CN110290597B - EPR data updating and transmitting method and device for automatic lathe - Google Patents
EPR data updating and transmitting method and device for automatic lathe Download PDFInfo
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Abstract
The invention aims to provide a method and a device for updating and transmitting EPR data of an automatic lathe, which are used for providing original data information for shaft part processing enterprises to realize production automation management and product tracing.
Description
Technical Field
The invention relates to the technical field of automation, in particular to a method and a device for updating and transmitting EPR data of an automatic lathe.
Background
The shaft parts are common and important parts in the mechanical industry, and are always used for supporting transmission parts, transmitting torque and bearing load, and the front feeding automatic numerical control lathe is a low-price automatic feeding, clamping and machining numerical control lathe capable of machining the shaft parts. At present, in most machining workshops, raw materials, semi-finished products to be machined and finished product stacks are disordered, and professional skill states of workers are irregular, so that a large number of unqualified products (dimension machining errors, surface roughness and the like do not meet standards) exist in the production process of shaft parts from the raw material end to the finished product, and during quality tracing, the operators have mutual push-off responsibility and the like. Not only can the staff of the production enterprise not reasonably manage, but also can lead to a large amount of waste of unqualified products (for example, when a certain procedure is unqualified, other procedures of the shaft can be continuously processed in the later period). In addition, the information of the quantity of each type of shaft from the raw material end to the warehouse entry, the quantity of unqualified products and the like has very important significance for the online tracing of the products.
Disclosure of Invention
The invention aims to provide a method and a device for updating and transmitting EPR data of an automatic lathe, which can finish the acquisition, updating and transmission of original data of a system. In order to realize the purpose, the technical scheme adopted by the invention is as follows:
the invention aims to provide a method and a device for updating and transmitting EPR data of an automatic lathe, which comprise the following parts:
the sub-stations are responsible for collecting the data such as the total number of the processing shafts, the number of unqualified products, the workload of operators, the execution condition and the like on each front feeding automatic numerical control lathe;
the switchboard is responsible for summarizing data transmitted from the substation according to a certain format and transmitting the summarized data to the PC client, and the substation and the switchboard are in wireless communication;
the PC client side collects the received information of each sub-site and finally broadcasts the information through a UDP network according to the client requirement format;
the method flow of the system data acquisition, updating and transmission method is divided into 5 major steps;
the system structure of the substation comprises a microcontroller, a power supply conversion module, a wireless transmission module, an RFID module, a technical sensor array, a sensor signal processing circuit module, a display module and a keyboard input module; the sub-station can be set to automatically jump when the sub-station is possibly far away from the switchboard, and can be used as a wireless transmitting module and a relay station of other sub-stations, so that transmission at a larger distance is completed through relay jumping;
the microcontroller adopts an ARM 32-bit Cortex-M3 processor with the characteristics of high performance, multiple interfaces, strong comprehensive performance and the like, and is matched with a crystal oscillator circuit, a reset circuit, a downloading circuit and the like to form a minimum working system to be responsible for tasks such as operation, data acquisition, information input and display of the substation device;
the power supply conversion module adopts chips such as standard devices L7815, L7809, L7805, LM1117-3.3 and the like, and is responsible for converting a +24v power supply in a weak electric box of a machine tool into +15v, +9v, +5v in three stages, so that the +5v and +3.3v power supplies required by a system are realized;
the wireless transmission module adopts a commercially available DL-LN33 wireless ad hoc network multi-hop module, the module is connected through a serial port in communication, automatic multi-hop receiving and sending can be realized, communication relay is realized, and in addition, a 1024-byte receiving and sending buffer area is arranged, so that the receiving and sending of multiple data can be realized without overflow;
the RFID module is based on an MFRC-522 chip and matched with part of peripheral circuit design, and can realize information reading and writing of a radio frequency card;
the counting sensor array adopts 2 alternating current two-wire inductive proximity switches FA18-8KB and 1 travel switch YBLX-ME/8104, wherein the inductive proximity switches FA18-8KB and the travel switch YBLX-ME/8104 adopt 90V-220V alternating current for power supply, are directly connected to an alternating current contactor, have the sensing distance of 8mm and are used for counting the detection of a shaft to be processed on a numerical control lathe at the transmission ends of two sides; the latter adopts an ohm dragon travel switch, and counts the workpieces when the main shaft is machined and the shaft to be machined is clamped;
the sensor signal processing circuit is used for realizing the processing and conversion of sensor signals so as to facilitate the signal acquisition of the microcontroller;
