliness coverage, and various abnormal information can not exchange by real-time communication, various production status and data can not real-time Transmission with share.And product quantity, start duration, run the data such as duration, fault duration, yield efficiency, production efficiency, rejection rate, electricity, tolerance and rely on for a long time manually to add up to fill in and calculate typing computer for analysis and form form, namely this pattern wastes time and energy, and does not accomplish again rapid reaction and production information resource sharing.
Meanwhile, because Zhi Gai enterprise mostly is group enterprise, group, to each apparatus for production line of Duo Jia strange land enterprise, production, the centralized supervisory of energy consumption and the enforcement of optimization, relies on complicate statistics to report and does not accomplish promptness, accuracy.
In addition, because the PLC of various brands is separate, programming tool is incompatible, and various brands PLC internal data is difficult to directly transmission mutually.And conventional metals lid production line workshop often uses the PLC of multiple brand, the PLC in whole metal lid production line workshop is networked, with regard to needing, the PLC of whole shop production line is united, namely with the PLC of same brand, such retrofit work amount and enormous costs.
Summary of the invention
The object of the invention is to provide a kind of metal cover production line information service method and system for needing above with technological deficiency, to realize in the comparatively large and production line of noise comparatively long vehicle that metal lid apparatus for production line operation exception, energy resource consumption are abnormal, product quality gathers automatically extremely, analyze, remote multi-media reports to the police and information interchange; By the data transmission between the man-machine multiple brand PLC realizing workshop each production line use as intermediary; Utilize the man-machine function that penetrates to download to realize long-distance Log server the PLC that the different brands that each production line uses is debugged in monitoring, thus reach the object that remote guide keeps in repair each apparatus for production line fault; Remote real-time monitor each bar lid production line condition of production and each order performance; Automatically generate product quantity, start duration in time, run data sheet and the strange land information resources share such as duration, fault duration, yield efficiency, production efficiency, rejection rate, electricity, tolerance.
Technical scheme of the present invention is as follows:
The invention provides a kind of metal cover production line information service method, comprise the steps:
(1) metal lid production line information service system is set up;
System is made up of intelligent electric meter, natural gas intelligent flowmeter, audible-visual alarm lamp, RS485 cable, on-the-spot PLC, on-the-spot HMI, short message transceiving module, RS232 cable, collection control HMI, sound equipment, smart mobile phone, relevant departments HMI, relevant individual PC, Ethernet cable, the network switch and the webserver;
On-the-spot HMI, collection control HMI, relevant departments HMI, relevant individual PC, the webserver use Ethernet cable access network switch respectively by the network interface respectively carried, composition Ethernet; Short message transceiving module is controlled between HMI with collection and is used RS232 cable to be connected by the RS232 interface carried; Collection control HMI and smart mobile phone carry out wireless messages exchange by GSM network; Be connected by tone frequency channel wire between HMI with sound equipment; On-the-spot HMI uses RS485 cable to be connected with natural gas intelligent flowmeter by the RS485 interface carried with intelligent electric meter with on-the-spot PLC, on-the-spot PLC; Input signal and audible-visual alarm lamp are connected to the IO terminals of on-the-spot PLC by common cable;
Subsystem is connected to form by above-mentioned; The Ethernet of each subsystem is connected with the form of VPN by internet, forms metal lid production line information service system of the present invention;
(2) data communication between each equipment is realized in system;
On-the-spot PLC and intelligent electric meter adopt RS485 standard serial mouth communication modes carry out between data transmit; In the optimum configurations CH1 passage of programming tool GX Developer V8.86, adopt the RS-485 type of No Protocol Communication agreement, its parameter carries out correspondence setting according to the regulation in intelligent electric meter DL/T645-2007 communication protocol; Use the RS2 instruction in PLC, carry out data transmission according to the byte format specified in DL/T645-2007 communication protocol and frame format, carry out the extraction of intelligent electric meter reading;
On-the-spot PLC and natural gas intelligent flowmeter adopt RS485 standard serial mouth communication modes carry out between data transmit; In the optimum configurations CH2 passage of programming tool GX Developer V8.86, adopt the RS-485 type of No Protocol Communication agreement, its parameter carries out correspondence setting according to the regulation in sky letter flow gauge communications protocol; Use the RS2 instruction in PLC, carry out data transmission according to sky letter flow gauge communications protocol and data unpacking method, carry out the extraction of natural gas intelligent flowmeter flow value;
Data between the RS485 standard serial mouth communication modes adopting PLC to have between on-the-spot HMI and on-the-spot PLC carries out are transmitted; Newly-increased the machine PLC in the system parameter setting interface of HMI programming tool EB8000V4.65, and arrange in interface in PORT COM, carry out setup parameter according to the communication format of PLC, set up the communication between on-the-spot HMI and on-the-spot PLC;
