CN107992008B - Industrial interconnection equipment and use method thereof - Google Patents
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
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- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41865—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by job scheduling, process planning, material flow
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
the invention provides an industrial interconnection device and a using method thereof, wherein the industrial interconnection device is used as a communication interface between a control system and production equipment; the apparatus comprises: the control signal interface module is used for issuing control signals to production execution equipment in the production equipment through the multi-path output port; the data acquisition interface module is used for receiving monitoring data of a product to be processed from production monitoring equipment in the production equipment through a plurality of input ports; the microprocessor module is used for sending the control signal to the control signal interface module, receiving the monitoring data sent by the data acquisition interface module and sending the monitoring data to the control system. The technical scheme provided by the invention realizes communication connection between different production equipment and the control system, and provides a standard access point for various lower-layer production equipment, so that the lower-layer production equipment can be conveniently accessed to an upper-layer control system, and the integrated and automatic management of various production equipment is realized.
Description
Technical Field
the invention relates to the technical field of automatic production, in particular to industrial interconnection equipment and a using method thereof.
Background
The integrated requirements for testing and equipment in production automation pipeline testing are higher and higher, a test station in the production automation pipeline often comprises a plurality of test units and equipment units, and the data interfaces and the control signal time sequences provided by the various test units and equipment units are not consistent.
In the prior art, most test instruments are communicated with a server through a special interface, a bar code scanning gun uploads a scanned product bar code through a serial port, and a programmable logic device is communicated with the server through a network port. In addition, if the server needs to control the production line, the production line switch may need to be controlled through a customized digital input/output port.
If a certain test station of the production automation assembly line comprises more test units and equipment units, due to the fact that data interfaces and control signal time sequences provided by various test units and equipment units are not consistent, and interfaces of a server are limited, data uploaded by all the test units and equipment units cannot be acquired simultaneously, and the efficiency of assembly line testing is affected as each test unit and equipment unit uploads data one by one.
Disclosure of Invention
the problem that the production automation assembly line comprises a plurality of test units and equipment units, and a server cannot rapidly acquire data uploaded by all the test units and the equipment units, so that the assembly line test efficiency is affected is solved.
In one aspect, the present invention provides an industrial interconnect device, which serves as a communication interface between a control system and a production device; the industrial interconnect device includes:
The control signal interface module is used for issuing a control signal for operating a product to be processed to production execution equipment in the production equipment through a plurality of paths of output ports configured by the control signal interface module;
the data acquisition interface module is used for receiving monitoring data of various production monitoring equipment in the production equipment on the product to be processed through a plurality of self-configured input ports;
And the microprocessor module is used for sending the control signal generated by the control system to the control signal interface module, receiving the monitoring data sent by the data acquisition interface module and sending the monitoring data to the control system.
In another aspect, the present invention provides another industrial interconnect device, which is used as a communication interface between a control system and a production device; the industrial interconnect device includes:
the control signal interface module is used for issuing a control signal for operating a product to be processed to production execution equipment in the production equipment through a plurality of paths of output ports configured by the control signal interface module;
The data acquisition interface module is used for receiving monitoring data of various production monitoring equipment in the production equipment on the product to be processed through a plurality of self-configured input ports;
The microprocessor module is used for determining the production state of the product to be processed according to the monitoring data received by the data acquisition interface module, generating a control signal for operating the product to be processed and sending the control signal to the control signal interface module;
The microprocessor module is also used for sending the monitoring data to the control system, receiving a control signal sent by the control system and sending the control signal to the control signal interface module.
In addition, the invention also provides a use method of the industrial interconnection equipment, which comprises the following steps:
The microprocessor module transmits a control signal generated by the control system and used for operating a product to be processed to the control signal interface module;
The control signal interface module issues the control signal to production execution equipment in the production equipment through a multi-path output port configured by the control signal interface module;
the data acquisition interface module receives monitoring data of various production monitoring equipment in the production equipment on the product to be processed through a plurality of paths of input ports configured by the data acquisition interface module;
And the microprocessor module receives the monitoring data sent by the data acquisition interface module and sends the monitoring data to the control system.
The technical scheme provided by the embodiment of the invention can have the following beneficial effects:
The industrial interconnection equipment integrates a control signal interface module and a data acquisition interface module, a microprocessor module sends a control signal of an external control system to the control signal interface module, and the control signal is sent to various production execution equipment through a multi-path output port of the control signal interface module; monitoring data of various production monitoring devices are received through a plurality of input ports of a data acquisition interface module; and the microprocessor module uploads the monitoring data to an external control system. The industrial interconnection equipment is used as a communication interface between the control system and the production equipment, communication connection between different production equipment and the control system is realized, a uniform equipment control and data acquisition interface is provided for upper software control systems such as a manufacturing execution system, a production monitoring system, a data analysis system and the like, and a standard access point is provided for various lower-layer production equipment, so that the standard access point can be conveniently accessed to the upper-layer control system. Finally, integrated and automatic management of the test stations with the production monitoring equipment and the production execution equipment is realized.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
Drawings
The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments consistent with the invention and together with the description, serve to explain the principles of the invention.
