CN111813058A - Visual monitoring method and system for anchor chain production condition - Google Patents
Visual monitoring method and system for anchor chain production condition Download PDFInfo
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- CN111813058A CN111813058A CN202010549604.7A CN202010549604A CN111813058A CN 111813058 A CN111813058 A CN 111813058A CN 202010549604 A CN202010549604 A CN 202010549604A CN 111813058 A CN111813058 A CN 111813058A
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- 238000000034 method Methods 0.000 title claims abstract description 75
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 73
- 238000012544 monitoring process Methods 0.000 title claims abstract description 65
- 230000000007 visual effect Effects 0.000 title claims abstract description 25
- 238000004891 communication Methods 0.000 claims abstract description 40
- 238000003466 welding Methods 0.000 claims description 28
- 238000010791 quenching Methods 0.000 claims description 27
- 230000000171 quenching effect Effects 0.000 claims description 27
- 238000005496 tempering Methods 0.000 claims description 26
- 238000010438 heat treatment Methods 0.000 claims description 25
- 238000012360 testing method Methods 0.000 claims description 19
- 230000015654 memory Effects 0.000 claims description 10
- 238000013480 data collection Methods 0.000 claims description 5
- 239000000498 cooling water Substances 0.000 claims description 4
- 238000009864 tensile test Methods 0.000 description 6
- 238000012545 processing Methods 0.000 description 4
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000001514 detection method Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical group [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
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- 238000003908 quality control method Methods 0.000 description 1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] 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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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32252—Scheduling production, machining, job shop
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention relates to the technical field of automatic production, in particular to a visual monitoring method and a system for anchor chain production conditions, wherein the system comprises a data acquisition unit, a field industrial control unit and a remote monitoring unit, wherein the field industrial control unit is respectively in communication connection with the data acquisition unit and the remote monitoring unit; the system comprises a data acquisition unit, a field industrial control unit, a communication module and a remote monitoring unit, wherein the data acquisition unit is used for acquiring operation parameters of a production process in a production area, the field industrial control unit comprises a touch screen, a PLC and the communication module which are sequentially connected, the PLC is used for acquiring the operation parameters acquired by the data acquisition unit, the touch screen is used for receiving control parameters set by a user and displaying the control parameters set by the user and the operation parameters acquired by the data acquisition unit in real time, the communication module is used for reporting the control parameters and the operation parameters to the remote monitoring unit, and the remote monitoring unit is used for receiving and displaying the control parameters and the operation parameters reported by the field industrial control unit in real time.
Description
Technical Field
The invention relates to the technical field of automatic production, in particular to a visual monitoring method and system for anchor chain production conditions.
Background
In ship and ocean engineering projects, the anchor chain belongs to important safety equipment, and in order to ensure that the ship and ocean engineering devices achieve safety and safety at the sea in extreme climate, extremely high requirements on the quality reliability of each chain link are required, so that the whole process management of the production condition of the anchor chain plays an important role in the quality control of anchor chain products. However, the existing anchor chain production monitoring is also carried out by a large amount of manual work, and whether the measured data meets the process requirements or not is judged manually by measuring the data in the production process in a manual field. Due to the adoption of the mode, a large amount of labor cost is increased, all detection data cannot be objectively and accurately ensured due to the existence of human factors, the follow-up quality problems are difficult to trace, a manager cannot conveniently master the field condition of anchor chain production in real time, and the process management efficiency of anchor chain production is greatly limited.
Disclosure of Invention
The invention aims to provide a visual monitoring method and a visual monitoring system for anchor chain production conditions, which are used for solving one or more technical problems in the prior art and at least providing a beneficial selection or creation condition.
In order to achieve the purpose, the invention provides the following technical scheme:
a visual monitoring system for anchor chain production conditions, the system comprising: the system comprises a data acquisition unit, a field industrial control unit and a remote monitoring unit, wherein the field industrial control unit is respectively in communication connection with the data acquisition unit and the remote monitoring unit;
the production area comprises a heat treatment area, a welding area and a tension test area, and the production process comprises a heat treatment process carried out in the heat treatment area, a welding process carried out in the welding area and a tension test process carried out in the tension test area;
the field industrial control unit comprises a touch screen, a PLC and a communication module, the touch screen, the PLC and the communication module are sequentially connected, and the communication module is also in communication connection with the remote monitoring unit;
the PLC is used for acquiring the operation parameters acquired by the data acquisition unit;
the touch screen is used for receiving control parameters set by a user and displaying the control parameters set by the user and the operation parameters acquired by the data acquisition unit in real time, the control parameters comprise product numbers and interval ranges of the operation parameters, and the control parameters are preset before production;
the communication module is used for reporting the control parameters and the operation parameters to a remote monitoring unit;
and the remote monitoring unit is used for receiving and displaying the control parameters and the operation parameters reported by the field industrial control unit in real time.
