CN115202304B - Material frame tracking method in forging production process - Google Patents

Material frame tracking method in forging production process Download PDF

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CN115202304B
CN115202304B CN202210850389.3A CN202210850389A CN115202304B CN 115202304 B CN115202304 B CN 115202304B CN 202210850389 A CN202210850389 A CN 202210850389A CN 115202304 B CN115202304 B CN 115202304B
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data
material frame
forgings
forging
workshop
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CN115202304A (en
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郑大定
张上
汪锋
雷星宇
张军
杨佩瑶
冉秀康
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Hubei Tri Ring Forging Co Ltd
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Hubei Tri Ring Forging Co Ltd
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    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/418Total 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]
    • G05B19/4185Total 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 the network communication
    • G05B19/4186Total 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 the network communication by protocol, e.g. MAP, TOP
    • GPHYSICS
    • G01MEASURING; TESTING
    • G01GWEIGHING
    • G01G19/00Weighing apparatus or methods adapted for special purposes not provided for in the preceding groups
    • G01G19/52Weighing apparatus combined with other objects, e.g. furniture
    • GPHYSICS
    • G05CONTROLLING; REGULATING
    • G05BCONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00Programme-control systems
    • G05B19/02Programme-control systems electric
    • G05B19/418Total 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]
    • G05B19/41875Total 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 quality surveillance of production
    • GPHYSICS
    • G06COMPUTING; CALCULATING OR COUNTING
    • G06KGRAPHICAL DATA READING; PRESENTATION OF DATA; RECORD CARRIERS; HANDLING RECORD CARRIERS
    • G06K7/00Methods or arrangements for sensing record carriers, e.g. for reading patterns
    • G06K7/10Methods or arrangements for sensing record carriers, e.g. for reading patterns by electromagnetic radiation, e.g. optical sensing; by corpuscular radiation
    • G06K7/10544Methods or arrangements for sensing record carriers, e.g. for reading patterns by electromagnetic radiation, e.g. optical sensing; by corpuscular radiation by scanning of the records by radiation in the optical part of the electromagnetic spectrum
    • G06K7/10821Methods or arrangements for sensing record carriers, e.g. for reading patterns by electromagnetic radiation, e.g. optical sensing; by corpuscular radiation by scanning of the records by radiation in the optical part of the electromagnetic spectrum further details of bar or optical code scanning devices

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Abstract

The invention provides a material frame tracking method in the forging production process, wherein a node monitoring module, a metal bar code of a material frame, a data storage module and an application terminal are in contact with a network server, the network server receives a work order containing product name, yield and batch number information issued by the application terminal of a manager, the network server also receives data transmitted by the node monitoring module, records forging information provided by each workshop in a database and provides access for the application terminal; the material frame tracking management is realized, and the problems that the traditional manufacturing process adopts manual management and operation, and the material circulation process is black are solved. The invention realizes effective dispatching of forgings and material frames, improves the tracking management efficiency of workshops and reduces the production cost.

Description

Material frame tracking method in forging production process
Technical Field
The invention belongs to the field of forging production and manufacturing, and particularly relates to a material frame tracking method in a production process.
Background
The forge piece is widely applied to strategic industrial equipment such as power industry, metallurgical industry, ship industry, military industry, heavy mining machinery, aerospace and the like. The production and manufacture of the forgings reflect the industrial level of a country to a certain extent, and have important significance for the development and construction of the country. However, many existing forging production lines are manually regulated and controlled, material frames are tracked and managed manually, operators repeatedly and repeatedly perform heavy physical labor for a long time, fatigue is easily generated, and the states and information of the forgings and the material frames in the conveying process cannot be obtained in real time, so that lean management and control of the whole production process are directly affected.
The problems of low material frame tracking efficiency, incomplete manufacturing information, incapability of storing and forming complete files of batches, excessive low material frame transfer speed, large backlog of products and the like caused by the black box in the material circulation process greatly reduce the production efficiency and the product quality of the forgings. When the traditional material frame tracking management method carries out forging transportation, the forging can be lost in the transportation process, even serious safety accidents are caused, and the reliability is low.
Therefore, it would be necessary to provide a method of tracking and managing material frames during forging production.
Disclosure of Invention
In order to improve the problems of low production efficiency and low product quality of the forging, the invention provides a material frame tracking method in the forging production process, which realizes effective tracking of the material frame, improves the tracking management efficiency of the forging, and ensures the accuracy and the instantaneity of the material frame tracking process.