FIG. 1 is a schematic diagram of an implementation environment of an industrial interconnect device, shown in an exemplary embodiment;
FIG. 2 is a schematic diagram of an implementation environment of an industrial interconnect device according to another exemplary embodiment;
FIG. 3 is a block diagram of an industrial interconnect device, shown in an exemplary embodiment;
FIG. 4 is a block diagram of an industrial interconnect device shown in another exemplary embodiment;
FIG. 5 is a block diagram of an industrial interconnect device shown in yet another exemplary embodiment;
FIG. 6 is a flow diagram illustrating a method for using an industrial interconnect device in accordance with an exemplary embodiment;
FIG. 7 is a schematic diagram illustrating a process for obtaining test data using industrial interconnect equipment in accordance with an exemplary embodiment;
FIG. 8 is a schematic diagram illustrating a process for obtaining test data using industrial interconnect equipment in accordance with another exemplary embodiment;
Fig. 9 is a schematic detailed flow chart of test data acquisition by using the industrial interconnection device according to the embodiment of the present invention;
FIG. 10 is a schematic diagram of the server performing analysis processing on data in the production process;
FIG. 11 is a schematic diagram of data after SPC analysis by the MES system;
FIG. 12 is a representation of an industrial interconnect device in accordance with the present invention.
Detailed Description
reference will now be made in detail to the exemplary embodiments, examples of which are illustrated in the accompanying drawings. When the following description refers to the accompanying drawings, like numbers in different drawings represent the same or similar elements unless otherwise indicated. The embodiments described in the following exemplary embodiments do not represent all embodiments consistent with the present invention. Rather, they are merely examples of apparatus and methods consistent with certain aspects of the invention, as detailed in the appended claims.
FIG. 1 is a schematic diagram of an implementation environment of an industrial interconnect device, according to an example embodiment. The implementation environment includes an industrial interconnect device 12, a production device 13, and a production management device 11. The production management apparatus 11 includes a production control system. The industrial interconnection device 12 serves as a connection device between the production device 13 and the enterprise production management device 11. The production equipment 13 herein refers to various automated production equipment used in industrial production processes, including production monitoring equipment (including detection equipment and production test equipment) and production execution equipment (e.g., robots, chip mounters, jigs, etc.). The industrial interconnection device 12 may obtain monitoring data of the production monitoring device in the production device 13 and send the data to the production management device 11, and the industrial interconnection device 12 may also receive a control signal issued by the production management device 11 and issue the control signal to the production execution device in the production device 13, so as to control the production execution device.
fig. 2 is a schematic diagram of an application scenario of an industrial interconnection device according to an exemplary embodiment. As shown in fig. 2, the upstream of the industrial interconnection device interfaces with a production management System (MES), i.e. a control System, of the management layer. The industrial interconnect equipment is interfaced downstream with various automated production equipment, such as PLCs (programmable logic controllers) in the equipment layer shown in fig. 2. The PLC can be connected with a manipulator and various production devices on a production line. As shown in fig. 2, the industrial interconnection device may also be connected to a computer, HMI (touch screen), a scanning gun, a tri-color light, and the like. The production management system collects monitoring data acquired by the industrial interconnected equipment in real time, analyzes the data acquired by the industrial interconnected equipment according to enterprise resource plans, product life cycle management, browser object models and the like provided by an enterprise layer, and issues control instructions to various downstream automatic production equipment through the industrial interconnected equipment.
For example, when the production of a workshop is abnormal, the MES can acquire production state data in time through an interface with industrial interconnection equipment, call a related intelligent system to perform SPC (Statistical Process Control) trend analysis, and intelligently judge whether the production is abnormal or not by comparing the acquired real-time data with conventional data; if the difference exceeds a certain threshold value, timely correcting errors in a stopping (production line suspension) or alarming mode, timely controlling defective products to be generated, and avoiding large-scale production waste. The intelligent manufacturing process needs a plurality of systems of software and hardware to be matched with each other, and the industrial interconnection equipment is used for acquiring real-time data and sending control commands and is an intelligent device between production management and field equipment control.
FIG. 3 is a block diagram of an industrial interconnect device, shown in an exemplary embodiment. The industrial interconnection device serves as a communication interface between the control system and the production device, as shown in fig. 3, and includes but is not limited to: a control signal interface module 31, a data acquisition interface module 32 and a microprocessor module 33. The microprocessor module 33 is respectively connected with the control signal interface module 31 and the data acquisition interface module 32.
The control signal interface module 31 is configured to issue a control signal for operating a product to be processed to a production execution device in the production device through a multi-path output port configured by the control signal interface module.
The control system may be a server and a display terminal. The control system can generate a control signal according to the data collected by the data collecting interface module 32, and the control signal is sent to the production execution device by the control signal interface module 31 of the industrial interconnection device to control the operation of the production execution device. The production execution equipment in the production equipment comprises a mechanical arm configured for realizing automatic feeding and discharging, various electric and pneumatic clamp tools for realizing the installation and positioning of a product to be tested, various transmission mechanisms controlled by a PLC (programmable logic controller), and the like.
