CN116184961A - Injection molding automatic laminating production line safety control system based on industrial Internet of things - Google Patents
Injection molding automatic laminating production line safety control system based on industrial Internet of things Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 152
- 238000010030 laminating Methods 0.000 title claims abstract description 105
- 238000001746 injection moulding Methods 0.000 title claims abstract description 23
- 238000004458 analytical method Methods 0.000 claims abstract description 71
- 238000011156 evaluation Methods 0.000 claims abstract description 65
- 238000012954 risk control Methods 0.000 claims abstract description 5
- 230000002159 abnormal effect Effects 0.000 claims description 43
- 238000012423 maintenance Methods 0.000 claims description 33
- 238000010438 heat treatment Methods 0.000 claims description 21
- 238000000034 method Methods 0.000 claims description 17
- 238000012797 qualification Methods 0.000 claims description 12
- 238000007405 data analysis Methods 0.000 claims description 6
- 238000005299 abrasion Methods 0.000 claims description 5
- 238000001816 cooling Methods 0.000 claims description 3
- 230000002452 interceptive effect Effects 0.000 claims description 3
- 230000009286 beneficial effect Effects 0.000 abstract description 8
- 238000010606 normalization Methods 0.000 abstract description 4
- 230000003044 adaptive effect Effects 0.000 abstract description 2
- 238000009472 formulation Methods 0.000 abstract description 2
- 238000011835 investigation Methods 0.000 abstract description 2
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- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 230000006854 communication Effects 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
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- 239000003960 organic solvent Substances 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 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]
- G05B19/41875—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 quality surveillance of production
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- G—PHYSICS
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B2219/00—Program-control systems
- G05B2219/30—Nc systems
- G05B2219/32—Operator till task planning
- G05B2219/32368—Quality control
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
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Abstract
The invention relates to the technical field of production line safety control, in particular to an injection molding automatic fitting production line safety control system based on an industrial Internet of things, which comprises a server, an operation safety evaluation unit, a self-checking analysis unit, a safety control unit, a risk control unit, a display unit and a feedback supervision analysis unit, wherein the server is used for monitoring the operation safety of an injection molding; the invention is beneficial to improving the working efficiency of the laminating equipment in the production line, carrying out fault analysis and investigation on the laminating equipment in the production line and improving the production quality of products by collecting the operation data of the laminating equipment in the production line, deeply marking the laminating equipment, carrying out formulation and normalization analysis, and carrying out adaptive regulation and control and safer and more reliable hierarchical management on the laminating equipment in the production line, thereby carrying out rapid, comprehensive, accurate and high-information-fidelity informatization management on the laminating equipment in the production line and improving the operation safety and stability of the laminating equipment in the production line.
Description
Technical Field
The invention relates to the technical field of production line safety control, in particular to an injection molding automatic fitting production line safety control system based on an industrial Internet of things.
Background
The injection molding part is a common name of various injection molding products produced by an injection molding machine, and comprises various packages, parts and the like, and is mainly made of polyethylene, polypropylene and other materials and added with various organic solvents, in the injection molding production process of electronic product parts, the production period of the injection molding part is very short, the product volume is smaller, in the early verification and sample supply stage of a project, the development cost of management and control equipment is reduced, the semi-automatic film pasting tool verification is designed preferentially, and the high-low light level surface product needs to be attached with a protective film;
the laminating production of injection molding parts is realized through laminating equipment in corresponding production lines, the laminating production lines comprise a large number of auxiliary equipment and automatic laminating equipment of different types, in order to ensure the integral normal operation of the laminating production lines, the auxiliary equipment and the automatic laminating equipment are required to be detected in real time, but the prior art lacks a technology capable of carrying out safety early warning on the laminating production lines, and the laminating production lines cannot be reasonably subjected to hierarchical management and control, use and fault information feedback, and the safety and stability of the production lines are reduced, and the processing efficiency of the laminating equipment in the production lines and the product quality are very easy to be reduced;
in view of the above technical drawbacks, a solution is now proposed.
Disclosure of Invention
The invention aims to provide an automatic injection molding fitting production line safety management and control system based on the industrial Internet of things, which is used for solving the technical defects, and is characterized in that operation data of fitting equipment in a production line are collected, and through deep and character marking, formulation and normalization analysis, the working efficiency of the fitting equipment in the production line and the production quality of products are improved, and meanwhile, the fitting equipment in the production line is adaptively regulated and controlled and is subjected to safer and more reliable hierarchical management, so that the rapid, comprehensive, accurate and high-information fidelity informatization management is performed on the fitting equipment in the production line, and the operation safety and stability of the fitting equipment in the production line are improved.