The technical scheme of the invention is as follows: the network server receives work orders containing product name, yield and batch number information issued by application terminals of management staff, also receives data transmitted by the node monitoring module, records the information of the forgings provided by each workshop in a database, and provides the information for the application terminals to access;
each workshop arranged according to the processing flow of the forging piece is provided with a node monitoring module, and the node monitoring module comprises an electronic scale, two code scanners for monitoring nodes of the material frames and networking control equipment; the two material frame monitoring nodes of each workshop are a material frame monitoring node No. 1 and a material frame monitoring node No. 2, a code scanner of each material frame monitoring node scans a metal bar code installed on a material frame to obtain material frame information, the material frame monitoring node No. 1 is an entering node, the material frame monitoring node No. 2 is an exiting node, and an electronic scale arranged at a discharge hole of each workshop obtains weighing data; the networking control equipment uses STM32F103 core board as core control module, can acquire real-time data that the electronic scale weighed and display on the display screen to pass through HTTP protocol and transmit it to the network server, the network server calculates the quantity of this discharge gate forging according to the singleness of forging and current weighing data again, and the data that pass through and calculate will be stored in the database together with forging, networking control equipment information, the current workshop information of material frame, scheduling time and singleness information, so that the later-stage material management of mill.
The device networking part of the networking control device adopts an ESP8266 (namely a WIFI chip) as a wireless communication module, and realizes the data communication between the STM32F103 core board and the ESP8266 through a serial port; the wireless communication module is externally connected with an antenna rod, and an AT instruction is adopted to realize a wireless communication function; when networking is performed for the first time, performing wireless communication module connection test and networking mode configuration; if the network is disconnected, the wireless communication module automatically connects the wireless network and acquires the connection of the network server according to the route configured last time.
The networking control equipment strengthens signal recognition sensitivity through the mode of the external antenna of wireless communication module, ensures the wiFi signal strength of operation in-process, and external antenna stick work frequency band contains wiFi frequency channel, can satisfy equipment wiFi communication requirement.
When the wireless communication module is connected with a power supply, the power supply indicator lamp is lightened, and the power supply indicator lamp is kept in a lightened state during the working period of the wireless communication module; when the wireless communication module is successfully connected to the network and the server, the networking indicator lamp flashes twice and the buzzer sounds to prompt that the wireless communication module is successfully connected, and the networking indicator lamp always keeps a lighting state in a network connected state; the wireless communication module is used for controlling whether the weighing data is uploaded or not through a key, and when the start key is pressed to indicate that the data uploading is started, the end key is pressed to indicate that the data uploading is stopped; the OLED display screen of the wireless communication module can display basic information of the wireless communication module, current time and networking state of the wireless communication module, and the display screen can refresh the weighing of the electronic scale every 0.5s, so that real-time performance of data display is ensured.
The metal bar codes used for marking the material frame are arranged on 4 side faces of the material frame, the 4 metal bar codes are all the same in size, the codes are the same, and the scanning identification is realized.
When the measured data measured by a gravity sensor on the electronic scale changes and the data received by a data input interface of the electronic scale fluctuates, the total weight of a material frame can be measured after the data is stably kept for a period of time, the obtained data is packed, the data is uploaded to an EMQX MQTT message proxy of a network server through a wireless communication module and stored in a database, the data is published to a theme corresponding to the node monitoring module based on the MQTT protocol of TCP, the weighing data can be obtained by subscribing the theme by the network server, so that the tracking of the discharge condition of a discharge port is realized, and the network server calculates the number of forgings of the discharge port according to the obtained weighing data;
when the measured data measured by the gravity sensor on the electronic scale is unchanged, the data can not be continuously uploaded.
When the electronic scale data input interface continuously receives N frames of the same data, the data received by the electronic scale input interface can be stably maintained after being judged to be fluctuated, and N=10 is adopted to upload the data;
when the input interface of the electronic scale continuously receives N+n frames of the same data, the data are not uploaded, wherein N is any positive integer; so each time of data uploading, the condition that 10 frames of the same data are continuously accepted after the data change exists; the data uploaded each time are data after being weighed and stabilized for more than 10 frames, which means that the weight of the forging is kept at the current stable value at the moment, namely, the state of the forging in the forging frame is unchanged, no new forging is added or the number of the forging is reduced, so that the data are not uploaded. The 10 frames are determined by the stabilizing time of part of electronic scales on the market, and the data collected by the electronic scales are kept unchanged for 1s to judge that weighing is stabilized at the moment. The lowest baud rate of serial data transmission of the electronic scale sensor connected with the MCU can be set to 1200, 120 bytes, namely 10 data frames, can be continuously transmitted every second, a current weighing result can be output every 0.1s, so that the data acquisition is more intensive, the uploading is a result which can be continuously stabilized for a plurality of frames and is not a process quantity, and the final effect of data acquisition is not affected by occasionally deleting one frame of data with byte errors.
Each frame of data of the electronic scale data input interface consists of 12 bytes, wherein the 1 st byte is a start bit, the 2 nd byte is a sign bit, the 3 rd to 8 th bytes are weighing data bits, the 9 th byte is a decimal point number, the 10 th to 11 th bytes are exclusive-or check bits, and the 12 th byte is an end bit.
The application terminal is a handheld industrial PDA, is provided with a camera, a touch screen, a keyboard and a wifi module, an Android operating system is operated in the handheld industrial PDA, a material frame tracking APP is operated in the Android operating system, the material frame tracking APP scans a metal bar code on a material frame through the camera to obtain the bar code number, a network access network server is used for inquiring records corresponding to the bar code number and displaying relevant information of the material frame in the material frame tracking APP, the information of the material frame in the network server is bound with current monitoring nodes or production information through an operation interface of the material frame tracking APP, and the information is updated in the network server for storage, wherein the storage information comprises material frame state change, and the number and model information of built-in forgings; when the number and the model of the forgings in the material frame are changed, information is modified in an operation interface provided by the material frame tracking APP, and the information is updated to the network server through the wifi module.