In a specific embodiment, to realize the production automation pipeline automation production, various production execution equipment needs to be configured for the production automation pipeline. Specifically, if the data acquisition interface module 32 detects that the pneumatic clamp for mounting the product to be detected is not returned during the movement process, which will cause the manipulator for automatically picking up the material to be detected to be unable to successfully pick up the product to be detected, the control system may issue a control signal to the pneumatic clamp. When the data acquisition interface module 32 detects that a certain number of products to be detected are accumulated in the production automation assembly line, the control system can control the alarm lamp of the automatic chip mounter to be turned on. The control system may send a control signal to the stop switch according to the monitoring data acquired by the data acquisition interface module 32 to stop the operation of the production automation line.
in the process that the server controls the plurality of production execution equipment to perform automatic production through the control signal interface module 31 of the industrial interconnection equipment, the control signal interface module 31 serves as an access point of the plurality of production execution equipment, and the server can realize the integration and automatic production of a production automation production line by setting the control signal time sequence of each production execution equipment.
The data acquisition interface module 32 receives monitoring data of the products to be processed from various production monitoring devices in the production devices through a plurality of self-configured input ports;
The data acquisition interface module 32 may include a plurality of serial ports, such as two RS232 interfaces, an RS485 interface, a digital signal input interface, and an analog signal input interface. The multi-channel input port of the data acquisition interface module 32 can be connected to various production monitoring devices to receive monitoring data sent by the various production monitoring devices. The monitoring data may include test data and probe data. The test data refers to the test results of various test instruments on the products to be processed. The detection data refers to digital signals or analog signals detected by various sensors. Such as the result of detection by a temperature sensor.
The monitoring data received by the data acquisition interface module 32 can be sent to the microprocessor module 33, the microprocessor module 33 uploads the monitoring data to the control system, and the control system analyzes and displays the monitoring data.
The test condition of the product needs to be recorded in the automatic production process of the production automation assembly line, and the test station with problems can be traced when the product is bad. Therefore, the product code of each product needs to be uploaded to the server through the data acquisition interface module 32 by establishing the corresponding relationship between the product code and the product, scanning the product code on the product label through the scanning gun. And binding the product code and the test data of the product by the server to form the corresponding relation between the product code and the product.
optionally, the data acquisition interface module 32 includes an RS232 interface, and the RS232 interface is used to connect the code reading device in the production device, and receive the identification information of the product to be processed read by the code reading device. The code reading device can be a code scanning gun or a radio frequency identification card reader. After the RS232 interface of the data acquisition interface module 32 receives the product identification information (such as the product barcode) read by the code reading device, the product identification information is sent to the microprocessor module 33, and the microprocessor module 33 sends the product identification information to the server or the display terminal.
in order to control the quality of finished products, various electrical, optical and mechanical indexes of the products need to be tested before the products leave a factory. Such as the operating voltage, power, or surface color uniformity, surface roughness, etc. of the product. The data acquisition interface module 32 receives the product code uploaded by the scanning gun and the test data uploaded by the test instrument, sends the product code and the test data to the microprocessor module 33, and the microprocessor module 33 sends the product code and the test data to the server for associated storage.
in one embodiment, the start-up requirements for each production test equipment are different for a particular station of the production automation line. In order to test the power value of a product, a program control power supply needs to be turned on 5 minutes in advance to supply power to equipment. The server firstly sends a control signal to turn on the program-controlled power switch through the control signal interface module 31, and then turns on the power meter to measure the product power through sending the control signal after 5 minutes. The data acquisition time sequence of each production test device is reasonably set by the server or the microprocessor module 33, and the data acquisition interface module 32 reads the test result of each production test device through a multi-path serial port, so that the integrated and automatic production of an automatic production line is realized.
The microprocessor module 33 is configured to issue a control signal generated by the control system to the control signal interface module 31, receive monitoring data sent by the data acquisition interface module 32, and send the monitoring data to the control system.
specifically, the control signal sent by the server or the display terminal is sent to the control signal interface module 31 by the microprocessor module 33, and the control signal is forwarded to each production execution device by the control signal interface module 31 of the industrial interconnection device, so as to control the operation of each production execution device. The microprocessor module 33 can also receive the monitoring data of each production monitoring device connected to the data acquisition interface module 32, and send the monitoring data to the control system for data analysis and display. The control system may be a server and a display terminal.
The microprocessor module 33 may comprise a network chip that may communicate with a server through a switch. The server accesses the microprocessor module 33 by means of an IP address. A server can access different microprocessor modules 33 by means of an IP address. Therefore, one server can remotely control a plurality of industrial interconnected devices to work.
the exemplary embodiment of the present invention provides another industrial interconnection device, which includes the control signal interface module 31, the data acquisition interface module 32 and the microprocessor module 33 described in the above exemplary embodiment.
