CN105629941B - A kind of real-time quality control system for the process that circulated using RFID to steel pipe - Google Patents
A kind of real-time quality control system for the process that circulated using RFID to steel pipe Download PDFInfo
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 129
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- 238000005554 pickling Methods 0.000 claims description 13
- 238000010438 heat treatment Methods 0.000 claims description 12
- 238000005259 measurement Methods 0.000 claims description 12
- 238000001514 detection method Methods 0.000 claims description 11
- 238000005303 weighing Methods 0.000 claims description 11
- 238000005097 cold rolling Methods 0.000 claims description 9
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Abstract
本发明涉及一种利用了RFID技术对钢管流转工序进行的实时品质管理系统。一种利用RFID对钢管流转工序的实时品质管理系统,包括钢管生产设备、钢管检验设备、带RFID标签的信息卡、RFID人员身份卡、RFID扫描仪、工业计算机系统和在线显示终端;该实时品质管理系统结构合理,结合条码技术与RFID标签技术,能够快速,实时地对钢管流转工序进行,还具有减少出错率、追溯性强并且能够实时远程在线监控的优点。
The invention relates to a real-time quality management system for steel pipe circulation process using RFID technology. A real-time quality management system using RFID for the steel pipe circulation process, including steel pipe production equipment, steel pipe inspection equipment, information cards with RFID tags, RFID personnel identity cards, RFID scanners, industrial computer systems and online display terminals; the real-time quality The management system has a reasonable structure, combined with barcode technology and RFID tag technology, can quickly and real-time carry out the steel pipe circulation process, and also has the advantages of reducing error rate, strong traceability and real-time remote online monitoring.
Description
技术领域technical field
本发明属于钢管生产、销售和使用等流转工序的品质管理系统,具体涉及一种利用了RFID技术对钢管流转工序进行的实时品质管理系统。The invention belongs to a quality management system for steel pipe circulation processes such as production, sales and use, and specifically relates to a real-time quality management system for steel pipe circulation processes using RFID technology.
背景技术Background technique
目前,钢管生产的管理系统一般采用ERP系统管理,由于钢管生产是根据客户的订单而定制不同规格,因此钢管的规格非常之多,甚至达到上千种。因此,实际钢管生产过程中具有不同的规格,不同大小的原坯、不同的材料以及不同的仓库库存的改制,因此生产过程中工序会不同调整,相当复杂,利用静态的ERP管理造成了生产工序的不稳定,并且出现问题也难以实时地找到原因,造成管理资源和生产资源的极大浪费,而且还深度影响钢管的品质。At present, the management system of steel pipe production is generally managed by ERP system. Since steel pipe production is customized according to customer orders, there are many specifications of steel pipes, even thousands of them. Therefore, the actual steel pipe production process has different specifications, different sizes of blanks, different materials, and different warehouse inventory restructuring, so the production process will be adjusted differently, which is quite complicated. The use of static ERP management has resulted in a production process. It is unstable, and it is difficult to find the cause in real time when problems occur, resulting in a great waste of management resources and production resources, and also deeply affects the quality of steel pipes.
发明内容Contents of the invention
本发明的发明目的是提供一种结构合理,结合条码技术与RFID标签技术,能够快速,实时地对钢管流转工序进行的实时品质管理系统;该实时品质管理系统还具有减少出错率、追溯性强并且能够实时远程在线监控的优点。The purpose of the present invention is to provide a real-time quality management system with a reasonable structure, combined with barcode technology and RFID tag technology, which can quickly and real-timely carry out the steel pipe circulation process; the real-time quality management system also has the advantages of reducing error rate and strong traceability And it has the advantages of real-time remote online monitoring.
为了实现上述发明目的,本发明采用了以下技术方案:In order to realize the above-mentioned purpose of the invention, the present invention adopts the following technical solutions:
一种利用RFID对钢管流转工序的实时品质管理系统,包括钢管生产设备、钢管检验设备、带RFID标签的信息卡、RFID人员身份卡、RFID扫描仪、工业计算机系统和在线显示终端;所述钢管生产设备包括冷轧控制设备、酸洗控制设备和热处理控制设备,冷轧控制设备包括PLC控制系统A和轧机;酸洗控制设备包括PLC控制系统B和酸洗设备;热处理控制设备包括PLC控制系统C和退火炉;所述钢管检验设备包括涡流探伤仪;工业计算机系统包括人机交互系统、数据库服务器和控制系统,人机交互系统、数据库服务器和控制系统之间相互连接;所述人机交互系统包括输入模块、数据输出显示界面和数据监控模块,输入模块连接数据输出显示界面,数据监控模块分别连接数据输出显示界面、数据库服务器和控制系统;所述带RFID标签的信息卡包括用于录入钢管检验预设规格数据的质量流转卡,所述RFID人员身份卡是钢管流转工序中用于唯一识别操作人员手工操作或录入数据的身份卡;所述RFID扫描仪连接人机交互系统上的输入模块,钢管框号内的质量流转卡通过RFID扫描仪,自动录入钢管框号、钢管规格和其他预设的质量要求至人机交互系统上;所述涡流探伤仪对所述框号的钢管的探伤数据分为手工记录数据和自动记录数据;涡流探伤仪上的自动记录数据自动录入人机交互系统;操作人员的手工记录数据通过他的RFID人员身份卡经过RFID扫描仪扫描后,将手工记录数据手工录入至他名下的人机交互系统上;所述冷轧控制设备、酸洗控制设备和热处理控制设备分别通过各自的PLC数据连接工业计算机系统,用于将它们各自的工艺参数实时录至工业计算机系统中;在线显示终端通过网络连接工业计算机系统,实时抓取工业计算机系统中的生产工艺参数、检验数据和人员操作。