Collection control HMI and short message transceiving module adopt RS232 standard serial mouth communication modes carry out between data transmit; Newly-increased no-protocol equipment in the system parameter setting interface of programming tool EB8000V4.65, and arrange in interface in PORT COM, carry out setup parameter according to the communication format of short message transceiving module, simultaneously in HMI according to short message transceiving module communications protocol form: $ $+6 passwords, order, parameter 1, parameter 2, * check code r n, write various macro instruction in conjunction with trigger content, carry out short message sending, set up the communication between collection control HMI and short message transceiving module;
Communication between collection control HMI and smart mobile phone, smart mobile phone is installed remote control tool VNC, controls HMI carry out communication by the port numbers of specifying and IP address with collection;
Relevant individual PC and on-the-spot HMI, collect the communication controlled between HMI, relevant departments HMI, PC install EasyAccess instrument, by the port numbers and IP address and the on-the-spot HMI that specify, collect control HMI, relevant departments HMI carries out communication;
On-the-spot HMI, collection control adopt the communication of Ethernet interface communication modes between HMI, relevant departments HMI, each HMI distributes different IP addresses and is used for distinguishing each HMI; In the system parameter setting interface of HMI programming tool EB8000V4.65, newly-increased required far-end HMI, and the IP address and port numbers that arrange required HMI are set in interface in IP address, set up on-the-spot HMI, the communication of collection control between HMI, relevant departments HMI;
The webserver and on-the-spot HMI, collect the communication controlled between HMI, relevant departments HMI, the webserver utilizes Microsoft Winsock Control control functionality with programming language Visual basic, set up server and on-the-spot HMI, collect the communication controlled between HMI, relevant departments HMI, and data are stored in the database of the webserver;
The communication between the collection control HMI of each subsystem, the webserver is set up by VPN between each subsystem;
(3) the automatic generation of the collection of signal, process and information;
By the power on signal of each major equipment of metal lid production line, run signal, each electrical fault signal, raw material number detection signal, finished product number detection signal, vision detection system on-line checkingi substandard product number detection signal, on-the-spot PLC is accessed, automatically to gather above-mentioned signal by I/O module; The one piece of intelligent electric meter install every strip metal lid production line and one piece of natural gas intelligent flowmeter access in 485 communication modules of on-the-spot PLC by RS485 communication interface, automatically to gather the reading of intelligent electric meter and natural gas intelligent flowmeter;
The energising gathered by on-the-spot PLC, operation, fault-signal carry out each state of real-time display device with the red, green, yellow look pilot lamp that 0 or 1 form triggers configuration on HMI at the scene;
The energising that on-the-spot PLC is gathered, operation, fault-signal in PLC programming tool, with the duration of each state of method programming count from adding per second; Raw material number, finished product number, vision detection system on-line checkingi substandard product number are with each quantity of method programming count from increasing; Then PLC internal clocking is utilized, time segment trigger internal auxiliary relay, and above-mentioned duration and quantity are carried out extraction preservation in the duration of regulation, obtain the energising duration in the unit interval, run duration, fault duration, raw material quantity, finished product quantity, unacceptable product number; Each duration and each quantity at the scene HMI picture show without symbol and 32 unsigned number word formats in real time with 16 respectively;
The reading of intelligent electric meter and natural gas intelligent flowmeter is after PLC reads at the scene, by the operational order of PLC in conjunction with clock trigger signal, calculates the power consumption in the unit interval and gas consumption;
At the scene on HMI, make numerical value input element: the theoretical speed of a motor vehicle of every part raw material available finished product number, 16 unsigned numbers in theory comprising the planned quantity of 32 unsigned numbers, 16 unsigned numbers, above-mentioned real-time data transmission is in corresponding on-the-spot PLC; In conjunction with the raw material number in the unit interval that automatic data acquisition and calculation goes out, finished product number, every part raw material available finished product number in theory, PLC operational order is utilized automatically to calculate following data by following formula:
The number of rejects=raw material number * every part raw material available finished product number-finished product number in theory,
Rejection rate=number of rejects/(raw material number * every part raw material available finished product number in theory),
Yield efficiency=finished product number/(running the theoretical speed of a motor vehicle of duration *),
Production efficiency=(finished product number/theoretical speed of a motor vehicle)/(running duration+fault duration),
Unit power consumption=power consumption/finished product number,
Unit gas consumption=gas consumption/finished product number;
Each data HMI make digital display element display at the scene above;
On HMI, single reset button is changed in making at the scene, touches to change single reset button and carry out interceptings preservation to the finished product number and duration that do this order product when changing order at every turn; In conjunction with planned quantity and the theoretical speed of a motor vehicle, automatically calculate the theoretical used time by on-the-spot PLC, formula is: theoretical used time=planned quantity/theoretical speed of a motor vehicle; Again in conjunction with product quantity and the operation duration of on-the-spot PLC programming count, automatically calculate order completion rate, formula is: order completion rate=product quantity/planned quantity, and automatically calculate time course, formula is: time course=used duration/theory used time; And at the scene HMI makes digital display element and show above-mentioned data;