The aim of the invention can be achieved by the following technical scheme:
the injection molding automatic attaching production line safety control system based on the industrial Internet of things comprises a server, an operation safety evaluation unit, a self-checking analysis unit, a safety control unit, a risk control unit, a display unit and a feedback supervision analysis unit;
the method comprises the steps that a server generates a control instruction and sends the control instruction to an operation safety evaluation unit, the operation safety evaluation unit immediately collects operation data of a production line after receiving the control instruction, the operation data comprise an operation sound frequency value and an operation current of laminating equipment in the production line, the operation data are analyzed to obtain the control instruction, a real-time safety evaluation value Aj and a fault signal, the control instruction and the real-time safety evaluation value Aj are sent to the safety control unit, and the fault signal is sent to a self-checking analysis unit;
after receiving the control instruction, the safety control unit analyzes the real-time safety evaluation value Aj to obtain a primary control signal, a secondary control signal and a tertiary control signal, and sends the primary control signal to the risk control unit, wherein the primary control signal, the secondary control signal and the tertiary control signal are collectively called as control signals, and the control signals are sent to the display unit and the feedback supervision analysis unit through the server;
after receiving the primary management and control signal, the risk management and control unit analyzes historical maintenance data of the acquired risk equipment, wherein the historical maintenance data comprises historical maintenance times and the time length from the last maintenance to the use of the last maintenance, the risk signal is obtained and sent to the safety management and control unit, and the attached equipment in the production line corresponding to the primary management and control signal is marked as risk equipment;
the self-checking analysis unit immediately collects risk data of the laminating equipment in the production line after receiving the fault signal, wherein the risk data comprises a bearing abrasion value and a heating value of the laminating equipment in the production line, analyzes the risk data to obtain an early warning signal, sends the early warning signal to the display unit, and immediately displays the early warning signal in a mode of word cooling and abnormal abrasion after receiving the early warning signal.
Preferably, the operation data analysis process of the operation safety evaluation unit is as follows:
the first step: collecting the duration from the starting working time to the ending working time of the laminating equipment, marking the duration as a time threshold, dividing the time threshold into o sub-time nodes, wherein o is a natural number larger than zero, acquiring the running sound audio frequency value of the laminating equipment in each sub-time node, marking the running sound audio frequency value larger than or equal to the preset running sound audio frequency value as an abnormal audio frequency value YPi, i is the number that the running sound audio frequency value is larger than or equal to the preset running sound audio frequency value, i is a natural number larger than zero, acquiring the total duration corresponding to the abnormal audio frequency value YPi, and obtaining the abnormal audio frequency value DY in unit time;
acquiring working current of laminating equipment in a production line in each sub-time node, marking working power larger than preset working current as overload current GLg, wherein g refers to the number of the overload currents, g is a natural number larger than zero, and acquiring total time S corresponding to the overload current;
and a second step of: the interference coefficient G is obtained through a formula, the abnormal audio value DY in unit time and the interference coefficient G are subjected to formulated analysis, namely a real-time safety evaluation value A is obtained through the formula, a bonding production line is marked as k, k is a natural number larger than zero, a real-time safety evaluation value Ak of bonding equipment in each production line is obtained, and the real-time safety evaluation value Ak is compared with a preset safety evaluation value recorded and stored in the real-time safety evaluation value A:
if the real-time safety evaluation value Ak is greater than or equal to a preset safety evaluation value, generating a control instruction;
and if the real-time safety evaluation value Ak is smaller than the preset safety evaluation value, generating a fault signal.
Preferably, the analysis process of the safety control unit is as follows:
after receiving the control instruction and the real-time safety evaluation value Aj, the safety control unit simultaneously acquires a preset safety evaluation value critical value P of the laminating equipment in the history production line and passes through a formula
Obtaining a real-time safety control coefficient, wherein a1 and a2 are preset proportional coefficients of a real-time safety evaluation value and a preset safety evaluation value critical value respectively, a1 is more than a2 is more than 0, a1+a2=1.874, BAj is a safety control coefficient of bonding equipment in a production line which is more than or equal to the preset safety evaluation value, and the real-time safety control coefficient BAj is compared with the inside of the safety control coefficientRecording a stored preset safety control coefficient interval for comparison and analysis:
if the safety control coefficient BAj is smaller than the minimum value in the preset safety control coefficient interval, generating a primary control signal;
if the safety control coefficient BAj is located in a preset safety control coefficient interval, generating a secondary control signal;
if the safety control coefficient BAj is greater than the maximum value in the preset safety control coefficient interval, generating a tertiary control signal, wherein the primary control signal is less than the secondary control signal and less than the tertiary control signal.