The control signal interface module 31 is configured to issue a control signal for operating a product to be processed to a production execution device in the production device through a multi-path output port configured by the control signal interface module;
The data acquisition interface module 32 is configured to receive monitoring data of the products to be processed from various production monitoring devices in the production devices through a plurality of input ports configured by the data acquisition interface module;
the microprocessor module 33 is configured to determine a production state of the product to be processed according to the monitoring data received by the data acquisition interface module, generate a control signal for operating the product to be processed, and send the control signal to the control signal interface module;
The microprocessor module 33 is further configured to send the monitoring data to the control system, receive a control signal issued by the control system, and send the control signal to the control signal interface module.
it should be explained that, the industrial interconnection device provided in this exemplary embodiment, besides serving as a communication interface between the control system and the production device, issues a control signal of the control system to the production execution device, and uploads monitoring data of the production monitoring device to the control system, the industrial interconnection device itself also has a data processing capability, determines a production state through analysis of the monitoring data, and generates a control signal in time accordingly to control the production execution device, thereby speeding up processing of a production fault and avoiding generation of a large amount of defective products.
In other words, the control signal may be generated by the microprocessor module 33 based on the monitored data, and may also be generated by the control system based on the monitored data. The control signal sent by the control system is sent to the control signal interface module 31 by the microprocessor module 33, and the control signal is forwarded to each production execution device by the control signal interface module 31 of the industrial interconnection device, so as to control the operation of each production execution device. The microprocessor module 33 can also receive the monitoring data of each production monitoring device connected to the data acquisition interface module 32, and send the monitoring data to the control system for data analysis and display.
the microprocessor module 33 itself also has data processing capability, and the microprocessor module 33 can determine the production state of the product to be processed according to the received monitoring data. For example, when the temperature detected by the temperature sensor is higher than the preset value, it may be considered that the product to be processed is abnormal, and the microprocessor module 33 may send a control signal to the production execution device, for example, control an alarm lamp to light up, so as to find out the abnormal condition of the production line in time.
on the basis of the industrial interconnection device provided by any of the above exemplary embodiments, the industrial interconnection device provided by the present invention may further include an optical coupling relay connecting the control signal interface module 31 and the microprocessor module 33; and the optical coupling relay is used for isolating the electric signal returned due to the fault of the production execution equipment after sending a control signal to the production execution equipment.
It should be noted that, if a fault (e.g. burn-out) occurs in the production execution device connected to the control signal interface module 31, when a control signal is sent to the production execution device, a large current may be returned to burn out the microprocessor module 33, so that signal isolation can be achieved through the optical coupling relay, the microprocessor module 33 is prevented from being burned out by the returned large current, and the reliability of the industrial interconnection device is improved.
on the basis of the industrial interconnection device provided in any of the above exemplary embodiments, the microprocessor module 33 is further configured to: comparing the monitoring data of the product to be processed with standard production data;
and when the difference between the monitoring data and the standard production data exceeds a preset threshold value, generating an alarm signal or a stop control signal, and sending the alarm signal or the stop control signal to production execution equipment in the production equipment through the control signal interface module.
that is to say, the monitoring data acquired by the industrial interconnection device can be sent to the server for data analysis, and the industrial interconnection device itself can also have data analysis capability. The microprocessor module 33 of the industrial interconnection device can compare the monitoring data with the standard production data, and when the difference exceeds a threshold value, the monitoring data is considered to be abnormal, so that the microprocessor module 33 sends an alarm signal or a stop control signal (a signal for controlling the production line to stop), faults can be found in time, and defective products are reduced.
In a specific application scenario, the data acquisition interface module 32 of the industrial interconnection device receives test data reported by various production test devices, and the server analyzes and obtains a product to be tested according to the test data, wherein the surface roughness index of the product to be tested deviates from the specification greatly. The yield of the product is too low, which may be a defect in a certain process. In this case, the continuous production causes production waste, and therefore, an automatic production line needs to be started to stop working. At this time, the server sends the stop control signal to the stop switch by issuing the stop control signal to the control signal interface module 31 of the industrial interconnection device, and the control signal interface 31 sends the stop control signal to the stop switch, so that the stop switch of the production automation assembly line is controlled, and finally the work of the production automation assembly line is stopped.
on the basis of the industrial interconnection device provided in any of the above exemplary embodiments, as shown in fig. 4, the industrial interconnection device may further include, on the basis of the control signal interface module 31, the data acquisition interface module 32, and the microprocessor module 33: and a touch display module 34 connected to the microprocessor module 33.
The touch display module 34 is used for displaying the monitoring data and sending a control signal to the control signal interface module 31.
This touch-control display module 34 provides the human-computer interaction interface for the production line operation personnel, the production data (including monitoring data) of various production facility outputs on the production line can be directly shown by the touch-control display module 34 of industry interconnection equipment, it can in time look over to be convenient for produce the line staff, to some emergency that the production line faces, the production line operation personnel can issue control signal to microprocessor module 33 through touch-control display module 34, send control signal to control signal interface module 31 by microprocessor module 33, and then control the production execution equipment who is connected to control signal interface module 31. Due to the fact that when abnormal conditions occur, production line workers can directly issue control signals through the touch display module 34, the control signals do not need to be issued after data analysis processing is conducted remotely through a server, and therefore the production state of a production line can be controlled more timely, and defective products are avoided. The touch display module 34 can also interact with a remote server, so that the space for installing a computer in a production line is saved.