When many production lines produce same order, the finished product number of involved production line and duration used are comprehensively unifiedly calculated, concentrate on on-the-spot HMI and show;
On each on-the-spot HMI, make character input element, carry out the input of input item number, material description, order number respectively, do different product with district office;
(4) to the automatic alarm of exception;
When each electrical fault signal gathered by on-the-spot PLC changes, contacts status 0 becomes 1, or 1 becomes 0, then think and have electric fault to occur; When electricity in the unit interval or tolerance exceed the numerical value of theory calculate, then think that energy consumption consumption is abnormal; When the number of rejects detected by vision detection system in the unit interval exceedes setting value, then think that product quality is abnormal;
When there is above-mentioned fault or exception, the audible-visual alarm lamp that on-the-spot PLC triggers presence is installed; There is identical abnormal show in each relevant departments HMI simultaneously; When extremely not getting rid of at short notice, the corresponding button on triggers presence HMI, simultaneously at the scene HMI character input element inputs respective code, just there is corresponding abnormal information in corresponding relevant departments HMI, automatically trigger sound equipment simultaneously and send alarm sound, after receiving abnormal information, utilize character input element input code mutually to be exchanged by Ethernet; When unresolved in problem is long-time, at the scene in PLC to timing, timing triggers the macro instruction that collects and control in HMI to rear and send the smart mobile phone of relevant abnormalities note to related personnel;
At the scene on HMI, make position state and element is set, comprise plant maintenance, change kind, change the edge of a knife, treat material, die change, make data input elements simultaneously and set every required theoretical duration; The corresponding button on triggers presence HMI, on-the-spot PLC starts timing, when above-mentioned a certain duration used exceedes setting value, then thinks this operation irregularity; Carry out triggering sound equipment and note, simultaneously abnormal information is recorded in the word address that on-the-spot HMI specifies automatically;
(5) the automatic generation of form;
With programming language Visual basic exploitation on the webserver, utilize Microsoft WinsockControl control functionality, set up the communication between the webserver and each HMI; Installation database management tool SQL-Server or Acess on the webserver simultaneously, building database, data by Winsock control timing extraction every day are put into database, form total production data form every day comprising following data structure and content:
(6) remote maintenance;
Penetrate in communication setting interface at the programming tool of HMI, the serial ports number between the IP address of HMI and HMI and PLC is set, utilize Ethernet to penetrate any place of function in Ethernet and communication is carried out to corresponding PLC; Use the programming tool of PLC, directly PLC is uploaded with relevant individual PC and download monitoring debugging.
The present invention also provides a kind of metal lid production line information service system, comprises intelligent electric meter, natural gas intelligent flowmeter, audible-visual alarm lamp, RS485 cable, on-the-spot PLC, on-the-spot HMI, short message transceiving module, RS232 cable, collection control HMI, sound equipment, smart mobile phone, relevant departments HMI, relevant individual PC, Ethernet cable, the network switch and the webserver; On-the-spot HMI, collection control HMI, relevant departments HMI, relevant individual PC, the webserver use Ethernet cable access network switch respectively by the network interface respectively carried, composition Ethernet; Short message transceiving module is controlled between HMI with collection and is used RS232 cable to be connected by the RS232 interface carried; Collection control HMI and smart mobile phone carry out wireless messages exchange by GSM network; Be connected by tone frequency channel wire between HMI with sound equipment; On-the-spot HMI uses RS485 cable to be connected with natural gas intelligent flowmeter by the RS485 interface carried with intelligent electric meter with on-the-spot PLC, on-the-spot PLC; Input signal and audible-visual alarm lamp are connected to the IO terminals of on-the-spot PLC by common cable; Subsystem is connected to form by above-mentioned; The Ethernet of each subsystem is connected with the form of VPN by internet, forms metal lid production line information service system of the present invention.
Note, in technique scheme:
PLC=Programmable Logic Controller, programmable logic controller (PLC) is a kind of electronic system of digital operation, aim at industrial environment application and design.
HMI=Human Machine Interface, man-machine interface or man-machine interface carry out medium that is mutual and message exchange between system and user, realizes the conversion that the internal form of information and the mankind can accept between form.
VPN=Virtual Private Network, VPN (virtual private network) is a kind of technology setting up dedicated network in common network.
Advantageous Effects of the present invention is:
The present invention replaces the work such as manual record calculating by automatic acquisition process state and data, decreases a large amount of workloads, improves the real-time of data, accuracy; By each equipment of remote guide maintenance maintenance, improve the promptness of equipment repair, decrease the hard work and transport cost of hurrying back and forth in strange land; By unit exception calling system, improve the rapid reaction of production, improve efficiency of operation etc.; By the production information resource sharing of Nei Ge company of group, facilitate carrying out of centralized supervisory and optimal enforcement.