Preferably, the historical maintenance data analysis process of the risk management and control unit is as follows:
step one: acquiring laminating equipment h in a production line corresponding to the primary control signal, wherein h refers to laminating equipment in the production line corresponding to the primary control signal, h is a natural number greater than zero, acquiring the time length from the first maintenance to the last maintenance of the risk equipment, marking the time length as the use time length, acquiring the historical maintenance times in the use time length, and obtaining the maintenance frequency PL of the risk equipment;
acquiring the time length from the latest maintenance of the analysis equipment to the use of the analysis equipment, marking the time length as a safe time length, simultaneously acquiring the time length from the starting of the analysis equipment to the use of the analysis equipment in a production line, marking the time length as a throwing time length, and marking the product between the safe time length and the throwing time length as a damage coefficient SS;
step two: obtaining a risk coefficient F through a formula, simultaneously obtaining a risk coefficient Fh of laminating equipment in a production line corresponding to the primary management and control signal, and comparing and analyzing the risk coefficient Fh with a preset risk coefficient recorded and stored in the risk coefficient Fh:
if the risk coefficient Fh is greater than or equal to a preset risk coefficient, generating a risk signal, sending the risk signal to a safety management and control unit, immediately acquiring a natural number of laminating equipment r which is greater than zero in a production line corresponding to the risk signal after the safety management and control unit receives the risk signal, acquiring an intersection between h and r, and re-marking a primary management and control signal corresponding to a subset in the intersection between h and r as a secondary management and control signal;
if the risk factor Fh is smaller than the preset risk factor, no signal is generated.
Preferably, after receiving the control signal, the display unit adjusts the corresponding pre-storing scheme of the laminating equipment in the production line according to the received control signal level;
the feedback supervision and analysis unit collects and analyzes the production data of the analysis equipment after receiving the control signal, and the specific analysis process is as follows:
SS1, acquiring production line laminating equipment corresponding to a safety control coefficient BAj, marking the production line laminating equipment as analysis equipment, acquiring real-time total yield of the analysis equipment in a time threshold, marking a difference value between the real-time total yield and a preset finished yield as a fault tolerance R, and comparing the fault tolerance R with a preset fault tolerance interval recorded and stored in the fault tolerance R:
if the fault tolerance R is smaller than the preset fault tolerance interval, generating a normal signal;
if the fault tolerance R is larger than a preset fault tolerance interval, generating an abnormal signal;
SS2, simultaneously obtaining the number of qualified bonding pieces of the analysis equipment in the time threshold, so as to obtain the bonding piece qualification rate HG of the bonding equipment in the analysis production line in the time threshold, and comparing and analyzing the bonding piece qualification rate HG with the preset bonding piece qualification rate recorded in the bonding piece qualification rate HG:
if the qualified rate HG of the attached piece is larger than or equal to the qualified rate of the preset attached piece, generating a qualified signal;
if the qualified rate HG of the attached piece is smaller than the qualified rate of the preset attached piece, generating a disqualified signal;
SS3, and performs interactive analysis on the normal signal, the abnormal signal, the pass signal and the fail signal:
when the normal signal and the qualified signal are generated, generating a preferred signal and sending the preferred signal to a display unit, and marking a production line corresponding to the preferred signal as '1' by the display unit;
when the normal signal and the unqualified signal or the abnormal signal and the qualified signal or the abnormal signal and the unqualified signal are generated, the normal signal is generated and sent to the display unit, and the display unit marks the production line corresponding to the normal signal as '2'.
Preferably, the risk data analysis process of the self-checking analysis unit is as follows:
acquiring bearing wear values of production line laminating equipment in each sub-time node, constructing a set A, acquiring a maximum subset and a minimum subset in the set A, and marking the difference between the maximum subset and the minimum subset as a wear span value KD;
the method comprises the steps of obtaining the heating value of laminating equipment in each sub-time node, comparing and analyzing the heating value with a preset heating value, obtaining the number of the heating values which are larger than or equal to the preset heating value, marking the number of the heating values as abnormal points, obtaining the total duration corresponding to the abnormal points, and marking the product of the abnormal points and the total duration as an abnormal coefficient YC;
obtaining a fault coefficient GZ through a formula, and carrying out difference analysis on the fault coefficient GZ and a preset fault coefficient recorded and stored in the fault coefficient GZ:
if the difference value between the fault coefficient GZ and the preset fault coefficient is positive, generating an early warning signal;
if the difference between the fault coefficient GZ and the preset fault coefficient is negative, no signal is generated.