A real-time quality management system using RFID for the steel pipe circulation process, including steel pipe production equipment, steel pipe inspection equipment, information cards with RFID tags, RFID personnel identity cards, RFID scanners, industrial computer systems and online display terminals; the steel pipes Production equipment includes cold rolling control equipment, pickling control equipment and heat treatment control equipment, cold rolling control equipment includes PLC control system A and rolling mill; pickling control equipment includes PLC control system B and pickling equipment; heat treatment control equipment includes PLC control system C and an annealing furnace; the steel pipe inspection equipment includes an eddy current flaw detector; the industrial computer system includes a human-computer interaction system, a database server and a control system, and the human-computer interaction system, the database server and the control system are connected to each other; the human-computer interaction The system includes an input module, a data output display interface and a data monitoring module, the input module is connected to the data output display interface, and the data monitoring module is respectively connected to the data output display interface, the database server and the control system; the information card with the RFID tag includes a The quality circulation card of the steel pipe inspection preset specification data, the RFID personnel identity card is the identity card used to uniquely identify the manual operation or data entry of the operator in the steel pipe circulation process; the RFID scanner is connected to the input on the human-computer interaction system module, the quality flow card in the steel pipe frame number automatically enters the steel pipe frame number, steel pipe specification and other preset quality requirements to the human-computer interaction system through the RFID scanner; The flaw detection data is divided into manual record data and automatic record data; the automatic record data on the eddy current flaw detector is automatically entered into the human-computer interaction system; the manual record data of the operator is scanned by the RFID scanner through his RFID personnel identity card, and then manually recorded The data is manually entered into the human-computer interaction system under his name; the cold rolling control equipment, pickling control equipment and heat treatment control equipment are respectively connected to the industrial computer system through their respective PLC data, and are used to record their respective process parameters in real time. To the industrial computer system; the online display terminal is connected to the industrial computer system through the network, and captures the production process parameters, inspection data and personnel operations in the industrial computer system in real time.
作为优选,数据库服务器至少包括预设的原料信息、预设钢管缺陷信息、预设的热处理信息和预设的缺陷原理关联信息;所述控制系统至少包括数据对比模块、数据匹配模块和数据运算模块。Preferably, the database server includes at least preset raw material information, preset steel pipe defect information, preset heat treatment information and preset defect principle related information; the control system includes at least a data comparison module, a data matching module and a data calculation module .
作为优选,还包括警报模块,所述控制系统连接警报模块。Preferably, an alarm module is also included, and the control system is connected to the alarm module.
进一步的,实时品质管理系统还包括成品钢管品质管理系统,成品钢管品质管理系统包括带RFID标签的成品钢管、预存入成品钢管数据的数据库服务器、远程RFID扫描仪和远程输入终端;所述RFID人员身份卡还包括销售人员身份卡和安装人员身份卡;所述成品钢管销售数据通过销售人员身份卡在远程RFID扫描仪后,录入远程输入终端,远程输入终端连接所述工业计算机系统;所述成品钢管安装数据通过安装人员身份卡在远程RFID扫描仪后,录入远程输入终端。Further, the real-time quality management system also includes a finished steel pipe quality management system, and the finished steel pipe quality management system includes finished steel pipes with RFID tags, a database server pre-stored in finished steel pipe data, a remote RFID scanner, and a remote input terminal; the RFID personnel The identity card also includes a salesperson's identity card and an installer's identity card; the sales data of the finished steel pipe is entered into the remote input terminal through the salesperson's identity card after the remote RFID scanner, and the remote input terminal is connected to the industrial computer system; the finished product The steel pipe installation data is entered into the remote input terminal after the installer's identity card is placed on the remote RFID scanner.
作为优选,所述探伤仪包括探伤模块、称重模块、尺寸测量模块和ID喷标模块,探伤仪的输出端连接工业计算机系统,将每支钢管ID和检验数据输入至数据库;钢管从框中陆续送入探伤仪时,探伤仪对单支钢管利用探伤模块探伤、称重模块称重、尺寸测量模块测量长度和直径,最后再利用喷标模块在钢管表面打上ID号;工业计算机系统录入每支同框钢管数据之后,工业计算机系统中的控制系统可以求和,并与所述钢管框号内的质量流转卡录入的数据匹配。这使得钢管探伤从最小流转单位的框号精细化到每支钢管,同时,提高质检和管理品质,减少出错率,利用做好钢管生产过程中的品质控制。As preferably, the flaw detector includes a flaw detection module, a weighing module, a size measurement module and an ID spraying module, the output end of the flaw detector is connected to an industrial computer system, and each steel pipe ID and inspection data are input to the database; When the flaw detector is successively sent to the flaw detector, the flaw detector uses the flaw detection module to detect the flaw of a single steel pipe, the weighing module weighs, the size measurement module measures the length and diameter, and finally uses the spraying module to mark the ID number on the surface of the steel pipe; the industrial computer system enters each After receiving the steel pipe data of the same frame, the control system in the industrial computer system can sum and match with the data entered in the quality flow card in the steel pipe frame number. This enables steel pipe flaw detection to be refined from the frame number of the smallest circulation unit to each steel pipe. At the same time, it improves quality inspection and management quality, reduces error rates, and makes use of quality control in the steel pipe production process.