The network server receives work orders containing product name, yield and batch number information issued by the application terminals of management staff, also receives data transmitted by the node monitoring module, records forging information provided by each workshop in a database, and provides the forging information for the application terminals to access;
each workshop arranged according to the processing flow of the forging is provided with a node monitoring module, and the node monitoring module comprises an electronic scale, two material frame monitoring nodes and networking control equipment; the two material frame monitoring nodes of each workshop are a material frame monitoring node No. 1 and a material frame monitoring node No. 2, a code scanner of each material frame monitoring node scans a metal bar code installed on a material frame to obtain material frame information, the material frame monitoring node No. 1 is an entering node, the material frame monitoring node No. 2 is an exiting node, and an electronic scale arranged at a discharge hole of each workshop obtains weighing data; the networking control equipment uses STM32F103 core board as core control module, can acquire real-time data that the electronic scale weighed and display on the display screen to pass through HTTP protocol and transmit it to the network server, the network server calculates the quantity of this discharge gate forging according to the singleness of forging and current weighing data again, and the data that pass through and calculate will be stored in the database together with forging, networking control equipment information, the current workshop information of material frame, scheduling time and singleness information, so that the later-stage material management of mill.
The device networking part of the networking control device adopts an ESP8266 (namely a WIFI chip) as a wireless communication module, and realizes the data communication between the STM32F103 core board and the ESP8266 through a serial port; the wireless communication module is externally connected with an antenna rod, and an AT instruction is adopted to realize a wireless communication function; when networking is performed for the first time, performing wireless communication module connection test and networking mode configuration; if the network is disconnected, the wireless communication module automatically connects the wireless network and acquires the connection of the network server according to the route configured last time.
The networking control equipment strengthens signal recognition sensitivity through the mode of the external antenna of wireless communication module, ensures the wiFi signal strength of operation in-process, and external antenna stick work frequency band contains wiFi frequency channel, can satisfy equipment wiFi communication requirement.
When the wireless communication module is connected with a power supply, the power supply indicator lamp is lightened, and the power supply indicator lamp is kept in a lightened state during the working period of the wireless communication module; when the wireless communication module is successfully connected to the network and the server, the networking indicator lamp flashes twice and the buzzer sounds to prompt that the wireless communication module is successfully connected, and the networking indicator lamp always keeps a lighting state in a network connected state; the wireless communication module is used for controlling whether the weighing data is uploaded or not through a key, and when the start key is pressed to indicate that the data uploading is started, the end key is pressed to indicate that the data uploading is stopped; the OLED display screen of the wireless communication module can display basic information of the wireless communication module, current time and networking state of the wireless communication module, and the display screen can refresh the weighing of the electronic scale every 0.5s, so that real-time performance of data display is ensured.
The metal bar codes used for marking the material frame are arranged on 4 side faces of the material frame, the 4 metal bar codes are all the same in size, the codes are the same, and the scanning identification is realized.
When the measured data measured by a gravity sensor on the electronic scale changes and the data received by a data input interface of the electronic scale fluctuates, the total weight of a material frame can be measured after the measured data is stably kept for a period of time, the obtained data is packaged, the obtained data is uploaded to an EMQX MQTT message proxy of a network server through a wireless communication module (ESP 8266 WIFI module) and stored in a database, the data is issued to a theme corresponding to the node monitoring module based on the MQTT protocol of TCP, the network server subscribes the theme, the weighing data can be obtained, the tracking of the discharging condition of a discharging port is realized, and the network server calculates the forging number of the discharging port according to the obtained weighing data;
when the measured data measured by the gravity sensor on the electronic scale is unchanged, the data can not be continuously uploaded.
When the electronic scale data input interface continuously receives N frames of the same data, the data received by the electronic scale input interface can be stably maintained after being judged to be fluctuated, and N=10 is adopted to upload the data;
when the input interface of the electronic scale continuously receives N+n frames of the same data, the data are not uploaded, wherein N is any positive integer; so each time of data uploading, the condition that 10 frames of the same data are continuously accepted after the data change exists;
the data uploaded each time are data after being weighed and stabilized for more than 10 frames, which means that the weight of the forging is kept at the current stable value at the moment, namely, the state of the forging in the forging frame is unchanged, no new forging is added or the number of the forging is reduced, so that the data are not uploaded. The 10 frames are determined by the stabilizing time of part of electronic scales on the market, and the data collected by the electronic scales are kept unchanged for 1s to judge that weighing is stabilized at the moment. The lowest baud rate of serial data transmission of the electronic scale sensor connected with the MCU can be set to 1200, 120 bytes, namely 10 data frames, can be continuously transmitted every second, a current weighing result can be output every 0.1s, so that the data acquisition is more intensive, the uploading is a result which can be continuously stabilized for a plurality of frames and is not a process quantity, and the final effect of data acquisition is not affected by occasionally deleting one frame of data with byte errors.