The beneficial effects of the invention are as follows:
(1) The invention is beneficial to improving the working efficiency of the laminating equipment in the production line and the production quality of products by collecting the operation data of the laminating equipment in the production line, deeply marking the laminating equipment, formulating and normalizing the data, and carrying out adaptability regulation and safer and more reliable hierarchical management on the laminating equipment in the production line, thereby carrying out rapid, comprehensive, accurate and high-information-fidelity informatization management on the laminating equipment in the production line and improving the operation safety and stability of the laminating equipment in the production line;
(2) The invention also analyzes the rationality of equipment control in an in-depth and normalization mode, i.e. combines and compares the hierarchical division of the acquisition object and the processing flow, is beneficial to reasonably controlling and using the laminating equipment in the production line, and reasonably carries out hierarchical management on the production line, improves the overall production efficiency of the production line and ensures the laminating processing quality of injection molding parts;
(3) The invention also analyzes the faults of the laminating equipment in the production line in a deep and information feedback mode, is beneficial to analyzing and checking the faults of the laminating equipment in the production line, and carries out display purpose reminding in a text display mode, thereby being beneficial to timely overhauling the laminating equipment corresponding to the fault signals and ensuring the overall working efficiency of the production line.
Drawings
The invention is further described below with reference to the accompanying drawings;
FIG. 1 is a block flow diagram of the system of the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Example 1:
referring to fig. 1, the invention discloses an injection molding automatic attaching production line safety management and control system based on an industrial internet of things, which comprises a server, an operation safety evaluation unit, a self-checking analysis unit, a safety management and control unit, a risk management and control unit, a display unit and a feedback supervision and analysis unit, wherein the server is in bidirectional communication connection with the operation safety evaluation unit, the server is in bidirectional communication connection with the safety management and control unit, the server is in bidirectional communication connection with the self-checking analysis unit, the server is in bidirectional communication connection with the feedback supervision and analysis unit, the server is in bidirectional communication connection with the risk management and control unit, and the server is in unidirectional communication connection with the display unit;
the server generates a control instruction and sends the control instruction to the operation safety evaluation unit, the operation safety evaluation unit immediately acquires operation data of the production line after receiving the control instruction, the operation data comprises an operation sound frequency value and an operation current of the laminating equipment in the production line, the operation data is analyzed to judge whether the laminating equipment in the production line safely operates or not so as to ensure the working efficiency of the laminating equipment in the production line and improve the production quality of products, and meanwhile, the laminating equipment in the production line is adaptively controlled and managed to perform rapid, comprehensive, accurate and high-information-fidelity informatization management on the laminating equipment in the production line and improve the operation safety and stability of the laminating equipment in the production line and realize safer and more reliable hierarchical management;
collecting the duration from the starting working time to the ending working time of the laminating equipment, marking the duration as a time threshold, dividing the time threshold into o sub-time nodes, wherein o is a natural number larger than zero, acquiring the running sound audio frequency value of the laminating equipment in each sub-time node, marking the running sound audio frequency value larger than or equal to the preset running sound audio frequency value as an abnormal audio frequency value, marking the running sound audio frequency value as a number YPi, i is the number of the running sound audio frequency value larger than or equal to the preset running sound audio frequency value, i {1,2, 3..i }, i is a natural number larger than zero, and acquiring the total duration corresponding to the abnormal audio frequency value YPi, so as to obtain the abnormal audio frequency value DY in unit time;
acquiring working current of laminating equipment in a production line in each sub-time node, marking working power larger than preset working current as overload current GLg, wherein g refers to the number of the overload currents, g {1,2,3,.. The number of g }, g is a natural number larger than zero, and acquiring total time S corresponding to the overload current;
and go through the formula
An interference factor is obtained, wherein,alpha is a preset deviation correction coefficient, b and c are preset proportional coefficients of overload current and total time respectively, b is more than c is more than 0, b+c=1.396, and the larger the value of the interference coefficient G is, the larger the interference to normal operation of laminating equipment in a production line is, and the larger the fault risk is;
in summary, the unit-time abnormal audio value DY and the interference coefficient G are formulated and analyzed by the formula
Obtaining real-time safety evaluation values, wherein c is a preset deviation correction factor, beta and epsilon are preset weight coefficients of an abnormal audio value and an interference coefficient in unit time respectively, beta is more than epsilon is more than 0, beta+epsilon=3.854, A is a real-time safety evaluation value, a bonding production line is marked as k, k is a natural number larger than zero, a real-time safety evaluation value Ak of bonding equipment in each production line is obtained, and the real-time safety evaluation value Ak is compared with the preset safety evaluation value recorded and stored in the real-time safety evaluation value Ak:
if the real-time safety evaluation value Ak is greater than or equal to the preset safety evaluation value, generating a control instruction, acquiring the number j, j {1,2,3, & gt, j } j of the real-time safety evaluation value Ak which is greater than or equal to the preset safety evaluation value, and transmitting the control instruction and the real-time safety evaluation value Aj to a safety control unit;
if the real-time safety evaluation value Ak is smaller than the preset safety evaluation value, generating a fault signal, and sending the fault signal to a self-checking analysis unit through a server, so that fault analysis and investigation of laminating equipment in a production line are facilitated;
after receiving the control instruction and the real-time safety evaluation value Aj, the safety control unit simultaneously acquires a preset safety evaluation value critical value P of the laminating equipment in the history production line and passes through a formula
Obtaining real-time safety control coefficients, wherein a1 and a2 are preset proportional coefficients of a real-time safety evaluation value and a preset safety evaluation value critical value respectively, a1 is more than a2 is more than 0, a1+a2=1.874, BAj is the safety control coefficient of laminating equipment in a production line which is more than or equal to the preset safety evaluation value,and comparing and analyzing the real-time safety control coefficient BAj with a preset safety control coefficient interval recorded and stored in the real-time safety control coefficient BAj: />
If the safety control coefficient BAj is smaller than the minimum value in the preset safety control coefficient interval, generating a primary control signal, and sending the primary control signal to the risk control unit through the server;
if the safety control coefficient BAj is located in a preset safety control coefficient interval, generating a secondary control signal;
if the safety control coefficient BAj is greater than the maximum value in the preset safety control coefficient interval, a third-stage control signal is generated, wherein the first-stage control signal is less than the second-stage control signal and less than the third-stage control signal, the first-stage control signal, the second-stage control signal and the third-stage control signal are all called as control signals, the control signals are sent to the display unit and the feedback supervision analysis unit through the server, and after the control signals are received, the display unit makes corresponding pre-stored scheme adjustment on the laminating equipment in the production line according to the received control signal level, so that the laminating equipment in the production line is reasonably controlled, and the working stability of the laminating equipment in the production line is improved.
Example 2:
the risk management and control unit immediately acquires laminating equipment h in a production line corresponding to the primary management and control signal after receiving the primary management and control signal, wherein h refers to laminating equipment in the production line corresponding to the primary management and control signal, h is a natural number larger than zero, meanwhile, the laminating equipment in the production line corresponding to the primary management and control signal is marked as risk equipment, historical maintenance data of the risk equipment are acquired, and the historical maintenance data comprise historical maintenance times and time length from last maintenance to the last use;
acquiring the time length from the first maintenance to the last maintenance of the risk equipment, marking the time length as the use time length, and acquiring the historical maintenance times in the use time length to obtain the maintenance frequency PL of the risk equipment, wherein the larger the value of the maintenance frequency PL is, the larger the risk of the fault of the risk equipment is;
acquiring the time length from the last maintenance to the use of the analysis equipment, marking the time length as a safe time length, simultaneously acquiring the time length from the beginning of the operation of the analysis equipment to the use of the analysis equipment, marking the time length as a throwing time length, marking the product between the safe time length and the throwing time length as a damage coefficient, marking the product as an SS (standard), and the larger the numerical value of the damage coefficient SS, the larger the risk of the failure of the analysis equipment;
and go through the formula
Obtaining risk coefficients, wherein F1 and F2 are preset weight coefficients of maintenance frequency and damage coefficient respectively, F1 is more than F2 is more than 0, f1+f2=1.532, d is a preset interference correction coefficient, F is a risk coefficient, and meanwhile, obtaining a risk coefficient Fh of laminating equipment in a production line corresponding to a primary management and control signal, and comparing the risk coefficient Fh with a preset risk coefficient recorded and stored in the risk coefficient Fh:
if the risk coefficient Fh is greater than or equal to a preset risk coefficient, a risk signal is generated and sent to a safety management and control unit, after the safety management and control unit receives the risk signal, the safety management and control unit immediately acquires laminating equipment r in a production line corresponding to the risk signal, r is a natural number greater than zero, an intersection between h and r is acquired, primary management and control signals corresponding to a subset in the intersection between h and r are re-marked as secondary management and control signals and sent to a display unit, reasonable management and control and use of laminating equipment in the production line are facilitated, production efficiency of laminating equipment in the production line is improved, and operation safety and stability of the laminating production line are improved.
If the risk factor Fh is smaller than the preset risk factor, no signal is generated.