On the basis of the industrial interconnection device provided by any of the above exemplary embodiments, as shown in fig. 5, the industrial interconnection device further includes: the network interface 351 is used for connecting the microprocessor module 33 with a control system, and the network interface 351 is used for transmitting the control signal generated by the control system to the microprocessor module 33 and sending the monitoring data of the product to be processed to the control system.
it should be noted that the network interface 351 is used for connecting the microprocessor module 33 and the control system. The control system may be a server. The network interface 351 is used for communicating with the server through the Ethernet switch, when a plurality of industrial interconnection devices are connected to one switch, the switch allocates an IP address for each industrial interconnection device, the server accesses the industrial interconnection devices through the IP addresses, and one server can remotely control the plurality of industrial interconnection devices to work simultaneously. In one embodiment, each test station in the production automation production line is provided with an industrial interconnection device, and all the industrial interconnection devices in the production automation production line are controlled through one server, so that the control of the whole production automation production line is realized.
According to the requirement, the industrial networking device can also be provided with a USB interface 352, and the USB interface 352 is used for connecting the microprocessor module 33 and the touch display module 34. The touch display module 34 includes a touch display screen.
the USB interface 352 may establish a communication connection between the microprocessor module 33 and the touch display module 34. The test data collected by the data collection interface module 32 is usually large, and the USB interface 352 can provide a high-speed signal transmission service for the communication between the microprocessor module 33 and the touch display module 34.
on the basis of the industrial interconnection device provided in any of the above exemplary embodiments, the data acquisition interface module 32 may further include:
And the RS485 interface is used for receiving the test data of the production test equipment in the production monitoring equipment to the product to be processed.
the RS485 interface can support differential signal transmission, and provides a physical link interface for connecting with various devices with RS485 communication functions in a half-duplex communication mode.
In one embodiment, the data acquisition interface module 32 may further include:
And the digital signal input interface is used for receiving digital detection signals reported by various digital sensors in the production equipment and sending the digital detection signals to the microprocessor module.
Of course, the data acquisition interface module 32 may also include an analog signal input interface. The digital signal input interface can be connected with various switches, such as a photoelectric switch. The digital signal input interface can also be connected with a module capable of generating a level signal. In other words, the data signal input interface receives a digital signal. The digital detection signals reported by various digital sensors received by the data signal input interface are sent to the microprocessor module 33, and are transmitted to the server by the microprocessor module 33 through the network interface. For example, the digital sensor may include a grating sensor, a magnetic grating sensor, a code wheel, a resonant sensor, a tachometer sensor, an inductive synchronizer, and the like.
The analog signal input interface is configured to receive analog detection signals reported by various analog sensors in the production equipment, and send the analog detection signals to the microprocessor module 33. The analog detection signal may be sent by the microprocessor module 33 to a server via the network interface 351, and analyzed and presented by the server.
the analog detection signal refers to an analog signal. The analog signal input interface can receive an analog signal sent by the analog sensor. Analog sensors installed automatically in production lines, such as pressure sensors, temperature sensors, flow sensors, acoustic sensors, electrical parameter sensors, etc. The sensor is limited by the field environment, the output voltage or current signal cannot be transmitted far away, or the sensor is complicated by too many wires. Therefore, the analog signal input interface of the industrial interconnection equipment receives voltage or current signals acquired by various analog sensors, and then the industrial interconnection equipment uniformly transmits the signals acquired by various sensors to the server. The problem of voltage or current that sensor output can not the teletransmission, wiring complicated when the sensor is more is solved.
In a specific embodiment, the analog signal input interface of the industrial interconnection device receives the voltage or current signal reported by the sensor, and then the microprocessor module 33 can convert the analog voltage or current signal into a digital signal in the production line field, and then upload the digital signal to the server for processing, so as to cope with various harsh industrial environments.
It should be noted that the microprocessor module 33 can implement a dynamically added control protocol in an online burning manner, so that various production devices can be connected to the industrial interconnection device, and the control system can send a uniform control command to control the various production devices and collect production data of the various production devices according to a uniform format.
The industrial interconnection equipment is used as a communication interface between various production equipment and a control system, provides a uniform interface for the control system to realize production monitoring, data analysis and manufacturing control, provides a standard access port for various production equipment, and can be accessed to the control system more conveniently by carrying out real-time adaptation conversion on a communication protocol of the industrial interconnection equipment.