进一步的,实时品质管理系统还包括工人退火操作管理系统,所述工人退火操作管理系统包括刷卡机和用于拍摄工人刷卡和退火操作的摄像头,所述刷卡机连接PLC的输入端,PLC的输出端连接摄像头;工人利用RFID人员身份卡刷卡时,刷卡机将刷卡信号输入PLC,PLC实时控制摄像头抓拍人员刷卡、人员退火操作的图像和视频,同时将抓拍图像和视频数据输入至工业计算机系统。Further, the real-time quality management system also includes a worker annealing operation management system, the worker annealing operation management system includes a card reader and a camera for photographing workers' card swiping and annealing operations, the card reader is connected to the input end of the PLC, and the output terminal of the PLC The terminal is connected to the camera; when the worker uses the RFID personnel identity card to swipe the card, the card swipe machine inputs the card swipe signal to the PLC, and the PLC controls the camera in real time to capture the images and videos of the personnel swipe the card and the personnel annealing operation, and at the same time input the captured images and video data to the industrial computer system.
进一步的,实时品质管理系统还包括地磅物流系统,地磅物流系统包括入口信息录入系统、出口信息确认系统、装载系统、门禁系统、地磅系统、带RFID标签的信息卡、RFID人员身份卡、RFID扫描仪、数据中心、控制中心和在线显示终端;所述门禁系统包括入库门禁和出库门禁,地磅系统包括空磅机构和复磅机构,所述入库门禁、RFID扫描仪和空磅机构均位于入口信息录入系统内,复磅机构和出库门禁均位于出口信息确认系统内;装载系统包括装载控制机构、校验机构、运输机构和仓储,仓储内放置有多个的单元储箱,所述校验机构包括RFID扫描机和用于记录单元储箱内装载物品信息的带RFID标签的信息卡,带RFID标签的信息卡位于单元储箱的表面,所述装载控制机构连接数据中心,装载控制机构操作运输机构由仓储内移动单元储箱至载具上;所述数据中心连接、采集并处理RFID扫描机、空磅机构和复磅机构的反馈数据,数据中心连接控制中心并将控制信号发送至控制中心;所述控制中心连接并控制入库门禁和出库门禁的启闭,控制中心连接装并控制载控制机构;所述在线显示终端与数据中心相连接。Further, the real-time quality management system also includes a weighbridge logistics system, which includes an entry information entry system, an export information confirmation system, a loading system, an access control system, a weighbridge system, information cards with RFID tags, RFID personnel identity cards, and RFID scanning instrument, data center, control center and online display terminal; the access control system includes storage access control and storage access control, and the weighbridge system includes an empty scale mechanism and a double scale mechanism. The storage access control, RFID scanner and empty scale mechanism are all Located in the entry information entry system, the weighing mechanism and the outbound access control are all located in the export information confirmation system; the loading system includes a loading control mechanism, a calibration mechanism, a transportation mechanism and storage, and multiple unit storage boxes are placed in the storage. The verification mechanism includes an RFID scanner and an information card with an RFID tag for recording the information of the items loaded in the unit storage box. The information card with the RFID tag is located on the surface of the unit storage box. The loading control mechanism is connected to the data center. The control mechanism operates the transportation mechanism from the mobile unit storage box in the warehouse to the carrier; the data center connects, collects and processes the feedback data of the RFID scanning machine, the empty scale mechanism and the double scale mechanism, and the data center connects to the control center and sends the control signal sent to the control center; the control center is connected to and controls the opening and closing of the storage access control and the storage access control, and the control center is connected to and controls the loading control mechanism; the online display terminal is connected to the data center.
进一步的,所述地磅物流系统中的数据中心位于数据库服务器内,地磅物流系统中的控制中心是工业计算机系统中控制系统的一部分。Further, the data center in the weighbridge logistics system is located in the database server, and the control center in the weighbridge logistics system is a part of the control system in the industrial computer system.
进一步的,所述空磅机构和复磅机构是同一地磅;所述入库门禁和出库门禁是同一门禁。Further, the empty scale mechanism and the double scale mechanism are the same weighbridge; the storage access control and the storage access control are the same access control.
作为优选,所述喷标模块包括ID喷标模块和刻度喷标模块,所述刻度喷标模块与尺寸测量模块信号连接。Preferably, the marking spraying module includes an ID marking marking module and a scale marking spraying module, and the scale marking spraying module is connected to the dimension measuring module by signal.
采用了上述技术方案实时品质管理系统,利用RFID对钢管流转工序实时录入和管理,具有如下优点:Adopting the real-time quality management system of the above-mentioned technical solution, using RFID to record and manage the steel pipe circulation process in real time, has the following advantages:
首先,本发明在传统的工艺卡上结合条码技术与RFID标签技术,将工艺卡变成一个智能工艺卡。该卡片不失传统工艺卡的功能,且具备条码扫描与感应功能,在复杂的生产环境下承担着数据承载功能。系统设计是智能卡感应为主,条码为辅,解决传统手写方式,避免手写的错误。简化员工对工艺卡的使用,上述带RFID标签的信息卡主要利用条码,上述RFID人员身份卡利用磁感应,这样结合标记钢管和人员,对整个流转工序进行管理,不仅具有很高的实时性和准确的追溯性,还可以利用工业计算机系统对这些标记的数据进行处理和分析,提高管理效率和生产效率,降低次品率。Firstly, the present invention combines barcode technology and RFID tag technology on the traditional craft card to turn the craft card into a smart craft card. The card does not lose the function of the traditional craft card, and has the function of barcode scanning and sensing, and bears the function of data bearing in the complex production environment. The system design is based on smart card sensing, supplemented by barcodes, which solves the traditional handwriting method and avoids handwriting errors. Simplify the use of process cards by employees. The above-mentioned information cards with RFID tags mainly use barcodes, and the above-mentioned RFID personnel identity cards use magnetic induction. In this way, combined with marking steel pipes and personnel, the entire circulation process is managed, which not only has high real-time and accuracy It can also use industrial computer systems to process and analyze these marked data, improve management efficiency and production efficiency, and reduce defective rate.