Example 3:
the feedback supervision and analysis unit immediately acquires the production line laminating equipment corresponding to the safety control coefficient BAj after receiving the control signal, marks the production line laminating equipment as analysis equipment, simultaneously collects production data of the analysis equipment, wherein the production data comprises real-time total output and the number of qualified laminating pieces of the analysis equipment, and analyzes the production data:
the method comprises the steps of obtaining real-time total yield of analysis equipment in a time threshold, marking a difference value between the real-time total yield and a preset finished yield as a fault tolerance R, and comparing the fault tolerance R with a preset fault tolerance interval recorded and stored in the fault tolerance R:
if the fault tolerance R is smaller than the preset fault tolerance interval, generating a normal signal;
if the fault tolerance R is larger than a preset fault tolerance interval, generating an abnormal signal;
meanwhile, the number of qualified bonding pieces of the analysis equipment in the time threshold is obtained, so that the bonding piece qualification rate HG of the bonding equipment in the analysis production line in the time threshold is obtained, and the bonding piece qualification rate HG is compared with the preset bonding piece qualification rate recorded in the bonding piece qualification rate HG:
if the qualified rate HG of the attached piece is larger than or equal to the qualified rate of the preset attached piece, generating a qualified signal;
if the qualified rate HG of the attached piece is smaller than the qualified rate of the preset attached piece, generating a disqualified signal;
and performing interactive analysis on the normal signal, the abnormal signal, the qualified signal and the unqualified signal:
when the normal signal and the qualified signal are generated, generating a preferred signal and sending the preferred signal to a display unit, wherein the display unit immediately marks a production line corresponding to the preferred signal as '1' after receiving the preferred signal, thereby being beneficial to preferentially selecting equipment and ensuring the quality and the production efficiency of the attaching processing of the injection molding;
when normal signals and unqualified signals or abnormal signals and qualified signals or abnormal signals and unqualified signals are generated, normal signals are generated and sent to the display unit, and the display unit immediately marks the production line corresponding to the normal signals as 2 after receiving the normal signals, so that the production line is conveniently distinguished from the production line marked as 1, and further reasonable use of the production line is facilitated.
Example 4:
the self-checking analysis unit immediately collects risk data of the laminating equipment in the production line after receiving the fault signal, wherein the risk data comprises bearing wear values and heating values of the laminating equipment in the production line, and analyzes the risk data, and the specific analysis process is as follows:
acquiring bearing wear values of production line laminating equipment in each sub-time node, constructing a set A, acquiring a maximum subset and a minimum subset in the set A, and marking a difference value between the maximum subset and the minimum subset as a wear span value KD, wherein the wear span value KD is used for reflecting the running condition of the bearing of the laminating equipment in working, and the greater the value is, the greater the abnormal risk of the bearing running of the conveying belt is;
the method comprises the steps of obtaining the heating value of laminating equipment in each sub-time node, comparing and analyzing the heating value with preset heating value, obtaining the number of heating values which are larger than or equal to the preset heating value, marking the heating value as an abnormal point, obtaining the total duration corresponding to the abnormal point, marking the product of the abnormal point and the total duration as an abnormal coefficient YC, and the larger the numerical value of the abnormal coefficient YC is, the larger the risk of equipment failure is;
and go through the formula
Obtaining a fault coefficient, wherein m and n are weight factors of an abnormal coefficient and a wear span value respectively, m is more than n is more than 0, m+n=3, 684 and GZ are fault coefficients, and performing difference analysis on the fault coefficient GZ and preset fault coefficients recorded and stored in the fault coefficient GZ:
if the difference value between the fault coefficient GZ and the preset fault coefficient is positive, generating an early warning signal, sending the early warning signal to a display unit, and immediately displaying the early warning signal in a mode of word cooling and abnormal abrasion after the display unit receives the early warning signal, so that the repairing of the laminating equipment corresponding to the fault signal is facilitated in time, and the overall working efficiency of the production line is ensured;
if the difference between the fault coefficient GZ and the preset fault coefficient is negative, no signal is generated.
In summary, the invention is beneficial to improving the working efficiency of the laminating equipment in the production line and improving the production quality of products by collecting the operation data of the laminating equipment in the production line, deeply marking the laminating equipment, formulating and normalizing the operation data, and carrying out adaptive regulation and safer and more reliable hierarchical management on the laminating equipment in the production line, thereby carrying out rapid, comprehensive, accurate and high-information-fidelity informatization management on the laminating equipment in the production line and improving the operation safety and stability of the laminating equipment in the production line; the rationality of equipment management and control is analyzed in an in-depth and normalization mode, namely, the hierarchical division of the acquired objects and the processing flow is combined and compared, so that reasonable management and control and use of laminating equipment in a production line are facilitated, the production line is more reasonably managed in a grading mode, the overall production efficiency of the production line is improved, and the laminating processing quality of injection molding parts is guaranteed; and analyzing faults of laminating equipment in the production line in a deep and information feedback mode, and prompting display purpose in a text display mode, so that the laminating equipment corresponding to the fault signals can be overhauled timely, and the overall working efficiency of the production line can be guaranteed.
The above formulas are all formulas obtained by collecting a large amount of data for software simulation and selecting a formula close to the true value, and coefficients in the formulas are set by a person skilled in the art according to practical situations, and the above is only a preferred embodiment of the present invention, but the protection scope of the present invention is not limited thereto, and any person skilled in the art is within the technical scope of the present invention, and the technical scheme and the inventive concept according to the present invention are equivalent to or changed and are all covered in the protection scope of the present invention.