Accompanying drawing explanation
Fig. 1 is metal lid production line information service system configuration diagram of the present invention.
Embodiment
Below in conjunction with accompanying drawing, the specific embodiment of the present invention is described further.
Flow process of the present invention is as follows:
One, metal lid production line information service system is as shown in Figure 1 set up.
1, the composition of system: system is made up of intelligent electric meter, natural gas intelligent flowmeter, audible-visual alarm lamp, RS485 cable, on-the-spot PLC, on-the-spot HMI, short message transceiving module, RS232 cable, collection control HMI, sound equipment, smart mobile phone, relevant departments HMI, relevant individual PC, Ethernet cable, the network switch, the webserver.
2, the signal wiring of system: on-the-spot HMI, collection control HMI, relevant departments HMI, relevant individual PC, the webserver use Ethernet cable access network switch respectively by the network interface respectively carried, composition Ethernet; Short message transceiving module is controlled between HMI with collection and is used RS232 cable to be connected by the RS232 interface carried; Collection control HMI and smart mobile phone carry out wireless messages exchange by GSM network; Be connected by tone frequency channel wire between HMI with sound equipment; On-the-spot HMI and on-the-spot PLC, and on-the-spot PLC is connected by the RS485 interface RS485 cable carried with natural gas intelligent flowmeter with intelligent electric meter; Input signal and audible-visual alarm lamp are connected to the IO terminals of on-the-spot PLC by common cable, form the subsystem of our company; When group has multiple subsidiary/member companies, each branch office: company 1, company 2 ... the Ethernet of the subsystem of company N is linked together with the form of VPN by internet, composition group production information network, i.e. metal lid production line information service system of the present invention.
3, the selection of hardware in system: intelligent electric meter, natural gas intelligent flowmeter, each HMI, short message transceiving module select (the DTS541 ammeter of such as HOLLEY company of existing product on market, the FCM-I type flowmeter of TANCY company, the MT8070 touch-screen HMI of WEINVIEW company, high-tech STE5002 short message transceiving module is interrogated in Shenzhen), PLC selects the CP1E of the PLC(such as OMRON of the used various brands of production line, the FX3U etc. of Mitsubishi), other network equipment, terminal, server, other electrical equipment select the universal product.
Two, the realization of data communication between each equipment in system.
With Mitsubishi PLC (FX3U) programming tool GX Developer V8.86, WEINVIEW touch-screen HMI(MT8070) programming tool EB8000V4.65, the programming language Visual basic on server be that example is described as follows.
On-the-spot PLC and intelligent electric meter adopt RS485 standard serial mouth communication modes carry out between data transmit.In the optimum configurations CH1 passage of programming tool GX Developer V8.86, adopt the RS-485 type of No Protocol Communication agreement, its relevant parameter is according to the carrying out correspondence setting specified in intelligent electric meter DL/T645-2007 communication protocol.Use the RS2 instruction in PLC, carry out data transmission, as the extraction of intelligent electric meter reading according to the byte format specified in DL/T645-2007 communication protocol and frame format.
On-the-spot PLC and natural gas intelligent flowmeter adopt RS485 standard serial mouth communication modes carry out between data transmit.In the optimum configurations CH2 passage of programming tool GX Developer V8.86, adopt the RS-485 type of No Protocol Communication agreement, its relevant parameter is according to the carrying out correspondence setting specified in sky letter flow gauge communications protocol.Use the RS2 instruction in PLC, carry out data transmission, as the extraction of natural gas intelligent flowmeter flow value according to sky letter flow gauge communications protocol and data unpacking method.
Data between the RS485 standard serial mouth communication modes adopting PLC itself to have between on-the-spot HMI and on-the-spot PLC carries out are transmitted, newly-increased the machine PLC in the system parameter setting interface of HMI programming tool EB8000V4.65, and arrange in interface in PORT COM, carry out setting relevant parameter according to the communication format of PLC.Thus the communication of setting up between HMI and the machine PLC.
Collection control HMI and short message transceiving module adopt RS232 standard serial mouth communication modes carry out between data transmit.Newly-increased no-protocol equipment in system parameter setting interface in programming tool EB8000V4.65, and arrange in interface in PORT COM, setting relevant parameter is carried out according to the communication format of short message transceiving module, simultaneously in HMI according to short message transceiving module communications protocol form ($ $+6 passwords, order, parameter 1, parameter 2, * check code r n) write various macro instruction in conjunction with trigger content, carry out sending each note, thus set up the communication between collection control HMI and short message transceiving module.
Communication between collection control HMI and smart mobile phone, smart mobile phone is installed VNC(remote control tool), carry out communication by the port numbers of specifying and IP address and HMI.
Relevant between individual PC and each HMI, PC installs EasyAccess instrument, carries out communication by the port numbers of specifying and IP address and HMI.