其次,由于钢管在检验过程中,有没有检验,客户是难以知道的。因此,本发明采用上述系统,可以采用该系统来约束所有的质检规范,使得客户实时可视其钢管的生产过程,钢管成品的质保书以及质保体系,也可以和本发明所提供系统的数据相关联,使得在销售环节也实现互联网化。让市场的购买者通过实时品质管理系统,能够在互联网上直接实时地看到钢管流转工序的生产规范,以及品质控制流程,能够对我公司的钢管生产规范,品质控制具有更强的信心。在生产管理上,也迫使企业的员工在该体系中有序运行,进而能够将员工的工作时间,工作效率以及出错率数据化和实时化。Secondly, it is difficult for customers to know whether the steel pipe has been inspected or not during the inspection process. Therefore, the present invention adopts the above-mentioned system, which can be used to constrain all quality inspection specifications, so that customers can visualize the production process of their steel pipes in real time, the quality assurance certificate and quality assurance system of finished steel pipes, and can also be compared with the data of the system provided by the present invention. Relevant, making the sales process also realize the Internet. Through the real-time quality management system, buyers in the market can directly see the production specifications of the steel pipe circulation process and the quality control process on the Internet in real time, and have stronger confidence in our company's steel pipe production specifications and quality control. In terms of production management, it also forces the employees of the enterprise to operate in an orderly manner in the system, so that the working hours, work efficiency and error rate of employees can be digitized and real-time.
再其次,本发明采用上述系统,还能够对钢管质检出现的缺陷快速录入到工业计算机系统中,通过数据库对比结合控制系统运行,能够快速反馈大面积缺陷的成因,从而快速追溯生产工序中的设备、控制器、工艺参数以及人员操作上的问题,便于快速追溯技术问题已经员工责任问题,从而不仅提高生产效率和管理效率,而且提供品质管理,进而减少损失。Secondly, the present invention adopts the above-mentioned system, which can also quickly enter the defects in the steel pipe quality inspection into the industrial computer system, and through the database comparison combined with the operation of the control system, the cause of large-area defects can be quickly fed back, so as to quickly trace the defects in the production process. Problems in equipment, controllers, process parameters, and personnel operations are easy to quickly trace technical problems and employee responsibility issues, thereby not only improving production efficiency and management efficiency, but also providing quality management to reduce losses.
另外,作为本发明的优选方案,本发明引入成品钢管品质管理系统,还能让我们的钢管产品打上标签,通过大数据管理,让我们公司能够实时地了解到钢管的销售时间、使用地点以及使用期限,从而通过网络手段保障钢管的使用安全和更换期限,不仅有利于本公司的销售,而且有利于解决钢管在销售后的超期服役的使用安全问题。In addition, as a preferred solution of the present invention, the present invention introduces the quality management system of finished steel pipes, which can also allow our steel pipe products to be labeled. Through big data management, our company can know the sales time, place of use and usage of steel pipes in real time. The time limit, so as to ensure the safety of steel pipes and the replacement period through network means, is not only beneficial to the company's sales, but also helps to solve the safety problem of steel pipes after they are sold for extended service.
附图说明Description of drawings
图1:本发明实施例的结构框图。Fig. 1: Structural block diagram of the embodiment of the present invention.
图2:本发明实施例的探伤过程的结构框图。Fig. 2: Structural block diagram of the flaw detection process of the embodiment of the present invention.
图3:本发明实施例的工人退火操作管理系统的结构框图。Fig. 3: A structural block diagram of the worker annealing operation management system of the embodiment of the present invention.
图4:本发明实施例的地磅物流系统的结构框图一。Fig. 4: Structural block diagram 1 of the weighbridge logistics system of the embodiment of the present invention.
图5:本发明实施例的地磅物流系统的结构框图二。Fig. 5: Structural block diagram 2 of the weighbridge logistics system of the embodiment of the present invention.
具体实施方式Detailed ways
下面结合附图对本发明做进一步描述。The present invention will be further described below in conjunction with the accompanying drawings.
如图1所示的一种利用RFID对钢管流转工序的实时品质管理系统,它主要包括钢管生产设备、钢管检验设备、带RFID标签的信息卡、RFID人员身份卡、RFID扫描仪、工业计算机系统和在线显示终端。As shown in Figure 1, a real-time quality management system using RFID for the steel pipe circulation process mainly includes steel pipe production equipment, steel pipe inspection equipment, information cards with RFID tags, RFID personnel identity cards, RFID scanners, and industrial computer systems and online display terminal.
上述工业计算机系统包括人机交互系统、数据库服务器和控制系统,人机交互系统、数据库服务器和控制系统之间相互连接,它们信号相互传递。人机交互系统包括输入模块、数据输出显示界面和数据监控模块,其中输入模块连接数据输出显示界面,数据监控模块分别连接数据输出显示界面、数据库服务器和控制系统。RFID扫描仪直接或间接地通过输入模块连接人机交互系统。The above-mentioned industrial computer system includes a human-computer interaction system, a database server and a control system. The human-computer interaction system, the database server and the control system are connected to each other, and their signals are transmitted to each other. The human-computer interaction system includes an input module, a data output display interface and a data monitoring module, wherein the input module is connected to the data output display interface, and the data monitoring module is respectively connected to the data output display interface, the database server and the control system. The RFID scanner is directly or indirectly connected to the human-computer interaction system through the input module.
上述数据库服务器至少包括预设的原料信息、预设钢管缺陷信息、预设的热处理信息和预设的缺陷原理关联信息;所述控制系统至少包括数据对比模块、数据匹配模块和数据运算模块。The above database server at least includes preset raw material information, preset steel pipe defect information, preset heat treatment information and preset defect principle related information; the control system includes at least a data comparison module, a data matching module and a data calculation module.