Wherein the industrial interconnect device provides an easily understandable, standardized communication protocol for communicating with the control system, the protocol having structural integrity, comprising: a start flag, a valid data length, a command word, valid data, a check bit, and an end flag; the start mark is 0xAA, the binary system is 10101010, and the circuit shows a regular peak-valley waveform which is easily distinguished from interference data; the valid data portion may be composed of a plurality of double bytes, a first byte of the double bytes being used for storing data length information and a second byte being used for data content information; the check bit adopts a byte XOR checksum algorithm of the effective data part, can check the integrity of the whole instruction data, prevents the data from being tampered or injecting external abnormal data, and increases the safety of the system instruction data. The command word is composed of two bytes, the first byte is an instruction large class, and the second byte is an instruction small class, and can provide control, data, real-time data and respond to various execution operation commands.
as shown in fig. 6, the present invention further provides a method for using an industrial interconnection device, which can be used in the industrial interconnection device provided in any of the above embodiments, and the method can include the following steps:
In step 601, the microprocessor module 33 issues a control signal generated by the control system to operate the product to be processed to the control signal interface module;
In step 602, the control signal interface module 31 issues the control signal to the production execution device in the production device through the multi-channel output port configured by itself;
in step 603, the data acquisition interface module 32 receives monitoring data of the product to be processed from various production monitoring devices in the production devices through a multi-path input port configured by the data acquisition interface module;
In step 604, the microprocessor module 33 receives the monitoring data sent by the data acquisition interface module and sends the monitoring data to the control system.
The microprocessor module 33, the control signal interface module 31, and the data acquisition interface module 32 are described in the above embodiments of the industrial interconnection device with reference to the microprocessor module 33, the control signal interface module 31, and the data acquisition interface module 32.
the data acquisition interface module 32 receives monitoring data of the products to be processed from various production monitoring devices in the production devices through a multi-channel input port configured by itself, and the monitoring data includes:
When a detection device on a product production line detects that a product to be processed reaches a test station, a code reading device in the production equipment is triggered to read product identification information of the product to be processed;
the data acquisition interface module 32 receives the product identification information sent by the code reading device and sends the product identification information to the microprocessor module 33.
it should be noted that the detection device may be an optoelectronic switch and a travel switch or a radio frequency identification antenna. FIG. 7 illustrates an exemplary embodiment of a process for obtaining test data using industrial interconnect equipment. The process is as follows: step 1, when a product to be processed reaches a test station, a photoelectric switch and a travel switch are triggered at the same time, a code reading device (an automatic scanning gun or a radio frequency identification card reader) in production equipment is triggered to start code scanning, and product identification information (such as a product bar code) of the product to be processed is read. And 2, the code reading equipment sends the read product bar code to the industrial interconnection equipment. And the industrial interconnection equipment receives the product bar code and temporarily stores the product bar code.
As shown in fig. 7, after receiving the product barcode, the industrial interconnection device sends the product barcode to the online server for temporary storage in step 3. And 4, the industrial interconnection equipment sends a data reading request to the online server, and the online server responds to the data reading request after receiving the data reading request and sends a data reading instruction to the industrial interconnection equipment. And 5, after receiving the data reading instruction, the industrial interconnection equipment reads the test data of the production test equipment connected with the corresponding interface according to the interface indicated by the data reading instruction. And 6, the industrial interconnection equipment sends the test data to the online server. And the industrial interconnection equipment sends a data reading request for multiple times until the test data of all the production test equipment is obtained. And 7, the online server stores the product bar code and the corresponding test data into the server. As shown in fig. 7, the test equipment may include a triad tester, an electrical parameter tester, an insulation withstand voltage tester, a ground tester, a leakage wave tester, and the like.
Optionally, the data acquisition interface module receives, through a multi-channel input port configured by itself, monitoring data of the product to be processed from various production monitoring devices in the production device, and the data acquisition interface module includes:
The data acquisition interface module 32 receives a trigger signal sent by the photoelectric sensor and the travel switch;
The microprocessor module 33 sends a data reading request to the control system according to the trigger signal;
The microprocessor module 33 receives a data reading instruction sent by the control system in response to the data reading request;
and the data acquisition interface module 32 reads the test data of the production test equipment connected with the corresponding interface according to the interface indicated by the data reading instruction.
FIG. 8 is a flow diagram illustrating a process for obtaining test data using industrial interconnect equipment, according to another exemplary embodiment. As shown in fig. 8, the process includes the steps of:
1. when the product passes through the RFID (radio frequency identification) antenna, the RFID reader reads the RFID label and converts the RFID label into bar code data to be transmitted to the online server.
2. and the line server finds the IP address corresponding to the industrial interconnection equipment according to the IP address and the antenna number of the RFID card reader, and stores the IP address, the work station number, the product bar code and other information of the industrial interconnection equipment into a bar code table to be processed by the line server. That is to say, one RFID card reader corresponds to one industrial interconnection device.
3. the photoelectric switch and the travel switch are triggered simultaneously to send signals to the industrial interconnection equipment.
4. the industrial interconnection equipment sends a data reading request to the online server, and the online server sends a data reading instruction to the industrial interconnection equipment after receiving the request.
5. after receiving the data reading instruction, the industrial interconnection equipment appoints the corresponding port to read the test data
6. And the industrial interconnection equipment sends the test data to the online server and sends a data reading request to the online server again until all the test equipment returns data.