Further, the heat treatment zone comprises a quenching zone and a tempering zone, and the heat treatment process comprises a quenching process and a tempering process; the PLC is including setting up in the first PLC in quenching district and setting up in the second PLC in tempering district, first PLC is used for obtaining the operating parameter of quenching process, the operating parameter of quenching process includes: quenching zone temperature, quenching sprocket frequency converter frequency and quenching furnace pressure; the second PLC is used for obtaining the operation parameters of the tempering process, and the operation parameters of the tempering process comprise: tempering area temperature, cooling water temperature, tempering sprocket frequency converter frequency and tempering furnace pressure; the first PLC is in communication connection with the second PLC through an RS485 interface, and the first PLC is connected with the communication module.
Further, the PLC further includes a third PLC disposed in the heat treatment area, the third PLC is configured to obtain operation parameters of the welding process, and the operation parameters of the welding process include: welding current, welding voltage, top chain pressure, jaw pressure, upsetting pressure and upsetting distance; and the first PLC is in communication connection with the third PLC through an RS485 interface.
Further, the PLC includes a fourth PLC disposed in the tensile testing area, the fourth PLC is configured to obtain an operation parameter of the tensile testing process, and the operation parameter of the tensile testing process includes: tension load and hoop deflection; and the first PLC is in communication connection with the fourth PLC through an RS485 interface.
Furthermore, the field industrial control unit also comprises a memory connected with the PLC, and the memory is used for storing control parameters set by a user and operating parameters collected by the data collection unit.
A visual monitoring method for anchor chain production conditions is applied to any visual monitoring system for anchor chain production conditions, and comprises the following steps:
the production process comprises a heat treatment process carried out in the heat treatment area, a welding process carried out in the welding area and a tension testing process carried out in the tension testing area;
the PLC acquires the operation parameters acquired by the data acquisition unit;
the method comprises the steps that a touch screen receives control parameters set by a user, the control parameters set by the user and operation parameters collected by a data collection unit are displayed in real time, the control parameters comprise product numbers and interval ranges of the operation parameters, and the control parameters are preset before production;
the communication module reports the control parameters and the operation parameters to a remote monitoring unit;
and the remote monitoring unit receives and displays the control parameters and the operation parameters reported by the field industrial control unit in real time.
Further, the method further comprises:
when the operation parameters exceed the range of the interval, the remote monitoring unit displays the operation parameters exceeding the range of the interval and a production area where the operation parameters are located;
further, the method further comprises:
the remote monitoring unit sequences the operation parameters according to a time sequence and presents the operation parameters in a report form;
further, the method further comprises:
the remote monitoring unit sequences the operation parameters collected in the production process according to the product numbers and presents the operation parameters in a report form.
The invention has the beneficial effects that: the invention provides a visual monitoring method and a system for anchor chain production condition, which display control parameters set by a user and operation parameters acquired by a data acquisition unit in real time through a touch screen, thereby facilitating the real-time check of the field management personnel, the field management personnel can control the production condition of the managed area in real time, the remote monitoring unit receives and displays the control parameters and the operation parameters reported by the field industrial control unit in real time, thereby facilitating the management personnel at the background to check the control parameters and the operation parameters in the production area in real time and visually monitor the production condition of the anchor chain, the anchor chain production condition can be managed on site and monitored remotely, so that the labor cost is saved, and the anchor chain production condition can be objectively and timely known. The invention greatly improves the management efficiency of anchor chain production process control and meets the management requirements of quick query and long-term storage of production records.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without inventive exercise.
FIG. 1 is a schematic structural diagram of a visual monitoring system for anchor chain production status according to an embodiment of the present invention;
fig. 2 is a schematic flow chart of a visual monitoring method for anchor chain production conditions according to an embodiment of the present invention.