带RFID标签的信息卡包括用于录入钢管检验预设规格数据的质量流转卡,RFID人员身份卡是钢管流转工序中用于唯一识别操作人员手工操作或录入数据的身份卡。The information card with RFID tag includes the quality circulation card used to enter the preset specification data of steel pipe inspection, and the RFID personnel identification card is the identity card used to uniquely identify the manual operation or data entry of the operator in the steel pipe circulation process.
RFID扫描仪连接人机交互系统上的输入模块,钢管框号内的质量流转卡通过RFID扫描仪,自动录入钢管框号、钢管规格和其他预设的质量要求至人机交互系统上。上述涡流探伤仪对框号的钢管的探伤数据分为手工记录数据和自动记录数据。涡流探伤仪上的自动记录数据自动录入人机交互系统;操作人员的手工记录数据通过他的RFID人员身份卡经过RFID扫描仪扫描后,将手工记录数据手工录入至他名下的人机交互系统上。The RFID scanner is connected to the input module on the human-computer interaction system, and the quality flow card in the steel pipe frame number passes through the RFID scanner to automatically input the steel pipe frame number, steel pipe specification and other preset quality requirements to the human-computer interaction system. The above-mentioned eddy current flaw detector detects data on steel pipes with frame numbers into manual record data and automatic record data. The automatic recording data on the eddy current flaw detector is automatically entered into the human-computer interaction system; the manual recording data of the operator is scanned by the RFID scanner through his RFID personnel identity card, and the manual recording data is manually entered into the human-computer interaction system under his name superior.
上述钢管生产设备包括冷轧控制设备、酸洗控制设备和热处理控制设备,冷轧控制设备包括PLC控制系统A和轧机;酸洗控制设备包括PLC控制系统B和酸洗设备;热处理控制设备包括PLC控制系统C和退火炉;所述钢管检验设备包括涡流探伤仪。具体地,PLC控制系统A包括PLC#2和检测轧机上参数的各个传感器以及改变轧机各个参数的执行器,PLC#2通过传感器来的信号,记录和保存数据,并且通过与预设的数据进行运行,反馈调节轧机。PLC#2同时又作为带RFID标签的一个控制器,或者说是带对应I D轧机的数据对工业计算机系统进行相互的数据传送。同理,PLC控制系统C包括PLC#1和检测退火炉上参数的各个传感器以及改变轧机各个参数的执行器,各个传感器诸如温度、压力、功率等数据,也是通过上述PLC#1对热处理过程进行反馈调节。酸洗控制设备也同理,不再赘述。上述钢管的生产设备输出的信号和质量流转卡一致,也都是带钢管框号的。另外,需要说明的是,上述钢管生产设备属于包括性的例举,其一定程度上对后续钢管的质量管理会产生一定影响。The above steel pipe production equipment includes cold rolling control equipment, pickling control equipment and heat treatment control equipment, cold rolling control equipment includes PLC control system A and rolling mill; pickling control equipment includes PLC control system B and pickling equipment; heat treatment control equipment includes PLC Control system C and an annealing furnace; the steel pipe inspection equipment includes an eddy current flaw detector. Specifically, the PLC control system A includes PLC#2 and various sensors that detect parameters on the rolling mill and actuators that change various parameters of the rolling mill. PLC#2 records and saves data through signals from sensors, and communicates with preset data Run, feedback to adjust the mill. PLC#2 also serves as a controller with RFID tags, or in other words, with data corresponding to ID rolling mills for mutual data transmission to industrial computer systems. Similarly, the PLC control system C includes PLC#1 and various sensors for detecting parameters on the annealing furnace and actuators for changing various parameters of the rolling mill. The data of each sensor such as temperature, pressure, power, etc. Feedback regulation. The same is true for the pickling control equipment, so I won't repeat it here. The signal output by the production equipment of the above-mentioned steel pipes is consistent with the quality flow card, and they all have steel pipe frame numbers. In addition, it should be noted that the above-mentioned steel pipe production equipment is an inclusive example, which will have a certain impact on the quality management of subsequent steel pipes to a certain extent.
上述冷轧控制设备、酸洗控制设备和热处理控制设备分别通过各自的PLC数据连接工业计算机系统,用于将它们各自的工艺参数实时录至工业计算机系统中。在线显示终端通过网络连接工业计算机系统,实时抓取工业计算机系统中的生产工艺参数、检验数据和人员操作。因此,在线显示终端可以是PC、手机、平板等可以通过HTTP上网的终端设备或者通过联网的PC软件、APP软件的的终端设备。The above-mentioned cold rolling control equipment, pickling control equipment and heat treatment control equipment are respectively connected to the industrial computer system through their respective PLC data, and are used to record their respective process parameters into the industrial computer system in real time. The online display terminal is connected to the industrial computer system through the network, and captures the production process parameters, inspection data and personnel operations in the industrial computer system in real time. Therefore, the online display terminal can be a terminal device such as a PC, a mobile phone, a tablet, etc. that can access the Internet through HTTP, or a terminal device through a networked PC software or APP software.
进一步地,本发明还可以包括一些警报器,控制系统连接警报器,品质管理系统出现大面积异常时,即可报警,报警器的形式可以是软件的报警显示模块,也可以带声音提示的硬件报警模块。Further, the present invention may also include some alarms, the control system is connected to the alarms, and when a large area of abnormality occurs in the quality management system, an alarm can be issued. The alarm can be in the form of a software alarm display module or a hardware with sound prompts. Alarm module.