On-the-spot HMI, collection control adopt the communication of Ethernet interface communication modes between HMI, relevant departments HMI, each HMI distributes different IP addresses and is used for distinguishing each HMI.In the system parameter setting interface of HMI programming tool EB8000V4.65, newly-increased required far-end HMI, and the IP address and port numbers that arrange required HMI are set in interface in IP address, thus set up the communication between required HMI.
Communication between the webserver and each HMI, the webserver uses programming language Visual basic, utilize Microsoft Winsock Control control functionality, set up the communication between the webserver and each HMI, and data are stored in the database of the webserver.
Between the subsystem of each company, set up the communication between each company collection control HMI, the webserver by VPN.
The automatic generation of three, the collection of each signal, process and each information.
The power on signal of each major equipment of metal lid production line (such as control power supply relaying contact), run signal (such as clutch coupling obtains electric relaying contact), each electrical fault signal, raw material number detection signal (such as feeding solenoid valve obtains electric relaying contact), finished product number detection signal (proximity transducer), vision detection system on-line checkingi substandard product number detection signal, access on-the-spot PLC by I/O module and automatically gather these signals.One piece of intelligent electric meter that every strip metal lid production line is installed and one piece of natural gas intelligent flowmeter access in 485 communication modules of on-the-spot PLC by RS485 communication interface, automatically gather the reading of intelligent electric meter and natural gas intelligent flowmeter.
The energising that on-the-spot PLC is gathered, operation, fault-signal carry out each state of real-time display device with the red, green, yellow look pilot lamp that 0 or 1 form triggers configuration on HMI.
Energising, operation, fault-signal, in PLC programming tool, add up the duration of each state with the method (as DINCPD200 instruction) from adding per second; Raw material number, finished product number, vision detection system on-line checkingi substandard product number are to carry out each quantity of programming count from the method (as DINCP D300 instruction) increased.Then PLC internal clocking is utilized, time segment trigger internal auxiliary relay, and duration above and quantity are carried out extractions in the duration of regulation preserve, the energising duration of (per hour, per tour, every day), operation duration, fault duration, raw material quantity, finished product quantity, unacceptable product number can be obtained in the unit interval.Each duration and each quantity show in real time without symbol and 32 unsigned number word formats with 16 respectively on HMI picture.
The reading of intelligent electric meter and natural gas intelligent flowmeter, after PLC reads, by the operational order of PLC in conjunction with clock trigger signal, can to calculate in the unit interval electricity and the tolerance of (per hour, per tour, every day).
On HMI, make numerical value input element: planned quantity (32 unsigned numbers), every part raw material available finished product number (16 unsigned numbers), theoretical speed of a motor vehicle (16 unsigned numbers) in theory, these real-time data transmissions are in corresponding PLC.In conjunction with the raw material number in the unit interval that automatic data acquisition and calculation goes out, finished product number, every part raw material available finished product number in theory, PLC operational order is utilized can automatically to calculate data below by following formula: (data of change all referred in the unit interval).
The number of rejects=raw material number * every part raw material available finished product number-finished product number in theory,
Rejection rate=number of rejects/(raw material number * every part raw material available finished product number in theory),
Yield efficiency=finished product number/(running the theoretical speed of a motor vehicle of duration *),
Production efficiency=(finished product number/theoretical speed of a motor vehicle)/(running duration+fault duration),
Unit power consumption=power consumption/finished product number,
Unit gas consumption=gas consumption/finished product number.
Each data make digital display element to show on HMI above.
On HMI, make and change single reset button, when changing order, touch is changed single reset button and is carried out intercepting preservation to the finished product number and duration that do this order product at every turn.In conjunction with planned quantity and the theoretical speed of a motor vehicle, automatically the theoretical used time (theoretical used time=planned quantity/theoretical speed of a motor vehicle) is calculated by PLC, again in conjunction with product quantity and the operation duration of PLC programming count, order completion rate (order completion rate=product quantity/planned quantity) and time course (time course=used duration/theory used time) automatically can be calculated.And on HMI, make digital display element to show each data.
If many production line produces same order, then the finished product number of these production lines and duration used are integrated, unified calculation, concentrate on HMI and show.
At the scene on each HMI, make character input element, energy input item number, material description, order number, come district office and do different product respectively.
Above data, state configuration in HMI, by ethernet communication, a large amount of information all can show in real time on corresponding HMI.Namely the data of all production lines of whole group company and state and multiple companies production line data and each state can be separated or centralized displaying.
Four, to the automatic alarm of exception.
The each electrical fault signal gathered by on-the-spot PLC changes (as contacts status 0 becomes 1, or 1 becomes 0) can think have electric fault to occur, if when in the unit interval, electricity or tolerance exceed the numerical value of theory calculate, can think that energy consumption consumption is abnormal, if the number of rejects detected by vision detection system in the unit interval exceedes setting value, can think that product quality is abnormal.