Each frame of data of the electronic scale data input interface consists of 12 bytes, wherein the 1 st byte is a start bit, the 2 nd byte is a sign bit, the 3 rd to 8 th bytes are weighing data bits, the 9 th byte is a decimal point number, the 10 th to 11 th bytes are exclusive-or check bits, and the 12 th byte is an end bit.
The application terminal is a handheld industrial PDA, is provided with a camera, a touch screen, a keyboard and a wifi module, an Android operating system is operated in the handheld industrial PDA, a material frame tracking APP is operated in the Android operating system, the material frame tracking APP scans a metal bar code on a material frame through the camera to obtain the bar code number, records corresponding to the material frame number are queried through a network access server and related information of the material frame in the material frame tracking APP is displayed, and the information of the material frame in the network server can be bound with current monitoring nodes or production information through an operation interface of the material frame tracking APP and updated into the network server for storage, wherein the information comprises material frame state change, and the quantity and model information of built-in forgings; when the quantity and the model of the forgings in the material frame are changed, information can be modified in an interface provided by the APP and updated to the network server through the wifi module.
The method is based on the existing forging production line, and combines field equipment, and material frame tracking management is realized in the production and manufacturing process of the forgings by utilizing a node monitoring module, a material frame marking module, a data storage module and an application terminal. In the intelligent material frame tracking management method, network connection is established with a network server to realize material frame tracking management, the problems of manual management and operation adopted in the traditional manufacturing process, black boxes in the material circulation process and the like are solved, and the accuracy and the instantaneity of the material frame tracking process are ensured by the method provided by the invention, and the method has the advantages of simplicity in implementation, lower cost and the like.
The node monitoring module comprises a No. 1 material frame monitoring node, a No. 2 material frame monitoring node scanner and an electronic scale which are arranged in each workshop; the electronic scales of each workshop are provided with gravity sensors and vibration sensors; the node monitoring module is connected with the networking control equipment, and the networking control equipment is used for connecting the forging piece frame falling times and the total weight data of the material frames, which are obtained by the vibration sensor and the gravity sensor in the electronic scale, with the network server and uploading the number and the total weight of the forging pieces falling into the material frames.
The material frame marking module comprises a metal bar code. The metal bar codes are used for marking the material frame, the metal bar codes are arranged on 4 side faces of the material frame, the 4 metal bar codes are the same in size and the same in code, and the scanning identification is realized.
The networking control equipment uses an STM32F103 core board (also called STM32F103 singlechip and STM32F103 development board) as a core control module, can acquire real-time data weighed by the electronic scale, display the real-time data on a display screen, and transmit the real-time data to a network server through an HTTP protocol, and the server calculates the number of the forgings at the discharge port according to the singleton of the forgings and the current weighing data. The networking control device is simply referred to as a device. The measured data is stored in a factory production information base (namely a database) together with time and equipment information so as to facilitate the management of materials in the later stage of the factory. When the equipment is connected with a power supply, the power supply indicator lamp is lightened, and the lightening state is kept during the working period of the equipment; when the equipment is successfully connected to the network and the server, the networking indicator lamp flashes twice and the buzzer sounds to prompt that the equipment is successfully connected, and the networking indicator lamp always keeps a lighting state in a network connected state; the device needs to control whether the weighing data is uploaded or not through a key, and when the start key is pressed to indicate that the data uploading starts, the end key is pressed to indicate that the data uploading is stopped. The OLED display screen of the device can display basic information of the device, current time and networking state of the device, and the display screen can refresh the weighing of the electronic scale every 0.5s, so that real-time performance of data display is ensured.
And the device networking part of the networking control device adopts an ESP8266 (namely a WIFI chip) as a WiFi module (namely a wireless communication module), and realizes data communication between the STM32F103 development board and the ESP8266 through a serial port. The WiFi module is externally connected with an antenna rod, and the wireless communication function is realized by adopting an AT instruction. When networking is performed for the first time, module connection test and networking mode configuration are required; if the network is disconnected later, the WiFi module automatically connects the wireless network and acquires the connection of the server according to the route configured last time. In order to ensure the WiFi signal strength in the operation process, the equipment strengthens the signal identification sensitivity in a mode of externally connecting an antenna through a WiFi module. The work frequency band of the external antenna rod comprises a WiFi frequency band, and the WiFi communication requirement of equipment can be met.
Each workshop is provided with two material frame monitoring nodes, transmits data to the data storage module and provides access for the application terminal.
The data storage module contains a database software. The database software is used for creating an identification database and storing binding information of the material frame, the forging and the workshop in the forging production and manufacturing process. The network server can receive the work orders containing the product name, yield and batch number information issued by the application terminal PDA of the manager, can also receive the data transmitted by the material frame node monitoring module, records the forge piece information provided by each workshop in the database, and provides the forge piece information for the application terminal to access.