实施例2:Example 2:
如图1所示,本实施例和实施例1的区别在于,本实施例还包括成品钢管品质管理系统,成品钢管品质管理系统包括带RFID标签的成品钢管、预存入成品钢管数据的数据库服务器、远程RFID扫描仪和远程输入终端;RFID人员身份卡还包括销售人员身份卡和安装人员身份卡。成品钢管销售数据通过销售人员身份卡在远程RFID扫描仪后,录入远程输入终端,远程输入终端连接所述工业计算机系统。图1中未示出远程RFID扫描仪,用实施例1的RFID扫描仪替代。成品钢管安装数据通过安装人员身份卡在远程RFID扫描仪后,录入远程输入终端。As shown in Figure 1, the difference between this embodiment and Embodiment 1 is that this embodiment also includes a finished steel pipe quality management system, and the finished steel pipe quality management system includes finished steel pipes with RFID tags, a database server that pre-stores the data of finished steel pipes, Remote RFID scanners and remote input terminals; RFID personnel identification cards also include sales personnel identification cards and installer identification cards. The sales data of the finished steel pipe is entered into the remote input terminal through the identity card of the salesperson behind the remote RFID scanner, and the remote input terminal is connected to the industrial computer system. The remote RFID scanner is not shown in FIG. 1 , and is replaced by the RFID scanner of Embodiment 1. The installation data of the finished steel pipe is entered into the remote input terminal after the installer's identity card is placed on the remote RFID scanner.
本实施例的另一个目的在于,本实施例不仅仅包括钢管生产环节的流转工序进行的品质管理,还包括后续的安装管理、质保服务以及服役期限监控,使得钢管的使用在全球范围内完成钢管物联建设,确保杜绝超期服役现象,而且能够快速追溯质保服务、也确保专人有序地控制安装管理。Another purpose of this embodiment is that this embodiment not only includes quality management in the circulation process of the steel pipe production link, but also includes subsequent installation management, quality assurance services, and service period monitoring, so that the use of steel pipes can be completed globally. The construction of the Internet of Things ensures that the phenomenon of overdue service is eliminated, and the quality assurance service can be quickly traced, and it is also ensured that special personnel can control the installation and management in an orderly manner.
实施例3:Example 3:
如图1和图2所示,本实施例和实施例1的区别在于,本实施例的探伤仪是集成探伤仪,它包括探伤模块、称重模块、尺寸测量模块和喷标模块,喷标模块包括ID喷标模块和刻度喷标模块,刻度喷标模块与尺寸测量模块信号连接。上述探伤仪的输出端连接工业计算机系统,将每支钢管ID和检验数据输入至数据库。钢管从框中陆续送入探伤仪时,探伤仪对单支钢管利用探伤模块探伤、称重模块称重、尺寸测量模块测量长度和直径,最后再利用ID喷标模块在钢管表面打上ID号。因为刻度喷标模块与尺寸测量模块信号连接,利用刻度喷标模块就可以很方便地在每支成品钢管上打上刻度,方便使用者截管安装。工业计算机系统录入每支同框钢管数据之后,工业计算机系统中的控制系统可以求和,并与所述钢管框号内的质量流转卡录入的数据匹配。这使得钢管探伤从最小流转单位的框号精细化到每支钢管,同时,提高质检和管理品质,减少出错率,利用做好钢管生产过程中的品质控制。另外,本实施例的最大优势在于,在钢管成品检验阶段,顺利地集成钢管参数测量模块,不仅一步将钢管的重量、长度进行测量,用于匹配框号中的质量流转数据,从而减少错误率,而且这些测量数据还用于品控,用于精细化管理将钢管品质管理至每支。尽管从框号到支的管理已经在现有钢管生产管理水平中有了质的飞跃,可本实施例还做到了将这些测量数据实时应用于ID参数喷标和刻度喷标中。须知,这些检测数据和实施例1中出现的很多钢管数据、编号均是输入至数据库的。而本实施例中的喷标ID号可以带有数据库访问地址信息,这样一来,每支钢管均可以通过喷标模块喷出的ID信息来访问其所有的钢管信息。As shown in Figure 1 and Figure 2, the difference between this embodiment and Embodiment 1 is that the flaw detector of this embodiment is an integrated flaw detector, which includes a flaw detection module, a weighing module, a size measurement module and a labeling module, and the labeling The module includes an ID spraying module and a scale spraying module, and the scale spraying module is connected to the size measurement module by signal. The output end of the above-mentioned flaw detector is connected to the industrial computer system, and the ID and inspection data of each steel pipe are input into the database. When the steel pipes are fed into the flaw detector successively from the frame, the flaw detector uses the flaw detection module to detect flaws, the weighing module to weigh, and the size measurement module to measure the length and diameter of a single steel pipe, and finally uses the ID spraying module to mark the ID number on the surface of the steel pipe. Because the scale spraying module is connected with the signal of the size measurement module, the scale spraying module can be used to easily mark the scale on each finished steel pipe, which is convenient for users to cut and install. After the industrial computer system enters the data of each steel pipe in the same frame, the control system in the industrial computer system can sum and match the data entered in the quality flow card in the frame number of the steel pipe. This enables steel pipe flaw detection to be refined from the frame number of the smallest circulation unit to each steel pipe. At the same time, it improves quality inspection and management quality, reduces error rates, and makes use of quality control in the steel pipe production process. In addition, the biggest advantage of this embodiment is that in the steel pipe product inspection stage, the steel pipe parameter measurement module is smoothly integrated, which not only measures the weight and length of the steel pipe in one step, but also uses it to match the quality flow data in the frame number, thereby reducing the error rate , and these measurement data are also used for quality control, and for refined management to manage the quality of steel pipes to each piece. Although the management from the frame number to the branch has made a qualitative leap in the existing steel pipe production management level, this embodiment also achieves the real-time application of these measurement data to ID parameter spraying and scale spraying. It should be noted that these test data and many steel pipe data and serial numbers appearing in Example 1 are all input into the database. The ID number of the spray label in this embodiment can have database access address information, so that each steel pipe can access all its steel pipe information through the ID information sprayed by the label spray module.