There is above fault or exception, the audible-visual alarm lamp that on-the-spot PLC triggers presence is installed, remind site operation personnel to have abnormal generation.Each relevant departments HMI occurs that identical abnormal show reminds related personnel simultaneously.Can not get rid of at short notice if abnormal, execute-in-place work only needs at the scene HMI to trigger the corresponding button, simultaneously at the scene HMI character input element inputs respective code, just there is corresponding abnormal information in corresponding relevant departments HMI, automatically trigger sound equipment simultaneously, send alarm sound, after the other side receives abnormal information, character input element can be utilized to input some codes and mutually exchanged by Ethernet.If also do not solve in the problem long period, to this event timing in PLC, trigger the macro instruction in collection control HMI after timing to setting-up time and send relevant abnormalities note to related personnel's mobile phone as SMS alarm.
At the scene on HMI, make position state and element be set, such as plant maintenance, change kind, change the edge of a knife, treat material, die change etc., make data input elements simultaneously and set every needed for theoretical duration.Before this type of event of process, HMI triggers the corresponding button, and PLC starts timing, if a certain event duration used exceedes setting value, can think this operation irregularity.With equally carrying out triggering sound equipment above and note is reported to the police.Abnormal information is recorded in the word address that HMI specifies automatically simultaneously.
Five, the generation of form.
With programming language Visual basic exploitation on the webserver, utilize Microsoft WinsockControl control functionality, set up the communication between the webserver and each HMI.Installation database management tool (SQL-Server or Acess) on the webserver simultaneously, building database, puts into database by the data needed for Winsock control timing extraction every day.Form total production data form every day comprising following data structure and content:
Six, remote maintenance.
Penetrate in communication setting interface at the programming tool of HMI, serial ports number between the IP address of HMI and HMI and PLC is set, Ethernet is utilized to penetrate function, communication can be carried out in any place in Ethernet to corresponding PLC, use the programming tool that PLC is corresponding, just as directly connect the PLC at scene at the scene with PC, PLC is uploaded and downloads monitoring debugging, thus reach the object that remote guide keeps in repair each apparatus for production line.
Above-described is only the preferred embodiment of the present invention, the invention is not restricted to above embodiment.Be appreciated that the oher improvements and changes that those skilled in the art directly derive without departing from the basic idea of the present invention or associate, all should think and be included within protection scope of the present invention.
Claims (1)
1. a metal cover production line information service method, is characterized in that comprising the steps:
(1) metal lid production line information service system is set up;
System is made up of intelligent electric meter, natural gas intelligent flowmeter, audible-visual alarm lamp, RS485 cable, on-the-spot PLC, on-the-spot HMI, short message transceiving module, RS232 cable, collection control HMI, sound equipment, smart mobile phone, relevant departments HMI, relevant individual PC, Ethernet cable, the network switch and the webserver;
On-the-spot HMI, collection control HMI, relevant departments HMI, relevant individual PC, the webserver use Ethernet cable access network switch respectively by the network interface respectively carried, composition Ethernet; Short message transceiving module is controlled between HMI with collection and is used RS232 cable to be connected by the RS232 interface carried; Collection control HMI and smart mobile phone carry out wireless messages exchange by GSM network; Collection control HMI, relevant departments HMI are connected by tone frequency channel wire with between sound equipment; On-the-spot HMI uses RS485 cable to be connected with natural gas intelligent flowmeter by the RS485 interface carried with intelligent electric meter with on-the-spot PLC, on-the-spot PLC; Input signal and audible-visual alarm lamp are connected to the IO terminals of on-the-spot PLC by common cable;
Subsystem is connected to form by above-mentioned; The Ethernet of each subsystem is connected with the form of VPN by internet, forms metal lid production line information service system of the present invention;
(2) data communication between each equipment is realized in system;
On-the-spot PLC and intelligent electric meter adopt RS485 standard serial mouth communication modes to carry out data transmission; In the optimum configurations CH1 passage of programming tool GX Developer V8.86, adopt the RS-485 type of No Protocol Communication agreement, its parameter carries out correspondence setting according to the regulation in intelligent electric meter DL/T645-2007 communication protocol; Use the RS2 instruction in PLC, carry out data transmission according to the byte format specified in DL/T645-2007 communication protocol and frame format, carry out the extraction of intelligent electric meter reading;
On-the-spot PLC and natural gas intelligent flowmeter adopt RS485 standard serial mouth communication modes to carry out data transmission; In the optimum configurations CH2 passage of programming tool GX Developer V8.86, adopt the RS-485 type of No Protocol Communication agreement, its parameter carries out correspondence setting according to the regulation in sky letter flow gauge communications protocol; Use the RS2 instruction in PLC, carry out data transmission according to sky letter flow gauge communications protocol and data unpacking method, carry out the extraction of natural gas intelligent flowmeter flow value;
The RS485 standard serial mouth communication modes adopting PLC to have between on-the-spot HMI and on-the-spot PLC carries out data transmission; Newly-increased the machine PLC in the system parameter setting interface of HMI programming tool EB8000V4.65, and arrange in interface in PORT COM, carry out setting parameter according to the communication format of PLC, set up the communication between on-the-spot HMI and on-the-spot PLC;