the display module and the keyboard input module are man-machine interaction equipment of the equipment and are used for setting a system, inputting information and displaying;
3. the switchboard system structure consists of a microcontroller, a power supply conversion module, a wireless transmission module, a display module and a keyboard input module;
the microcontroller adopts an ARM 32-bit Cortex-M3 processor with the characteristics of high performance, multiple interfaces, strong comprehensive performance and the like, and is matched with a crystal oscillator circuit, a reset circuit, a downloading circuit and the like to form a minimum working system to take charge of the tasks of the operation, data acquisition, information input, display and the like of the substation device;
the power supply conversion module adopts chips such as standard devices L7815, L7809, L7805, LM1117-3.3 and the like, and is responsible for converting a +24v power supply in a weak electric box of a machine tool into +15v, +9v, +5v in three stages, so that the +5v and +3.3v power supplies required by a system are realized;
the wireless transmission module adopts a commercially available DL-LN33 wireless ad hoc network multi-hop module, the module is connected through a serial port in communication, automatic multi-hop receiving and sending can be realized, communication relay is realized, and in addition, a 1024-byte receiving and sending buffer area is arranged, so that the receiving and sending of multiple data can be realized without overflow;
the display module and the keyboard input module are man-machine interaction equipment of the equipment and are used for setting a system, inputting information and displaying;
the PC client automatically receives data signals from each substation end according to the received information of each substation, the microcontroller immediately transmits the information to the PC client through the SCI serial communication interface at a certain baud rate after receiving the information, and meanwhile, the microcontroller counts forwarded data, analyzes whether the data transmission of each substation is overtime or not, alarms on the display module when the data transmission is overtime, and simultaneously transmits the data to the PC client for the EPR system to display; the working state (three states of shutdown/standby/normal production) of the equipment is provided by the switchboard, if the switchboard considers that the networking of the substation is received, but the data of the substation is never received, the switchboard considers that the equipment is in a standby state at present; the normal received data is in a normal production state; when the networking of the substation is not detected, the system power supply is not provided and the system is in a 'shutdown' state;
5. the method flow of the system data acquisition, update and transmission method is totally divided into 5 major steps, and through implementation of the five major steps, the system can perform data networking for a plurality of front feeding automatic numerical control lathes, so that real-time online acquisition, update and transmission of data such as the total number of machining shafts, the number of unqualified products, the workload of operators, the execution condition and the like, and final broadcasting can be realized;
the first step is as follows: acquiring basic data of equipment in different stations, and acquiring data such as the total number of machining shafts, the number of unqualified products, the workload of operators, the execution condition and the like, wherein the total number of the machining shafts is always realized by a counting sensor; the work task amount is issued and input by a networking network and is confirmed by an operator by swiping a card; the quantity of unqualified products is manually input by equipment operators; the equipment task execution condition is calculated and displayed by the extension set in real time according to the total task amount and the total number of the processing shafts; the method for acquiring the basic data of the equipment by the sub-site is divided into a plurality of small steps;
s1: and powering up and initializing the substation microcontroller. The substation and the numerical control lathe share a power supply, when the numerical control lathe is powered on, the substation is powered on and initialized, and the initialization comprises peripherals such as GPIO (general purpose input/output)/timer/SCI (serial communication interface)/external interrupt/FLASH and the like;
s2: reading FLASH data, configuring the system and updating display screen display. As the system may have a rapid power failure condition, the substation stores the FLASH data by using the battery power of the board itself for later data reading;
s3: performing self-networking by sites; the sub-sites send instructions to the host computer end, and the host computer immediately replies according to the port numbers of the sub-sites after receiving the instructions; when the sub-site receives the reply information, networking is successful, otherwise, task networking fails; if the networking fails, the information needs to be sent again after 60 seconds, the handshake is further carried out, and when the attempts fail for more than 3 times, the alarm prompt is carried out on the display screen;
s4: the substations receive data from the sensor array. The sensor array is used for sensing the shaft parts, sensing when the shaft parts to be machined exist and the shaft parts not to be machined exist can be transmitted, and further counting of the total number of the machining shafts and calculation of other information are achieved;