7. The line server finds the product bar code read by the corresponding RFID card reader in the list to be processed of the line server according to the IP address of the industrial interconnection equipment sending the test data
8. And the online server uploads the product bar code and the corresponding test data to the server for storage. And analyzing and processing the test data by the server.
optionally, after the microprocessor module 33 receives the monitoring data sent by the data collecting interface module 32 and sends the monitoring data to the control system in step 604, the method further includes:
the microprocessor module 33 compares the monitoring data of the product to be processed with the standard production data;
And when the difference between the monitoring data and the standard production data exceeds a preset threshold value, sending an alarm signal or sending a stop control signal.
that is, the industrial interconnection device may send the monitoring data to the server for processing, and may also be processed by the microprocessor module 33 of the industrial interconnection device as required. Comparing the monitoring data of the product to be processed with the standard production data by the microprocessor module 33 of the industrial interconnection equipment; and when the difference between the monitoring data and the standard production data exceeds a preset threshold value, sending an alarm signal or sending a stop control signal. Therefore, faults can be found in time, defective products are reduced, data analysis processing is carried out by comparing the data with that of the data sent to the server, and the data are directly analyzed and processed by the microprocessor module 33, so that the fault analysis is more efficient.
Fig. 9 is a schematic detailed flow chart of test data acquisition by using the industrial interconnection device according to the embodiment of the present invention. As shown in fig. 9. The process is as follows:
1. The photoelectric switch and the travel switch are triggered simultaneously, the automatic code scanning gun starts to scan codes to obtain product bar codes, and the product bar codes are sent to the industrial interconnection equipment.
2. And the industrial interconnection equipment receives the product bar code and then sends the product bar code to the online server.
3. and after receiving the bar code of the product, the line server checks whether the previous product is tested. And caching the received product bar code, and checking whether the cached bar code exists.
4. The photoelectric switch and the travel switch are simultaneously triggered to send signals to the industrial interconnection equipment.
5. And the industrial interconnection equipment sends a test data reading request to the line server.
6. And the line server sends the test item data reading instructions of all the test equipment to the IP ports of the industrial interconnection equipment one by one according to the test item configuration.
7. the industrial interconnection equipment receives the data reading instruction in the TCP port, sends the data reading instruction to the specified test equipment, and reads the test data of the specified test item.
8. And the industrial interconnection equipment sends the test data to the online server for temporary storage.
9. The line server checks whether all the test items under each test device have been sent. If not, returning to the step 6, and if so, executing the next step.
10. and the line server binds and stores the cached product bar code and the cached test data to the line server, and clears the cached product bar code.
11. the main data server may periodically save the data of the line server to the main data server.
As shown in fig. 10, the MES system of the server can perform SPC statistical analysis and through-rate statistical analysis on the test data in the production process. And when the analysis result is abnormal, stopping production to improve the quality, and continuing production when the analysis result is not abnormal. FIG. 11 is a schematic diagram of data after SPC analysis by the MES system. As shown in fig. 11, the test result of the four-in-one integrated tester with the product barcode of 3310126700010 is abnormal. At the moment, the MES system can alarm in time and send down a stop line control signal.
It should be noted that the related automation devices in the factory workshop of the manufacturing industry are various in types, complicated in communication protocols, non-uniform in standards, and especially difficult to monitor the status of the production equipment. In order to realize the mutual communication among different brands and different types of equipment, data are transmitted to a control system for further analysis and calculation, remote monitoring and management are realized, the operation and maintenance cost is saved, and the method is a great challenge for managers. In order to realize communication with various production devices, the most obvious defect at present is that complex and various lines need to be deployed in a workshop, and the production safety of the workshop is influenced.
as shown in fig. 12, which is a presentation form of the industrial interconnection device provided by the present invention, it can be seen from the figure that the industrial interconnection device includes a plurality of ports, and the plurality of ports can be adapted to different production devices, so that rapid acquisition of production data can be achieved, and error can be corrected in time when a fault occurs. The industrial interconnection equipment can realize interconnection and intercommunication of production equipment of different types and different models in a highly integrated network protocol mode, so that workshop production and process management and control are unified. The CPU of the industrial interconnection equipment is designed by adopting a super-strong industrial singlechip, has the characteristics of low cost, high reliability, strong anti-interference capability, low power consumption, small volume and the like, and most importantly, the intelligent interconnection is realized!
in summary, the industrial interconnection device provided by the invention has the following advantages: a plurality of production devices can be controlled in a remote, reliable, real-time and cooperative mode, and flexible manufacturing is improved; the transparent process, the remote control and the man-machine cooperation are realized; the production transfer time can be effectively reduced; and (4) integrating and analyzing data.
the industrial interconnection equipment provided by the invention solves the problem of equipment connection with multiple communication interfaces and complex protocols, realizes high-efficiency interconnection and intercommunication and realizes complex connection of equipment of various brands; various communication protocol interactions are realized; various communication interface online is realized; the high-efficiency and stable operation of data communication is realized.
It will be understood that the invention is not limited to the precise arrangements described above and shown in the drawings and that various modifications and changes may be made without departing from the scope thereof. The scope of the invention is limited only by the appended claims.