Collection control HMI and short message transceiving module adopt RS232 standard serial mouth communication modes to carry out data transmission; Newly-increased no-protocol equipment in the system parameter setting interface of programming tool EB8000V4.65, and arrange in interface in PORT COM, carry out setting parameter according to the communication format of short message transceiving module, simultaneously in collection control HMI according to short message transceiving module communications protocol form: $ $+6 passwords, order, parameter 1, parameter 2, * check code r n, write various macro instruction in conjunction with trigger content, carry out short message sending, set up the communication between collection control HMI and short message transceiving module;
Set up the communication between collection control HMI and smart mobile phone, smart mobile phone is installed remote control tool VNC, control HMI by the port numbers of specifying and IP address with collection and carry out communication;
Set up relevant individual PC and on-the-spot HMI, collect the communication controlled between HMI, relevant departments HMI, PC installs EasyAccess instrument, by the port numbers and IP address and the on-the-spot HMI that specify, collect control HMI, relevant departments HMI carries out communication;
On-the-spot HMI, collection control adopt the communication of Ethernet interface communication modes between HMI, relevant departments HMI, each HMI distributes different IP addresses and is used for distinguishing each HMI; In the system parameter setting interface of HMI programming tool EB8000V4.65, newly-increased required far-end HMI, and the IP address and port numbers that arrange required far-end HMI are set in interface in IP address, set up on-the-spot HMI, the communication of collection control between HMI, relevant departments HMI;
Set up the webserver and on-the-spot HMI, collect the communication controlled between HMI, relevant departments HMI, the webserver utilizes Microsoft Winsock Control control functionality with programming language Visual basic, set up server and on-the-spot HMI, collect the communication controlled between HMI, relevant departments HMI, and data are stored in the database of the webserver;
The communication between the collection control HMI of each subsystem, the webserver is set up by VPN between each subsystem;
(3) the automatic generation of the collection of signal, process and information;
By the power on signal of each major equipment of metal lid production line, run signal, each electrical fault signal, raw material number detection signal, finished product number detection signal, vision detection system on-line checkingi substandard product number detection signal, on-the-spot PLC is accessed, automatically to gather above-mentioned signal by I/O module; The one piece of intelligent electric meter install every strip metal lid production line and one piece of natural gas intelligent flowmeter access in the RS485 communication module of on-the-spot PLC by RS485 communication interface, automatically to gather the reading of intelligent electric meter and natural gas intelligent flowmeter;
The energising gathered by on-the-spot PLC, operation, fault-signal carry out each state of real-time display device with the red, green, yellow look pilot lamp that 0 or 1 form triggers configuration on HMI at the scene;
The energising that on-the-spot PLC is gathered, operation, fault-signal in PLC programming tool, with the duration of each state of method programming count from adding per second; With method programming count raw material number, finished product number, vision detection system on-line checkingi substandard product number from increasing; Then PLC internal clocking is utilized, time segment trigger internal auxiliary relay, and above-mentioned duration and quantity are carried out extraction preservation in the duration of regulation, obtain the energising duration in the unit interval, run duration, fault duration, raw material quantity, finished product quantity, unacceptable product number; Each duration and each quantity at the scene HMI picture show without symbol and 32 unsigned number word formats in real time with 16 respectively;
The reading of intelligent electric meter and natural gas intelligent flowmeter is after PLC reads at the scene, by the operational order of PLC in conjunction with clock trigger signal, calculates the power consumption in the unit interval and gas consumption;
At the scene on HMI, make numerical value input element: the theoretical speed of a motor vehicle of every part raw material available finished product number, 16 unsigned numbers in theory comprising the planned quantity of 32 unsigned numbers, 16 unsigned numbers, above-mentioned real-time data transmission is in corresponding on-the-spot PLC; In conjunction with the raw material number in the unit interval that automatic data acquisition and calculation goes out, finished product number, every part raw material available finished product number in theory, PLC operational order is utilized automatically to calculate following data by following formula:
The number of rejects=raw material number * every part raw material available finished product number-finished product number in theory,
Rejection rate=number of rejects/(raw material number * every part raw material available finished product number in theory),
Yield efficiency=finished product number/(running the theoretical speed of a motor vehicle of duration *),
Production efficiency=(finished product number/theoretical speed of a motor vehicle)/(running duration+fault duration),
Unit power consumption=power consumption/finished product number,
Unit gas consumption=gas consumption/finished product number;
The above number of rejects, rejection rate, yield efficiency, production efficiency, unit power consumption, unit gas consumption data HMI make digital display element display at the scene;