for the alternating current two-wire sensor FA18-8KB, because the power supply and the signal wire are shared, when metal is in a detection range, the metal is equivalent to short circuit, and the input of the subsequent signal processing circuit is low level; otherwise, it is equivalent to open circuit, and the input of the following signal processing circuit is normal alternating current signal; after signal conditioning, the output of the signal conditioning can be changed into a rectangular wave signal for the microcontroller to collect;
for the travel switch, the output is rectangular wave signal with low level of 0V and high level of +24V, and the rectangular wave signal is subjected to amplitude limiting and filtering by the signal processing circuit and then is sent to the microcontroller for collection and processing;
the second step is that: and comprehensively judging the data of the substation, and for the front feeding numerical control lathe, as the feeding is firstly transmitted in the production process of the shaft to be processed, the inductive switch can sense the signal of the proximity switch, then the workpiece is clamped and processed, and finally the discharging is transmitted. Aiming at the number counting of the processing shafts, a three-point counting weighting method is adopted;
s1: waiting for the signal of the proximity switch 1, wherein the system is inevitably sensed by the proximity switch 1 when feeding, and timing by a timer when receiving the signal of the sensor;
s2: judging whether a signal of the travel switch exists subsequently, judging whether the signal of the travel switch exists or not through interruption, and if the signal of the travel switch exists, judging that the signal is an effective signal, and performing the step 3; otherwise, continuously waiting, and once the waiting time is too long, setting the program to be 25S, considering the processing number of the workpieces, about 3-5 signals in one minute, considering the signal of the first step as an interference signal, and abandoning the counting;
s3: judging whether a signal of the proximity switch 2 exists at last; judging whether a signal of the proximity switch 2 exists or not through interruption, and if so, judging that the signal is an effective signal, and judging in the step 3; otherwise, continuously waiting, once the waiting time is too long, setting 20S in the program, the discharging transmission distance is shorter, the normal condition is 3-7S, considering the signal of the first step as an interference signal, and then abandoning the counting,
s4: counting the total count value of the current machining shaft, calculating the task completion condition and counting the number of unqualified products; the total task amount is issued to the sub-sites by an EPR system through a switchboard, then the total task amount is confirmed after an operator swipes a card, and the task completion condition is expressed by percentage; the number of unqualified products is manually input by an operator, and the number of the unqualified products can be increased or reduced one by one through keys on the device;
the third step: networking data transmission by sub-sites, wherein each sub-site has a unique port number, and the switchboard also has a unique port number; during networking, each substation sends a 'ready' character to the switchboard, then waits for the switchboard to reply an 'ok' character, if the ok character is received within a fixed time of 10s, the networking is considered to be successful, otherwise, the networking is considered to be unsuccessful; aiming at the branch stations and the switchboard which are successfully networked, the switchboard displays the information of each branch station in the network on a display end; through repeated design modification and experiments, a data random transmission method is provided;
s1: firstly, setting a program in a substation microcontroller to generate random numbers, wherein the range of the random numbers is from 0 to 100, and the random numbers are generated every 1S;
s2: if two continuously generated random numbers are the same, namely one random number is an odd number C1, the other generated random number is C2 and is still an odd number, or namely one random number is an even number C1, and the other generated random number is C2 and is still an even number, data transmission is generated; otherwise no data is sent. Through a large number of experimental tests, the time occupied by the sub-site for sending the data once is about 2-12S, and the requirement can be completely met;
the fourth step: the general machine gathers data and sends to the PC client, and the general machine is after receiving the data that the website transmitted, through calculating immediately, extracts effective data, stores in the memory, then carries out SCI serial port communication according to the agreement format, sends this data to the PC client, and to the data that EPR needs, the numerical control lathe has that the working equipment has three kinds of states at present:
normal working state-receiving protocol command, indicating normal working state;
waiting or maintaining-the equipment is powered on, and sending FE 01100110 EF, which indicates that the equipment is in a work waiting or maintaining state;
shutdown, namely, if the hardware acquisition end has no power supply, the hardware acquisition end does not carry out networking and does not send messages and is in a shutdown state;
the fifth step: the PC client distributes data through the network, and after receiving the instruction data, the PC statistically processes the following information: the working state of the equipment, the total number of the machining shafts of each front feeding numerical control lathe, the current task completion amount, the number of unqualified products, the unqualified rate, the operator and other information. And then, the information is subjected to data distribution to an EPR system end in a UDP communication mode through a PC network, and basic data are provided for modernization management of a factory workshop.