Claims (11)
1. An industrial interconnection device, characterized in that the industrial interconnection device serves as a communication interface between a control system and a production device; the industrial interconnect device includes:
The control signal interface module is used for issuing a control signal for operating a product to be processed to production execution equipment in the production equipment through a plurality of paths of output ports configured by the control signal interface module;
The data acquisition interface module is used for receiving monitoring data of various production monitoring equipment in the production equipment on the product to be processed through a plurality of self-configured input ports;
And the microprocessor module is used for issuing the control signal generated by the control system to the control signal interface module, receiving the monitoring data sent by the data acquisition interface module and sending the monitoring data to the control system, wherein the microprocessor module can realize a dynamic newly-added control protocol in an online burning mode, so that various production equipment can be connected with industrial interconnection equipment, and further the control system can send a uniform control command to control various production equipment.
2. the industrial interconnect device of claim 1, wherein the microprocessor module is further configured to:
Comparing the monitoring data of the product to be processed with standard production data;
and when the difference between the monitoring data and the standard production data exceeds a preset threshold value, generating an alarm signal or a stop control signal, and sending the alarm signal or the stop control signal to production execution equipment in the production equipment through the control signal interface module.
3. The industrial interconnect device of claim 1, further comprising:
And the network interface is used for transmitting the control signal generated by the control system to the microprocessor module and sending the monitoring data of the product to be processed to the control system.
4. the industrial interconnect device of claim 1, the data collection interface module comprising:
the RS485 interface is used for receiving the test data of the production test equipment in the production monitoring equipment to the product to be processed;
The digital signal input interface is used for receiving digital detection signals reported by various digital sensors in the production monitoring equipment;
and the RS232 interface is used for connecting the code reading equipment in the production monitoring equipment and receiving the identification information of the product to be processed read by the code reading equipment.
5. The industrial interconnect device of claim 1, further comprising:
The optical coupling relay is connected with the control signal interface module and the microprocessor module; and the optical coupling relay is used for isolating the electric signal returned due to the fault of the production execution equipment after sending a control signal to the production execution equipment.
6. An industrial interconnection device, characterized in that the industrial interconnection device serves as a communication interface between a control system and a production device; the industrial interconnect device includes:
The control signal interface module is used for issuing a control signal for operating a product to be processed to production execution equipment in the production equipment through a plurality of paths of output ports configured by the control signal interface module;
the data acquisition interface module is used for receiving monitoring data of various production monitoring equipment in the production equipment on the product to be processed through a plurality of self-configured input ports;
The microprocessor module is used for determining the production state of the product to be processed according to the monitoring data received by the data acquisition interface module, generating a control signal for operating the product to be processed and sending the control signal to the control signal interface module;
the microprocessor module is also used for sending the monitoring data to the control system, receiving the control signal sent by the control system and sending the control signal to the control signal interface module, wherein the microprocessor module can realize a dynamic newly-added control protocol through an online burning mode, so that various production equipment can be connected with industrial interconnection equipment, and the control system can send a uniform control command to control various production equipment.
7. the industrial interconnect device of claim 6, further comprising:
And the touch display module is used for displaying the monitoring data received by the data acquisition interface module, monitoring a touch signal triggered by a user, issuing a control instruction to the microprocessor module according to the touch signal, and generating a control signal for operating the product to be processed by the microprocessor module according to the control instruction.
8. the industrial interconnect device of claim 7, further comprising:
And the USB interface is used for establishing the connection between the microprocessor module and the touch display module.
9. A method for using an industrial interconnect device according to any of claims 1-8, the method comprising:
The microprocessor module transmits a control signal generated by the control system and used for operating a product to be processed to the control signal interface module;
The control signal interface module issues the control signal to production execution equipment in the production equipment through a multi-path output port configured by the control signal interface module;
the data acquisition interface module receives monitoring data of various production monitoring equipment in the production equipment on the product to be processed through a plurality of paths of input ports configured by the data acquisition interface module;
and the microprocessor module receives the monitoring data sent by the data acquisition interface module and sends the monitoring data to the control system.
10. The method of claim 9, wherein the data collection interface module receives monitoring data of the product to be processed from various production monitoring devices in the production device through a plurality of input ports configured in the data collection interface module, and the method comprises:
when a detection device on a product production line detects that a product to be processed reaches a test station, a code reading device in the production equipment is triggered to read product identification information of the product to be processed;
and the data acquisition interface module receives the product identification information sent by the code reading equipment and sends the product identification information to the microprocessor module.
11. The method of claim 9, wherein the data collection interface module receives monitoring data of the product to be processed from various production monitoring devices in the production device through a plurality of input ports configured in the data collection interface module, and the method comprises:
The data acquisition interface module receives a trigger signal sent by the photoelectric sensor and the travel switch;
The microprocessor module sends a data reading request to the control system according to the trigger signal;
the microprocessor module receives a data reading instruction sent by the control system in response to the data reading request;
and the data acquisition interface module reads the test data of the production test equipment connected with the corresponding interface according to the interface indicated by the data reading instruction.
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