Drawings
FIG. 1 is a simplified flow chart of a forging production process;
FIG. 2 is a structural explanatory diagram of the present invention;
FIG. 3 is a schematic diagram of a networked control device;
FIG. 4 is a schematic diagram of a networked control device;
fig. 5 is a data parsing flow diagram of a networked control device.
Detailed Description
In fig. 1-4, with STM32F103 core board as core control module, a networking control device (abbreviated as device) is designed, the device can obtain real-time data weighed by the electronic scale, display on the OLED display screen, and transmit the real-time data to the network server through WiFi, and the network server calculates the number of the forgings at the discharge port according to the single weight of the forgings and the current weighing data. The measured historical data is stored in a factory production information base together with time and equipment information so as to facilitate factory production management. When the equipment is connected with a power supply, the power supply indicator lamp is lightened, and the lightening state is kept during the working period of the equipment; when the equipment is successfully connected to the network and the network server, the networking indicator lamp flashes twice, the buzzer sends out prompt sound to prompt that the equipment is successfully connected, and the networking indicator lamp always keeps a lighting state in a network connected state; the device needs to control whether the weighing data is uploaded or not through a key, when the start key is pressed to indicate that the weighing data is ready to be uploaded, and when the end key is pressed to indicate that the weighing data is stopped to be uploaded.
The networking control equipment adopts low-voltage power supply, and the power supply voltage range is as follows: 2V-3.6V, and the highest working voltage is 3.6V. When 220V alternating current is connected, voltage modulation is needed through a converter by adopting a micro USB power interface.
And the electronic scale data acquisition part adopts serial port communication, the STM32F103 core board is connected with an RS232 interface of the electronic scale through the serial port, receives uninterrupted data frames from the electronic scale, immediately analyzes the data frames, and extracts the weight data of the forging currently weighed by the electronic scale according to the structure of the data frames. After the data fluctuation, if the development board acquires 10 identical data frames and the current equipment is in a data uploading state, the weighing data, the time and the equipment information are uploaded to a network server through the WiFi module.
And in the device networking part, the ESP8266 is adopted as a WiFi module, and data communication between the STM32F103 development board and the ESP8266 is realized through a serial port. ESP8266 WiFi module external antenna stick adopts the AT instruction to realize wireless communication function. When networking is performed for the first time, module connection test and networking mode configuration are required; if the network is disconnected later, the WiFi module automatically connects the wireless network according to the route configured last time and acquires the connection of the network server.
A state indicating part, wherein the power supply indicating lamp is continuously lightened after the equipment is electrified; the networking indicator lamp flashes when the network state of the equipment changes and continuously lights in the networking state; the buzzer prompts when the network connection state changes, and the beeping sound is also used as the prompting sound of the key state change.
The appearance diagram of the networking control equipment is shown in fig. 4, a PCB (printed circuit board) which takes STM32F103 as a core and controls peripheral functions is arranged in the equipment packaging box, a micro USB power interface and an electronic scale RS232 interface are connected onto the PCB, and meanwhile, a data uploading and uploading ending button, a power supply and a network state indicator lamp are led out. When a data uploading key is pressed, the device starts to transmit the data from the current acquisition to the cloud server; when the upload end key is pressed, the data upload is immediately ended. The power indicator lamp keeps a lighting state when the equipment is electrified; the network state indicator lights flash for a moment when the network state of the equipment changes, continuously light up when the network is normally connected, and keep off when no network is connected. The connected OLED display screen can display basic information of equipment, current time and networking state of the equipment, and the display screen can refresh the weighing of the electronic scale every 0.5s, so that real-time performance of data display is ensured. The STM32F103 core development board comprises three communication serial ports, namely USART1, USART2 and USART3, wherein the USART1 is used as a debugging information output interface, the USART2 is used as a WiFi module communication interface, and the USART3 is used as an electronic scale data input interface.
In order to ensure the WiFi signal strength in the operation process, the device enhances the signal identification sensitivity in a mode of externally connecting an antenna with an ESP8266 WiFi module. The work frequency band of the external antenna rod comprises a WiFi frequency band, and the WiFi communication requirement of equipment can be met.
The baud rate of the USART3 interface of the wireless communication module is matched with the output baud rate of the electronic scale sensor, and the baud rate is set to 2400, 8-bit data bits and 1-bit stop bit. The serial communication of the electronic scale uses a continuous mode 4, wherein each frame of the communication mode comprises 12 bytes, and the specific rules are as follows:
the data transmitted was the current weight (gross weight) data (weight value at overload 999999) displayed by the meter. Each frame of data consists of 12 sets of data. The format is shown in the following table: (exclusive or=2, 3, … …, 9)
Figure BDA0003753239420000081
Continuously detecting the data receiving condition of the USART3, if any byte of one frame of data is not in accordance with the requirement, re-detecting the first byte received later, and directly discarding the byte data with errors.
When the data received by the serial port can be stably maintained (10 frames of the same data are continuously received) after fluctuation, the data can be uploaded to a network server, namely, the data is released to a theme corresponding to the electronic scale, if the data is still maintained unchanged later, the data can not be continuously uploaded, and therefore, each time of data uploading, the situation that 10 frames of the same data are continuously received after the data change exists.