Detailed Description
The conception, the specific structure and the technical effects of the present invention will be clearly and completely described in conjunction with the embodiments and the accompanying drawings to fully understand the objects, the schemes and the effects of the present invention. It should be noted that the embodiments and features of the embodiments in the present application may be combined with each other without conflict.
Referring to fig. 1, fig. 1 shows a visual monitoring system for production condition of an anchor chain according to an embodiment of the present invention, where the system includes: the system comprises a data acquisition unit, a field industrial control unit and a remote monitoring unit, wherein the field industrial control unit is respectively in communication connection with the data acquisition unit and the remote monitoring unit;
the production area comprises a heat treatment area, a welding area and a tension test area, and the production process comprises a heat treatment process carried out in the heat treatment area, a welding process carried out in the welding area and a tension test process carried out in the tension test area;
the field industrial control unit comprises a touch screen, a Programmable Logic Controller (PLC) and a communication module, wherein the touch screen, the PLC and the communication module are sequentially connected, and the communication module is also in communication connection with the remote monitoring unit; in this embodiment, the communication module is further connected to the remote monitoring unit in an ethernet manner;
the PLC is used for acquiring the operation parameters acquired by the data acquisition unit;
the touch screen is used for receiving control parameters set by a user and displaying the control parameters set by the user and the operation parameters acquired by the data acquisition unit in real time, the control parameters comprise product numbers and interval ranges of the operation parameters, and the control parameters are preset before production;
the communication module is used for reporting the control parameters and the operation parameters to a remote monitoring unit;
and the remote monitoring unit is used for receiving and displaying the control parameters and the operation parameters reported by the field industrial control unit in real time.
In the embodiment, before production is started, a field manager sets control parameters through a touch screen, and can automatically acquire operation parameters of a production process in a production area through a data acquisition unit, then a PLC acquires the operation parameters acquired by the data acquisition unit, the touch screen displays the control parameters set by a user and the operation parameters acquired by the data acquisition unit in real time, so that the field manager can conveniently check the control parameters and the operation parameters in real time, the field manager can control the production condition of a managed area in real time, and a remote monitoring unit receives and displays the control parameters and the operation parameters reported by a field industrial control unit in real time, so that a background manager can conveniently check the control parameters and the operation parameters in the production area in real time, and can visually monitor the production condition of an anchor chain, the anchor chain production condition can be managed on site and monitored remotely, so that the labor cost is saved, the anchor chain production condition can be objectively and timely known, and the anchor chain production process management efficiency is improved.
As a further improvement of the above technical solution, the heat treatment zone comprises a quenching zone and a tempering zone, and the heat treatment process comprises a quenching process and a tempering process; the PLC comprises a first PLC arranged in the quenching area and a second PLC arranged in the tempering area; the quenching zone is provided with a first thermocouple thermometer, a quenching chain wheel frequency converter and a first pressure sensor, the first thermocouple thermometer, the quenching chain wheel frequency converter and the first pressure sensor are respectively connected with a first PLC, the first PLC is used for acquiring the operation parameters of the quenching process, and the operation parameters of the quenching process comprise: quenching zone temperature, quenching sprocket frequency converter frequency and quenching furnace pressure;
the tempering area is provided with a second thermocouple thermometer and a second pressure sensor, a third thermocouple thermometer is arranged in the cooling water, the second thermocouple thermometer, the third thermocouple thermometer, the tempering chain wheel frequency converter and the second pressure sensor are respectively connected with a second PLC, the second PLC is used for obtaining operation parameters of the tempering process, and the operation parameters of the tempering process comprise: tempering area temperature, cooling water temperature, tempering sprocket frequency converter frequency and tempering furnace pressure;
the first PLC is in communication connection with the second PLC through an RS485 interface, and the first PLC is connected with the communication module.
As a further improvement of the above technical solution, the PLC further includes a third PLC disposed in the heat treatment area, where the third PLC is configured to obtain operation parameters of the welding process, and the operation parameters of the welding process include: the first PLC and the third PLC are in communication connection through an RS485 interface;
in the embodiment, the welding current is collected through a current transformer, the current transformer transmits a collected analog quantity signal to a current controller, and the current controller transmits the collected analog quantity signal to a third PLC; the welding voltage is collected through a voltage transformer, the voltage transformer transmits the collected analog quantity signal to a voltage controller, and the analog quantity signal is transmitted to the third PLC by the voltage controller for detection; the top chain pressure is acquired through a third pressure sensor, the jaw pressure is acquired through a fourth pressure sensor, the upsetting pressure is acquired through a fifth pressure sensor, and the third PLC is respectively connected with the third pressure sensor, the fourth pressure sensor and the fifth pressure sensor so as to acquire the top chain pressure, the jaw pressure and the upsetting pressure; the third PLC is also connected with an electronic ruler, and the electronic ruler is used for measuring the position of the upsetting oil cylinder in real time; and the third PLC is also used for calculating the change value of the positions of the upsetting oil cylinders before and after processing, and taking the change value of the positions of the upsetting oil cylinders before and after processing as the upsetting distance.