Claims (6)
1. The injection molding automatic attaching production line safety management and control system based on the industrial Internet of things is characterized by comprising a server, an operation safety evaluation unit, a self-checking analysis unit, a safety management and control unit, a risk management and control unit, a display unit and a feedback supervision analysis unit;
the method comprises the steps that a server generates a control instruction and sends the control instruction to an operation safety evaluation unit, the operation safety evaluation unit immediately collects operation data of a production line after receiving the control instruction, the operation data comprise an operation sound frequency value and an operation current of laminating equipment in the production line, the operation data are analyzed to obtain the control instruction, a real-time safety evaluation value Aj and a fault signal, the control instruction and the real-time safety evaluation value Aj are sent to the safety control unit, and the fault signal is sent to a self-checking analysis unit;
after receiving the control instruction, the safety control unit analyzes the real-time safety evaluation value Aj to obtain a primary control signal, a secondary control signal and a tertiary control signal, and sends the primary control signal to the risk control unit, wherein the primary control signal, the secondary control signal and the tertiary control signal are collectively called as control signals, and the control signals are sent to the display unit and the feedback supervision analysis unit through the server;
after receiving the primary management and control signal, the risk management and control unit analyzes historical maintenance data of the acquired risk equipment, wherein the historical maintenance data comprises historical maintenance times and the time length from the last maintenance to the use of the last maintenance, the risk signal is obtained and sent to the safety management and control unit, and the attached equipment in the production line corresponding to the primary management and control signal is marked as risk equipment;
the self-checking analysis unit immediately collects risk data of the laminating equipment in the production line after receiving the fault signal, wherein the risk data comprises a bearing abrasion value and a heating value of the laminating equipment in the production line, analyzes the risk data to obtain an early warning signal, sends the early warning signal to the display unit, and immediately displays the early warning signal in a mode of word cooling and abnormal abrasion after receiving the early warning signal.
2. The injection molding automated bonding production line safety control system based on the industrial internet of things according to claim 1, wherein the operation data analysis process of the operation safety evaluation unit is as follows:
the first step: collecting the duration from the starting working time to the ending working time of the laminating equipment, marking the duration as a time threshold, dividing the time threshold into o sub-time nodes, wherein o is a natural number larger than zero, acquiring the running sound audio frequency value of the laminating equipment in each sub-time node, marking the running sound audio frequency value larger than or equal to the preset running sound audio frequency value as an abnormal audio frequency value YPi, i is the number that the running sound audio frequency value is larger than or equal to the preset running sound audio frequency value, i is a natural number larger than zero, acquiring the total duration corresponding to the abnormal audio frequency value YPi, and obtaining the abnormal audio frequency value DY in unit time;
acquiring working current of laminating equipment in a production line in each sub-time node, marking working power larger than preset working current as overload current GLg, wherein g refers to the number of the overload currents, g is a natural number larger than zero, and acquiring total time S corresponding to the overload current;
and a second step of: the interference coefficient G is obtained through a formula, the abnormal audio value DY in unit time and the interference coefficient G are subjected to formulated analysis, namely a real-time safety evaluation value A is obtained through the formula, a bonding production line is marked as k, k is a natural number larger than zero, a real-time safety evaluation value Ak of bonding equipment in each production line is obtained, and the real-time safety evaluation value Ak is compared with a preset safety evaluation value recorded and stored in the real-time safety evaluation value A:
if the real-time safety evaluation value Ak is greater than or equal to a preset safety evaluation value, generating a control instruction;
and if the real-time safety evaluation value Ak is smaller than the preset safety evaluation value, generating a fault signal.
3. The injection molding automation laminating production line safety control system based on the industrial internet of things according to claim 1, wherein the analysis process of the safety control unit is as follows:
after receiving the control instruction and the real-time safety evaluation value Aj, the safety control unit simultaneously acquires a preset safety evaluation value critical value P of the laminating equipment in the history production line and passes through a formula
Obtaining a real-time safety control coefficient, wherein a1 and a2 are preset proportional coefficients of a real-time safety evaluation value and a preset safety evaluation value critical value respectively, a1 is more than a2 is more than 0, a1+a2=1.874, BAj is a safety control coefficient of bonding equipment in a production line which is more than or equal to the preset safety evaluation value, and the real-time safety control coefficient BAj is recorded in the real-time safety control coefficient BAjAnd (3) performing comparison and analysis in a stored preset safety control coefficient interval:
if the safety control coefficient BAj is smaller than the minimum value in the preset safety control coefficient interval, generating a primary control signal;
if the safety control coefficient BAj is located in a preset safety control coefficient interval, generating a secondary control signal;
if the safety control coefficient BAj is greater than the maximum value in the preset safety control coefficient interval, generating a tertiary control signal, wherein the primary control signal is less than the secondary control signal and less than the tertiary control signal.