FIG. 5 is a flow chart of data parsing for a serial port, each frame of data containing 12 bytes, accepting data and updating the serial port state by a switch-case statement. When the serial port state is set to 0, the analysis is started when the received byte is 0x02, otherwise, the starting byte is continued to be waited. If the start byte is 0x02, the serial port state is set to 1, the data of the sign bit is received, the sign is positive when the received data byte of the sign bit is 0x2B, and the sign is negative when the received data byte of the sign bit is 0x 2D. When the data of the sign bit is neither 0x2B nor 0x2D, judging that the data is not satisfactory, setting the serial port state to 0, and restarting to detect the start byte. If the bit of the symbol data is correct, the serial port state is set to 2, weighing data is received, and the weighing data consists of 6 bytes. Only the weighing data is within 0x 30-0 x39 and is limited data for 6 bytes, when the weighing data is not satisfactory, the serial port state is set to 0, and the detection of the starting byte is restarted. And if the weighing data is correct, the serial port state is positioned at 3, and decimal point position data is received. Only the decimal point data is limited data within 0x 30-0 x34, when the decimal point data does not meet the requirements, the serial port state is set to 0, and the detection of the starting byte is restarted. If the weighing data is correct, the serial port state is set to 4, and the high 4-bit check data is received. When the high 4-bit check data is incorrect, the serial port state is set to 0, and the detection of the start byte is restarted. If the high 4-bit check data is correct, the serial port state is set to be 5, and the low 4-bit check data is received. When the low 4-bit check data is incorrect, the serial port state is set to 0, and the detection of the start byte is restarted. If the low 4-bit check data is correct, the serial port state is set to 6, and the end data is received. When the end data byte is not 0x03, the serial port state is set to 0, and the detection of the start byte is restarted. If the received byte is 0x03, extracting the valid data of the frame and analyzing. After extracting one frame of effective data, the serial port state is set to 0 to receive the data of the next frame, and a complete serial port data analysis flow is formed.
Taking a forging workshop arranged in a forging processing flow as an example, the material frame tracking method in the forging production process is described:
the raw materials are firstly sent to a forging workshop for processing, after the forging is completed, a task that the batch of forgings are generated and transferred to a heat treatment workshop is carried out, binding information of the forgings and the forging workshop is generated, and scheduling time and single number information are recorded. The transfer transportation task comprises the total number and the weight of single forgings, the batch number of the forgings, whether the single forgings are large, a transportation starting point and a transportation end point, when the network server receives the transfer transportation task of the forging workshop, the network server generates a transportation instruction aiming at the transfer transportation task, gives priority to the transportation instruction, obtains a metal bar code in an idle state according to the transportation instruction, and compares the transportation task with the load capacity limit of a material frame in the idle state of the workshop.
When the total weight of single batch forgings in the forging workshop is larger than the load capacity limit of the material frame in the idle state of the workshop, the transportation efficiency of the batch forgings is reduced, and at the moment, the network server can send a transportation instruction to other workshops and select the material frames in the idle state of the other workshops. The network server selects the idle material frames of other workshops to be transferred to the forging workshop nearby according to the priority of the carrying instruction, and selects the heat treatment workshop with the shortest path from the forging workshop to be transferred as far as possible.
The total weight and the quantity of the forgings in different batches are inconsistent, and the types of the forgings are different, so that the load capacity limits of the material frames in different models are also inconsistent. When a single batch of forgings are large forgings, the network server generates a carrying instruction aiming at a large forgings transferring and transporting task, gives priority to the carrying instruction, acquires a large metal bar code in an idle state according to the carrying instruction, and compares the large material frame carrying capacity limit in the idle state of the workshop. When the weight of the single batch of large forgings is larger than the load capacity limit of the large material frames in the idle state of the workshop, the network server sends a carrying instruction to other workshops at the moment, and the carrying instruction is selected from the large material frames in the idle state of the other workshops. The network server can reasonably distribute the material frames according to the carrying instructions with different priorities, and the large material frames in the nearby workshops are preferentially selected for transferring.
When idle state material frames of other workshops are transferred to the forging workshop, the total weight of the forgings is equal to or smaller than the load capacity limit of the material frames in the idle state of the current workshop, the material frames are scanned at a No. 1 material frame monitoring node of the forging workshop to upload a network server, the network server uploads new identification items of a database, material frame binding forging workshop information is written, and scheduling time and single number information are recorded.
The material frame receives the forging through the conveyer belt to the assembly line, uninterrupted time falls into the forging on the assembly line, the vibration sensor of the electronic scale calculates the number of the forging at the discharge port according to the single weight of the forging and the current weighing data, and judges whether the weight is within the reasonable weight range of a single forging, if yes, the weight sensor on the electronic scale calculates the number of the newly-increased forging, the weight sensor on the electronic scale judges whether the material frame is filled into the newly-increased forging through the continuously-increased weight, the networking control equipment connects the number of times of the falling frames of the forging and the total weight data of the material frame obtained by the vibration sensor and the weight sensor in the electronic scale with the network server, the network server calculates the number of the forging at the discharge port according to the single weight of the forging and the current weighing data, and records the scheduled time and the single number information of the forging, and the node monitoring module information are bound to the forging, and the forging workshop information.