As a further improvement of the above technical solution, the PLC includes a fourth PLC disposed in the tensile testing area, the fourth PLC is configured to obtain an operation parameter of the tensile testing process, and the operation parameter of the tensile testing process includes: the first PLC and the fourth PLC are in communication connection through an RS485 interface.
In this embodiment, the fourth PLC is connected to a sixth pressure sensor, and the sixth pressure sensor transmits the collected tension load to the fourth PLC; the fourth PLC is also connected with an electronic ruler, and the electronic ruler is used for measuring the position of the tension oil cylinder in real time; and the fourth PLC is also used for calculating the change value of the positions of the tension oil cylinders before and after processing, and taking the change value of the positions of the tension oil cylinders before and after processing as the deformation of the iron ring.
As a further improvement of the above technical solution, the field industrial control unit further includes a memory connected to the PLC, and the memory is used for storing control parameters set by a user and operating parameters acquired by the data acquisition unit.
The number of the memory can be one, and one memory is respectively connected with the first PLC, the second PLC, the third PLC and the fourth PLC through 4 ports; the number of the memories may be 4, and the first PLC, the second PLC, the third PLC, and the fourth PLC are each connected to one memory.
In this embodiment, the remote monitoring unit includes a server and a display, which are connected to each other, the server and the communication module are connected via an ethernet, the server is configured to obtain the control parameters and the operation parameters sent by the communication module, and the display is configured to display the control parameters and the operation parameters reported by the field industrial control unit.
Referring to fig. 2, an embodiment of the present invention further provides a visual monitoring method for anchor chain production conditions, which is applied to any one of the visual monitoring systems for anchor chain production conditions described above, where the method includes the following steps:
s100, a data acquisition unit acquires operation parameters of a production process in a production area;
the production area comprises a heat treatment area, a welding area and a tension test area, and the production process comprises a heat treatment process carried out in the heat treatment area, a welding process carried out in the welding area and a tension test process carried out in the tension test area;
s200, the PLC acquires the operation parameters acquired by the data acquisition unit;
step S300, the touch screen receives control parameters set by a user and displays the control parameters set by the user and the operation parameters collected by the data collection unit in real time;
the control parameters comprise product numbers and interval ranges of operation parameters, and are preset before production;
step S400, the communication module reports the control parameters and the operation parameters to a remote monitoring unit;
and S500, the remote monitoring unit receives and displays the control parameters and the operation parameters reported by the field industrial control unit in real time.
As a further improvement of the above technical solution, when the operation parameter exceeds the interval range, the remote monitoring unit displays the operation parameter exceeding the interval range and the production area where the operation parameter is located;
as a further improvement of the above technical solution, the method further comprises: and the remote monitoring unit sequences the operation parameters according to the time sequence and presents the operation parameters in a report form.
As a further improvement of the above technical solution, the method further comprises: the remote monitoring unit sequences the operation parameters collected in the production process according to the product numbers and presents the operation parameters in a report form.
While the present invention has been described in considerable detail and with particular reference to a few illustrative embodiments thereof, it is not intended to be limited to any such details or embodiments or any particular embodiments, but rather it is to be construed that the invention effectively covers the intended scope of the invention by virtue of the prior art providing a broad interpretation of such claims in view of the appended claims. Furthermore, the foregoing describes the invention in terms of embodiments foreseen by the inventor for which an enabling description was available, notwithstanding that insubstantial modifications of the invention, not presently foreseen, may nonetheless represent equivalent modifications thereto.