另外,如图3所示,本实施例和实施例1的区别还在于,本实施例还包括工人退火操作管理系统,工人退火操作管理系统包括刷卡机和用于拍摄工人刷卡和退火操作的摄像头,刷卡机连接PLC的输入端,PLC的输出端连接摄像头;工人利用RFID人员身份卡刷卡时,刷卡机将刷卡信号输入PLC,PLC实时控制摄像头抓拍人员刷卡、人员退火操作的图像和视频,同时将抓拍图像和视频数据输入至工业计算机系统。其中的PLC可以是PLC控制系统C中的PLC,工人退火操作管理系统的目的一方面能够实时有序地监控工人,让工人能够有序稳定地操作,提高钢管品质;第二方面可以将退火数据放到网络远端,让购买者能够看到退火过程。In addition, as shown in Figure 3, the difference between this embodiment and Embodiment 1 is that this embodiment also includes a worker annealing operation management system, and the worker annealing operation management system includes a card reader and a camera for photographing workers' card swiping and annealing operations , the card reader is connected to the input terminal of the PLC, and the output terminal of the PLC is connected to the camera; when the worker uses the RFID personnel identity card to swipe the card, the card reader inputs the card swipe signal to the PLC, and the PLC controls the camera in real time to capture the images and videos of the personnel swipe card and personnel annealing operation, and at the same time Input the captured image and video data into the industrial computer system. The PLC can be the PLC in the PLC control system C. The purpose of the worker annealing operation management system is to monitor the workers in real time and orderly on the one hand, so that the workers can operate in an orderly and stable manner and improve the quality of steel pipes; on the other hand, the annealing data can be Put it on the remote side of the network, so that the buyer can see the annealing process.
实施例4:Example 4:
如图1和图4所示,本实施例和实施例1的区别在于,本实施例的还包括地磅物流系统,地磅物流系统包括入口信息录入系统1、出口信息确认系统3、装载系统2、门禁系统、地磅系统、带RFID标签的信息卡4、RFID人员身份卡、RFID扫描仪、数据中心、控制中心和在线显示终端,门禁系统包括入库门禁和出库门禁,地磅系统包括空磅机构的复磅机构。数据中心连接、采集并处理RFID扫描机、空磅机构和复磅机构的反馈数据,数据中心连接控制中心并将控制信号发送至控制中心。控制中心连接并控制入库门禁和出库门禁的启闭,控制中心连接装并控制载控制机构;在线显示终端与数据中心相连接。入口信息录入系统1包括入库门禁、RFID扫描仪和空磅机构,入口信息录入系统增设了载具识别及记录的功能,驾驶人员需携带RFID人员身份卡,RFID人员身份卡上记录有多种信息包括:载具牌照、型号、驾驶员身份信息以及载货量;当驾驶员将人员身份卡在RFID扫描机上扫描时,可以将人员身份卡的信息输送至数据中西进行核对,没有错误入库门禁打开,并将入库载具进行记录。As shown in Figures 1 and 4, the difference between this embodiment and Embodiment 1 is that this embodiment also includes a weighbridge logistics system, and the weighbridge logistics system includes an entry information entry system 1, an export information confirmation system 3, a loading system 2, Access control system, weighbridge system, information card with RFID tag 4, RFID personnel identity card, RFID scanner, data center, control center and online display terminal, access control system includes storage access control and delivery access control, and weighbridge system includes empty scale mechanism The complex weighing mechanism. The data center connects, collects and processes the feedback data of the RFID scanning machine, the empty scale mechanism and the double scale mechanism, and the data center connects with the control center and sends the control signal to the control center. The control center is connected to and controls the opening and closing of the storage access control and the storage access control, and the control center is connected to and controls the load control mechanism; the online display terminal is connected to the data center. Entrance information entry system 1 includes warehousing access control, RFID scanner and empty scale mechanism. The entrance information entry system adds the function of vehicle identification and recording. Drivers need to carry RFID personnel identity cards, which record various The information includes: vehicle license plate, model, driver's identity information, and cargo capacity; when the driver scans the identity card on the RFID scanning machine, the information of the identity card can be sent to the data center for verification, and no errors are stored in the warehouse The access control is opened, and the incoming vehicles are recorded.
出口信息确认系统3包括复磅机构和出库门禁;出口信息确认系统3用于最终清点出库,通过复磅机构对载具和货物进行称重,减去空磅机构称重得到的载具重量,获得载货重量数据并发送至数据中心,通过与理论值比较相差的重量在一定范围内时,则载货数量清点无误,打开出库门禁,完成清点出库。若误差超出范围,则需人工进行检查,找出误差原因。这样可以有效的降低清点时间,提高效率,并且保证出库时无多载或少载。The export information confirmation system 3 includes a re-weighing mechanism and outbound access control; the export information confirming system 3 is used for the final check-out of the warehouse. Weight: Get the cargo weight data and send it to the data center. When the weight difference from the theoretical value is within a certain range, the cargo quantity is counted correctly, and the outbound access control is opened to complete the inventory outbound. If the error exceeds the range, manual inspection is required to find out the cause of the error. This can effectively reduce the inventory time, improve efficiency, and ensure that there is no over-load or under-load when leaving the warehouse.