After one batch of forgings in the forging workshop are framed, the forgings reach No. 2 material frame monitoring nodes through the conveyor belt, the forgings are turned out of the forging workshop through the No. 2 material frame monitoring nodes and are sent to the next workshop for next round of processing. And uploading a database modification identification entry by the network server, erasing material frame binding forging workshop information, reserving binding records of the batch of forgings and the forging workshops, and waiting for the network server to issue a processing task instruction for transferring the batch of forgings to the next workshop.

Claims (8)

1. A material frame tracking method in the forging production process is characterized in that:
the network server receives work orders containing product name, yield and batch number information issued by the application terminals of management staff, also receives data transmitted by the node monitoring module, records forging information provided by each workshop in a database, and provides the forging information for the application terminals to access;
each workshop arranged according to the processing flow of the forging piece is provided with a node monitoring module, and the node monitoring module comprises an electronic scale, two code scanners for monitoring nodes of the material frames and networking control equipment; the two material frame monitoring nodes of each workshop are a material frame monitoring node No. 1 and a material frame monitoring node No. 2, a code scanner of each material frame monitoring node scans a metal bar code installed on a material frame to obtain material frame information, the material frame monitoring node No. 1 is an entering node, the material frame monitoring node No. 2 is an exiting node, and an electronic scale arranged at a discharge hole of each workshop obtains weighing data; the networking control equipment takes an STM32F103 core board as a core control module, can acquire real-time data weighed by the electronic scale, displays the real-time data on a display screen, transmits the real-time data to a network server through an HTTP protocol, calculates the number of the forgings at the discharge port according to the singleness of the forgings and the current weighing data, and stores the calculated data together with the forgings, networking control equipment information, current workshop information of a material frame, scheduling time and singleness information into a database so as to facilitate later material management of a factory;
the raw materials are firstly sent to a forging workshop for processing, a task that the batch of forgings are generated after the forging is completed and transferred to a heat treatment workshop, binding information of the forgings and the forging workshop is generated, and scheduling time and single number information are recorded; the transfer transportation task comprises the total number and the weight of single forgings, the batch number of the forgings, whether the single forgings are large, a transportation starting point and a transportation end point, when the network server receives the transfer transportation task of the forging workshop, the network server generates a transportation instruction aiming at the transfer transportation task, gives priority to the transportation instruction, acquires a metal bar code in an idle state according to the transportation instruction, and compares the transportation task with the load capacity allowance of a material frame in the idle state of the workshop;
when the total weight of a single batch of forgings in the forging workshop is larger than the load capacity limit of a material frame in an idle state of the workshop, the transportation efficiency of the batch of forgings is reduced, and at the moment, a network server sends a transportation instruction to other workshops and selects the material frames in the idle state of the other workshops; the network server selects idle state material frames of other workshops nearby according to the priority of the carrying instruction and transfers the idle state material frames to the forging workshop, and selects a heat treatment workshop with the shortest path from the forging workshop to transfer as much as possible;
the total weight and the number of the forgings in different batches are inconsistent, and the types of the forgings are different, so that the load capacity limits of the material frames in different types are also inconsistent; when a single batch of forgings are large forgings, the network server generates a carrying instruction aiming at a large forgings transferring and transporting task, gives priority to the carrying instruction, acquires a large metal bar code in an idle state according to the carrying instruction, and compares the large material frame carrying capacity limit in the idle state of the workshop; when the weight of the single batch of large forgings is larger than the load capacity limit of the large material frames in the idle state of the workshop, the network server sends a carrying instruction to other workshops at the moment, and the carrying instruction is selected from the large material frames in the idle state of the other workshops; the network server reasonably distributes the material frames according to the carrying instructions with different priorities, and preferentially selects the transfer of the large material frames of nearby workshops;
when the idle state material frames of other workshops are transferred to the forging workshop, the total weight of the forgings is equal to or smaller than the load capacity limit of the material frames in the idle state of the current workshop, the material frames are scanned at a No. 1 material frame monitoring node of the forging workshop to upload a network server, the network server uploads a new identification entry of a database, the material frames are written in to bind the forging workshop information, and the scheduled time and single number information are recorded;
the material frame receives the forgings through the conveyor belt to the assembly line, uninterrupted time on the assembly line falls into the forgings, the vibration sensor of the electronic scale calculates the number of forgings at the discharge port according to the single weight of the forgings and the current weighing data, and judges whether the weight is within the reasonable weight range of a single forgings, if yes, the number of the newly-added forgings is counted, the weight sensor on the electronic scale judges whether the material frame is filled with the newly-added forgings or not through the continuously-increased weight, the networking control equipment connects the times of the falling of the forgings and the total weight data of the material frame obtained by the vibration sensor and the weight sensor in the electronic scale with the network server, the network server calculates the number of the forgings at the discharge port according to the single weight of the forgings and the current weighing data, and the calculated historical data and node monitoring module information are bound with the forgings, the material frame and workshop information, and the scheduled time and the single number information are recorded;
after one batch of forgings in the forging workshop are framed, the forgings reach a No. 2 material frame monitoring node through a conveyor belt, the forgings are transferred out of the forging workshop through a No. 2 material frame monitoring node code scanner, and the forgings are sent to a next workshop for next round of processing; and uploading a database modification identification entry by the network server, erasing material frame binding forging workshop information, reserving binding records of the batch of forgings and the forging workshops, and waiting for the network server to issue a processing task instruction for transferring the batch of forgings to the next workshop.