Claims (9)
1. A visual monitoring system for anchor chain production conditions, the system comprising: the system comprises a data acquisition unit, a field industrial control unit and a remote monitoring unit, wherein the field industrial control unit is respectively in communication connection with the data acquisition unit and the remote monitoring unit;
the production area comprises a heat treatment area, a welding area and a tension test area, and the production process comprises a heat treatment process carried out in the heat treatment area, a welding process carried out in the welding area and a tension test process carried out in the tension test area;
the field industrial control unit comprises a touch screen, a PLC and a communication module, the touch screen, the PLC and the communication module are sequentially connected, and the communication module is also in communication connection with the remote monitoring unit;
the PLC is used for acquiring the operation parameters acquired by the data acquisition unit;
the touch screen is used for receiving control parameters set by a user and displaying the control parameters set by the user and the operation parameters acquired by the data acquisition unit in real time, the control parameters comprise product numbers and interval ranges of the operation parameters, and the control parameters are preset before production;
the communication module is used for reporting the control parameters and the operation parameters to a remote monitoring unit;
and the remote monitoring unit is used for receiving and displaying the control parameters and the operation parameters reported by the field industrial control unit in real time.
2. The visual monitoring system for the production condition of the anchor chain according to claim 1, wherein:
the heat treatment zone comprises a quenching zone and a tempering zone, and the heat treatment process comprises a quenching process and a tempering process;
the PLC is including setting up in the first PLC in quenching district and setting up in the second PLC in tempering district, first PLC is used for obtaining the operating parameter of quenching process, the operating parameter of quenching process includes: quenching zone temperature, quenching sprocket frequency converter frequency and quenching furnace pressure;
the second PLC is used for obtaining the operation parameters of the tempering process, and the operation parameters of the tempering process comprise: tempering area temperature, cooling water temperature, tempering sprocket frequency converter frequency and tempering furnace pressure;
the first PLC is in communication connection with the second PLC through an RS485 interface, and the first PLC is connected with the communication module.
3. A visual monitoring system for the production of an anchor chain according to claim 2, wherein: the PLC further comprises a third PLC arranged in the heat treatment area, the third PLC is used for obtaining operation parameters of the welding process, and the operation parameters of the welding process comprise: welding current, welding voltage, top chain pressure, jaw pressure, upsetting pressure and upsetting distance; and the first PLC is in communication connection with the third PLC through an RS485 interface.
4. The visual monitoring system for the production condition of the anchor chain according to claim 2, wherein the PLC includes a fourth PLC disposed in the tension test area, the fourth PLC is configured to obtain the operation parameters of the tension test process, and the operation parameters of the tension test process include: tension load and hoop deflection; and the first PLC is in communication connection with the fourth PLC through an RS485 interface.
5. The visual monitoring system for the production condition of the anchor chain as claimed in claim 1, wherein the on-site industrial control unit further comprises a memory connected with the PLC, and the memory is used for storing the control parameters set by the user and the operation parameters collected by the data collection unit.
6. A visual monitoring method for the production condition of an anchor chain, which is applied to the visual monitoring system for the production condition of the anchor chain according to any one of claims 1 to 5, and which comprises:
the production process comprises a heat treatment process carried out in the heat treatment area, a welding process carried out in the welding area and a tension testing process carried out in the tension testing area;
the PLC acquires the operation parameters acquired by the data acquisition unit;
the method comprises the steps that a touch screen receives control parameters set by a user, the control parameters set by the user and operation parameters collected by a data collection unit are displayed in real time, the control parameters comprise product numbers and interval ranges of the operation parameters, and the control parameters are preset before production;
the communication module reports the control parameters and the operation parameters to a remote monitoring unit;
and the remote monitoring unit receives and displays the control parameters and the operation parameters reported by the field industrial control unit in real time.
7. The visual monitoring method for the production condition of the anchor chain according to claim 6, further comprising:
and when the operation parameters exceed the range of the interval, the remote monitoring unit displays the operation parameters exceeding the range of the interval and the production area where the operation parameters are located.
8. The visual monitoring method for the production condition of the anchor chain according to claim 6, further comprising:
and the remote monitoring unit sequences the operation parameters according to the time sequence and presents the operation parameters in a report form.
9. The visual monitoring method for the production condition of the anchor chain according to claim 6, further comprising:
the remote monitoring unit sequences the operation parameters collected in the production process according to the product numbers and presents the operation parameters in a report form.
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| CN209543126U (en) * | 2019-01-23 | 2019-10-25 | 上海金纬管道设备制造有限公司 | A kind of glass fibre MULTILAYER COMPOSITE reinforced pipe production control system |
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