装载系统2包括装载控制机构、校验机构、运输机构和仓储,仓储内放置有多个的单元储箱,校验机构包括RFID扫描机和带RFID标签的信息卡4,带RFID标签的信息卡4粘贴于单元储箱的表面,装载控制机构连接数据处理中心,装载控制机构操作运输机构由仓储内移动单元储箱至载具上;The loading system 2 includes a loading control mechanism, a verification mechanism, a transportation mechanism and a warehouse. Multiple unit storage boxes are placed in the warehouse. The verification mechanism includes an RFID scanner and an information card 4 with an RFID tag. The information card with an RFID tag 4 Pasted on the surface of the unit storage box, the loading control mechanism is connected to the data processing center, and the loading control mechanism operates the transportation mechanism to move the unit storage box from the warehouse to the carrier;
仓储内的单元储箱用于装钢管,单元储箱内的钢管规格及数量并不完全相同,当货物放入单元储箱时,操作人员首先扫描单元储箱表面的RFID标签信息卡,在数据中心寻找到对应的单元储箱编号,在数据中心中将单元储箱内的钢管信息:如长度、管厚等规格,以及钢管的数量和单元储箱的摆放位置,进行信息更改置换,最后保留在数据中心内等待调用。The unit storage boxes in the warehouse are used to hold steel pipes. The specifications and quantities of steel pipes in the unit storage boxes are not exactly the same. The center finds the corresponding unit storage box number, and changes and replaces the steel pipe information in the unit storage box in the data center: such as length, pipe thickness and other specifications, as well as the number of steel pipes and the placement position of the unit storage box, and finally Remains in the data center waiting to be called.
在装载环节中,驾驶员在进入入口信息录入系统1时,RFID扫描机读取到的RFID人员身份卡上的装货规格、数量信息,并发送至数据中心,数据中心将信息进行处理,将多个单元储箱进行组合完成配货:In the loading link, when the driver enters the entrance information entry system 1, the RFID scanning machine reads the loading specification and quantity information on the RFID personnel identity card and sends it to the data center, which processes the information and converts it to the data center. Multiple unit storage boxes are combined to complete the distribution:
数据中心读取各个单元储箱的位置,数据中心通过控制中心操作装载控制机构启动运输机构,运输机构根据位置信息带着RFID扫描机对要装载的单元储箱上的信息卡进行信息读取,与数据中心内的编号进行校对,确认无误后将单元储箱运送至载具上。The data center reads the position of each unit storage box, and the data center operates the loading control mechanism through the control center to start the transportation mechanism, and the transportation mechanism takes the RFID scanner to read the information on the information card on the unit storage box to be loaded according to the location information. Check with the serial number in the data center, and transport the unit storage box to the carrier after confirming that it is correct.
本实施例中的RFID扫描仪、在线显示终端均通过无线设备与数据中心连接,无线设备可以采用wifi或Bluetooth等常用的无线对接设备进行连接,时RFID扫描仪的摆放位置可以根据实际使用环境进行灵活的调节,甚至可以增设服务,保证使用者可以在局域网以外的网络进行远程控制。The RFID scanner and the online display terminal in this embodiment are all connected to the data center through a wireless device, and the wireless device can be connected with commonly used wireless docking devices such as wifi or Bluetooth, and the RFID scanner can be placed according to the actual use environment It can be adjusted flexibly, and even additional services can be added to ensure that users can perform remote control in networks other than the LAN.
本实施例中的显示终端除了在线显示终端,还增设有网络显示终端,管理/操作人员可以远程进行监控,同时可以进行远程控制。In addition to the online display terminal, the display terminal in this embodiment is additionally equipped with a network display terminal, so that management/operating personnel can perform remote monitoring and remote control.
装载系统2内设有清单打印机,装载控制机构连接并控制清单打印机,当驾驶员持RFID人员身份卡进入时,RFID扫描机扫描信息,并生成一份清单表格,传送至装载控制机构,装载控制机构控制清单打印机打印货物清单表格,驾驶员取来表格并对载具上的单元储箱编号进行人工初步确认,并且使货物情况更清楚,易于后续处理。The loading system 2 is equipped with a list printer, and the loading control mechanism is connected to and controls the list printer. When the driver enters with the RFID personnel ID card, the RFID scanner scans the information and generates a list form, which is sent to the loading control mechanism. The agency control list printer prints the cargo list form, and the driver takes the form and manually confirms the unit storage tank number on the vehicle, and makes the cargo situation clearer and easier for follow-up processing.
本实施例中的运输机构采用行车,载具采用普通的货车,但是并不限于货车,也可以是飞机、货轮等其他运输工具。The transportation mechanism in this embodiment adopts a driving vehicle, and the carrier adopts an ordinary truck, but it is not limited to a truck, and may also be other means of transportation such as an airplane and a freighter.
实施例5:本实施例与实施例4的区别在于:本实施例的地磅物流系统中的数据中心位于数据库服务器内,地磅物流系统中的控制中心是工业计算机系统中控制系统的一部分。Embodiment 5: The difference between this embodiment and Embodiment 4 is that the data center in the weighbridge logistics system of this embodiment is located in the database server, and the control center in the weighbridge logistics system is a part of the control system in the industrial computer system.
实施例6:如图5所示,本实施例与实施例4的区别在于:本实施例的空磅机构和复磅机构是同一地磅。入库门禁和出库门禁是同一门禁,大大减省了成本。而且磅的统一还提高了精度,门禁的统一,减少了一个门禁口子,除了减省成本还提高了管理安全性。Embodiment 6: As shown in Figure 5, the difference between this embodiment and Embodiment 4 is that the empty scale mechanism and the double scale mechanism of this embodiment are the same weighbridge. The entry control and exit control are the same access control, which greatly reduces the cost. Moreover, the unification of pounds also improves the accuracy, and the unification of access control reduces an access control opening, which not only reduces costs but also improves management security.
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