2. The method for tracking the material frame in the forging production process according to claim 1, wherein the method comprises the following steps of: the device networking part of the networking control device adopts ESP8266 as a wireless communication module, and realizes the data communication between the STM32F103 core board and the ESP8266 through a serial port; the wireless communication module is externally connected with an antenna rod, and an AT instruction is adopted to realize a wireless communication function; when networking is performed for the first time, performing wireless communication module connection test and networking mode configuration; if the network is disconnected, the wireless communication module automatically connects the wireless network and acquires the connection of the network server according to the route configured last time.
3. The method for tracking the material frame in the forging production process according to claim 1, wherein the method comprises the following steps of: the networking control equipment strengthens signal recognition sensitivity through the mode of the external antenna of wireless communication module, ensures the wiFi signal strength of operation in-process, and external antenna stick work frequency band contains wiFi frequency channel, can satisfy equipment wiFi communication requirement.
4. The method for tracking the material frame in the forging production process according to claim 1, wherein the method comprises the following steps of: when the wireless communication module is connected with a power supply, the power supply indicator lamp is lightened, and the power supply indicator lamp is kept in a lightened state during the working period of the wireless communication module; when the wireless communication module is successfully connected to the network and the server, the networking indicator lamp flashes twice and the buzzer sounds to prompt that the wireless communication module is successfully connected, and the networking indicator lamp always keeps a lighting state in a network connected state; the wireless communication module is used for controlling whether the weighing data is uploaded or not through a key, and when the start key is pressed to indicate that the data uploading is started, the end key is pressed to indicate that the data uploading is stopped; the OLED display screen of the wireless communication module can display basic information of the wireless communication module, current time and networking state of the wireless communication module, and the display screen can refresh the weighing of the electronic scale every 0.5s, so that real-time performance of data display is ensured.
5. The method for tracking the material frame in the forging production process according to claim 1, wherein the method comprises the following steps of: the metal bar codes used for marking the material frame are arranged on 4 side faces of the material frame, the 4 metal bar codes are all the same in size, the codes are the same, and the scanning identification is realized.
6. The method for tracking the material frame in the forging production process according to claim 1, wherein the method comprises the following steps of: when the measured data measured by a gravity sensor on the electronic scale changes and the data received by a data input interface of the electronic scale fluctuates, the total weight of a material frame can be measured after the data is stably kept for a period of time, the obtained data is packed, the data is uploaded to an EMQX MQTT message proxy of a network server through a wireless communication module and stored in a database, the data is published to a theme corresponding to the node monitoring module based on the MQTT protocol of TCP, the weighing data can be obtained by subscribing the theme by the network server, so that the tracking of the discharge condition of a discharge port is realized, and the network server calculates the number of forgings of the discharge port according to the obtained weighing data;
when the measured data measured by the gravity sensor on the electronic scale is unchanged, the data can not be continuously uploaded.
7. The method for tracking the material frame in the forging production process according to claim 1, wherein the method comprises the following steps of: when the electronic scale data input interface continuously receives N frames of the same data, the data received by the electronic scale input interface can be stably maintained after being judged to be fluctuated, and the data is uploaded;
when the input interface of the electronic scale continuously receives N+n frames of the same data, the data are not uploaded, wherein N is any positive integer;
each frame of data of the electronic scale data input interface consists of 12 bytes, wherein the 1 st byte is a start bit, the 2 nd byte is a sign bit, the 3 rd to 8 th bytes are weighing data bits, the 9 th byte is a decimal point number, the 10 th to 11 th bytes are exclusive-or check bits, and the 12 th byte is an end bit.
8. The method for tracking the material frame in the forging production process according to claim 1, wherein the method comprises the following steps of: the application terminal is a handheld industrial PDA, is provided with a camera, a touch screen, a keyboard and a wifi module, an Android operating system is operated in the handheld industrial PDA, a material frame tracking APP is operated in the Android operating system, the material frame tracking APP scans a metal bar code on a material frame through the camera to obtain the bar code number, a network access network server is used for inquiring records corresponding to the bar code number and displaying relevant information of the material frame in the material frame tracking APP, the information of the material frame in the network server is bound with current monitoring nodes or production information through an operation interface of the material frame tracking APP, and the information is updated in the network server for storage, wherein the storage information comprises material frame state change, and the number and model information of built-in forgings; when the number and the model of the forgings in the material frame are changed, information is modified in an operation interface provided by the material frame tracking APP, and the information is updated to the network server through the wifi module.
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