On HMI, single reset button is changed in making at the scene, touches to change single reset button and carry out interceptings preservation to the finished product number and duration that do this order product when changing order at every turn; In conjunction with planned quantity and the theoretical speed of a motor vehicle, automatically calculate the theoretical used time by on-the-spot PLC, formula is: theoretical used time=planned quantity/theoretical speed of a motor vehicle; Again in conjunction with product quantity and the operation duration of on-the-spot PLC programming count, automatically calculate order completion rate, formula is: order completion rate=product quantity/planned quantity, and automatically calculate time course, formula is: time course=used duration/theory used time; And at the scene HMI makes digital display element and show above-mentioned theory used time, order completion rate, time course data;
When many production lines produce same order, the finished product number of involved production line and duration used are comprehensively unifiedly calculated, concentrate on on-the-spot HMI and show;
On each on-the-spot HMI, make character input element, carry out the input of input item number, material description, order number respectively, do different product with district office;
(4) to the automatic alarm of exception;
When each electrical fault signal gathered by on-the-spot PLC changes, contacts status 0 becomes 1, or 1 becomes 0, then think and have electric fault to occur; When electricity in the unit interval or tolerance exceed the numerical value of theory calculate, then think that energy consumption consumption is abnormal; When the number of rejects detected by vision detection system in the unit interval exceedes setting value, then think that product quality is abnormal;
When there is above-mentioned fault or exception, the audible-visual alarm lamp that on-the-spot PLC triggers presence is installed; There is identical abnormal show in each relevant departments HMI simultaneously; When extremely not getting rid of at short notice, the corresponding button on triggers presence HMI, simultaneously at the scene HMI character input element inputs respective code, just there is corresponding abnormal information in corresponding relevant departments HMI, automatically trigger sound equipment simultaneously and send alarm sound, after receiving abnormal information, utilize character input element input code mutually to be exchanged by Ethernet; When unresolved in problem is long-time, at the scene in PLC to timing, timing triggers the macro instruction that collects and control in HMI to rear and send the smart mobile phone of relevant abnormalities note to related personnel;
At the scene on HMI, make position state and element is set, comprise plant maintenance, change kind, change the edge of a knife, treat material, die change, make data input elements simultaneously and set every required theoretical duration; Safeguard at treatment facility, change kind, change the edge of a knife, wait to expect or before die change event, the corresponding button on triggers presence HMI, on-the-spot PLC starts timing, when above-mentioned a certain duration used exceedes setting value, then think this operation irregularity, carry out triggering sound equipment and note, simultaneously abnormal information is recorded in the word address that on-the-spot HMI specifies automatically;
(5) the automatic generation of form;
With programming language Visual basic exploitation on the webserver, utilize Microsoft WinsockControl control functionality, set up the communication between the webserver and each HMI; Installation database management tool SQL-Server or Acess on the webserver simultaneously, building database, data by Winsock control timing extraction every day are put into database, form total production data form every day comprising following data structure and content:
Field name: ID, its data type is Integer, and its implication is increasing sequence, and its data extracting mode is automatically formed;
Field name: production wire size, its data type is Text, and its implication is production line numbering, and its data extracting mode is that rule is corresponding;
Field name: date, its data type is Datetime, and its implication is that data extract the date, and its data extracting mode is Clock Extraction during transmission;
Field name: product quantity, its data type is long, and its implication is each product of production line quantity every day, and its data extracting mode is automatically formed in PLC, timing transmission;
Field name: start duration, its data type is long, and its implication is each production line start every day duration, and its data extracting mode is automatically formed in PLC, timing transmission;
Field name: run duration, its data type is long, its implication is each production line operation every day duration, and its data extracting mode is automatically formed in PLC, timing transmission;
Field name: fault duration, its data type is long, and its implication is the total duration of each production line fault every day, and its data extracting mode is automatically formed in PLC, timing transmission;
Field name: yield efficiency, its data type is long, and its implication is each production line output efficiency every day, and its data extracting mode is automatically formed in PLC, timing transmission;
Field name: production efficiency, its data type is long, and its implication is each production line production efficiency every day, and its data extracting mode is automatically formed in PLC, timing transmission;
Field name: rejection rate, its data type is long, and its implication is each production line rejection rate every day, and its data extracting mode is automatically formed in PLC, timing transmission;
Field name: electricity, its data type is long, and its implication is each production line power consumption every day, and its data extracting mode is automatically formed in PLC, timing transmission;
Field name: tolerance, its data type is long, and its implication is each production line air consumption every day, and its data extracting mode is automatically formed in PLC, timing transmission;
(6) remote maintenance;
Penetrate in communication setting interface at the programming tool of HMI, the serial ports number between the IP address of HMI and HMI and PLC is set, utilize Ethernet to penetrate any place of function in Ethernet and communication is carried out to corresponding PLC; Use the programming tool of PLC, directly PLC is uploaded with relevant individual PC and download monitoring debugging.
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