4. The injection molding automated bonding production line safety control system based on the industrial internet of things according to claim 1, wherein the historical maintenance data analysis process of the risk management and control unit is as follows:
step one: acquiring laminating equipment h in a production line corresponding to the primary control signal, wherein h refers to laminating equipment in the production line corresponding to the primary control signal, h is a natural number greater than zero, acquiring the time length from the first maintenance to the last maintenance of the risk equipment, marking the time length as the use time length, acquiring the historical maintenance times in the use time length, and obtaining the maintenance frequency PL of the risk equipment;
acquiring the time length from the latest maintenance of the analysis equipment to the use of the analysis equipment, marking the time length as a safe time length, simultaneously acquiring the time length from the starting of the analysis equipment to the use of the analysis equipment in a production line, marking the time length as a throwing time length, and marking the product between the safe time length and the throwing time length as a damage coefficient SS;
step two: obtaining a risk coefficient F through a formula, simultaneously obtaining a risk coefficient Fh of laminating equipment in a production line corresponding to the primary management and control signal, and comparing and analyzing the risk coefficient Fh with a preset risk coefficient recorded and stored in the risk coefficient Fh:
if the risk coefficient Fh is greater than or equal to a preset risk coefficient, generating a risk signal, sending the risk signal to a safety management and control unit, immediately acquiring a natural number of laminating equipment r which is greater than zero in a production line corresponding to the risk signal after the safety management and control unit receives the risk signal, acquiring an intersection between h and r, and re-marking a primary management and control signal corresponding to a subset in the intersection between h and r as a secondary management and control signal;
if the risk factor Fh is smaller than the preset risk factor, no signal is generated.
5. The automatic injection molding fitting production line safety control system based on the industrial Internet of things according to claim 1, wherein the display unit adjusts corresponding pre-storing schemes for fitting equipment in the production line according to the received control signal level after receiving the control signal;
the feedback supervision and analysis unit collects and analyzes the production data of the analysis equipment after receiving the control signal, and the specific analysis process is as follows:
SS1, acquiring production line laminating equipment corresponding to a safety control coefficient BAj, marking the production line laminating equipment as analysis equipment, acquiring real-time total yield of the analysis equipment in a time threshold, marking a difference value between the real-time total yield and a preset finished yield as a fault tolerance R, and comparing the fault tolerance R with a preset fault tolerance interval recorded and stored in the fault tolerance R:
if the fault tolerance R is smaller than the preset fault tolerance interval, generating a normal signal;
if the fault tolerance R is larger than a preset fault tolerance interval, generating an abnormal signal;
SS2, simultaneously obtaining the number of qualified bonding pieces of the analysis equipment in the time threshold, so as to obtain the bonding piece qualification rate HG of the bonding equipment in the analysis production line in the time threshold, and comparing and analyzing the bonding piece qualification rate HG with the preset bonding piece qualification rate recorded in the bonding piece qualification rate HG:
if the qualified rate HG of the attached piece is larger than or equal to the qualified rate of the preset attached piece, generating a qualified signal;
if the qualified rate HG of the attached piece is smaller than the qualified rate of the preset attached piece, generating a disqualified signal;
SS3, and performs interactive analysis on the normal signal, the abnormal signal, the pass signal and the fail signal:
when the normal signal and the qualified signal are generated, generating a preferred signal and sending the preferred signal to a display unit, and marking a production line corresponding to the preferred signal as '1' by the display unit;
when the normal signal and the unqualified signal or the abnormal signal and the qualified signal or the abnormal signal and the unqualified signal are generated, the normal signal is generated and sent to the display unit, and the display unit marks the production line corresponding to the normal signal as '2'.
6. The automatic laminating production line safety control system of injection molding based on industrial internet of things according to claim 1, wherein the risk data analysis process of the self-checking analysis unit is as follows:
acquiring bearing wear values of production line laminating equipment in each sub-time node, constructing a set A, acquiring a maximum subset and a minimum subset in the set A, and marking the difference between the maximum subset and the minimum subset as a wear span value KD;
the method comprises the steps of obtaining the heating value of laminating equipment in each sub-time node, comparing and analyzing the heating value with a preset heating value, obtaining the number of the heating values which are larger than or equal to the preset heating value, marking the number of the heating values as abnormal points, obtaining the total duration corresponding to the abnormal points, and marking the product of the abnormal points and the total duration as an abnormal coefficient YC;
obtaining a fault coefficient GZ through a formula, and carrying out difference analysis on the fault coefficient GZ and a preset fault coefficient recorded and stored in the fault coefficient GZ:
if the difference value between the fault coefficient GZ and the preset fault coefficient is positive, generating an early warning signal;
if the difference between the fault coefficient GZ and the preset fault coefficient is negative, no signal is generated.
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