Drawings
Fig. 1 is a networking topology of system devices.
Fig. 2 is a block diagram of a system substation.
Fig. 3 is a block diagram of the system switchboard.
FIG. 4 shows a method flow of data collection, update and transmission in the system.
Fig. 5 is a schematic view of the installation position of the counting sensor.
FIG. 6 is a flow chart of a three-point counting weighting method.
The exchange and the PC client end communication protocol format.
Detailed Description
In order to make those skilled in the art fully understand the technical solutions and advantages of the present invention, the following embodiments are further described.
The networking topology structure of the system device is shown in fig. 1, and the whole EPR data acquisition, updating and transmission device consists of three blocks which are respectively a plurality of sub-sites, a switchboard and a PC client. The sub-stations are responsible for collecting the data such as the total number of the processing shafts, the number of unqualified products, the workload of operators, the execution condition and the like on each front feeding automatic numerical control lathe; the switchboard is responsible for summarizing data transmitted from the substation according to a certain format and transmitting the summarized data to the PC client, and the substation and the switchboard are in wireless communication; and the PC client collects the received information of each sub-site, and finally broadcasts the information through a UDP network according to a client required format.
The extension system is shown in fig. 2, and comprises a microcontroller, a power conversion module, a wireless transmission module, an RFID module, a technical sensor array, a sensor signal processing circuit module, a display module, and a keyboard input module. The microcontroller adopts an ARM 32-bit Cortex-M3 processor with the characteristics of high performance, multiple interfaces, strong comprehensive performance and the like, and is matched with a crystal oscillator circuit, a reset circuit, a downloading circuit and the like to form a minimum working system to take charge of the tasks of the operation, data acquisition, information input, display and the like of the substation device. The power conversion module adopts chips such as standard devices L7815, L7809, L7805, LM1117-3.3 and the like, and is responsible for converting a +24v power supply in a weak electric box of a machine tool into +15v, +9v, +5v in three stages, so that the +5v and +3.3v power supplies required by the system are realized. The wireless transmission module adopts a commercially available DL-LN33 wireless ad hoc network multi-hop module, the module is connected through a serial port in communication, automatic multi-hop receiving and sending can be realized, communication relay is realized, and in addition, a 1024-byte receiving and sending buffer area is arranged, so that the situation that multiple times of data are received and sent without overflow can be realized.
The RFID module is based on an MFRC-522 chip, and can realize information reading and writing of a radio frequency card by matching with part of peripheral circuit design. The counting sensor array adopts 2 alternating current two-wire inductive proximity switches FA18-8KB and 1 travel switch YBLX-ME/8104, the former adopts 90V-220V alternating current for power supply, is directly connected to an alternating current contactor, has the sensing distance of 8mm and is used for counting the detection of the transmission ends of the shaft to be processed on the numerical control lathe at two sides; the latter adopts an ohm dragon travel switch, and the workpieces are counted when the machining main shaft is assembled and clamped with the shaft to be machined. The sensor signal processing circuit is used for processing and converting sensor signals so as to facilitate the microcontroller to acquire the signals. The display module and the keyboard input module are man-machine interaction equipment of the equipment and are used for setting, inputting and displaying information of the system.
The structure block diagram of the switchboard system is shown in fig. 3, and the switchboard system is composed of a microcontroller, a power supply conversion module, a wireless transmission module, a display module and a keyboard input module. The module configuration is basically similar to that of a substation, only the RFID module, the technical sensor array and the sensor signal processing circuit module are omitted in hardware, and other configurations are the same. The wireless transmission module automatically receives data signals from each substation end, the microcontroller immediately transmits the information to the PC client end through the SCI serial communication interface at a certain baud rate after receiving the information, meanwhile, statistics is carried out on forwarded data, whether data transmission of the substation is overtime or not is analyzed, when the data transmission is overtime, an alarm is given on the display module, and meanwhile, the data transmission is transmitted to the PC client end for the EPR system to display. The working state of the equipment is provided by the switchboard, if the switchboard considers that networking of the substation is received but data of the substation is never received, the switchboard considers that the equipment is in a standby state at present; normally receiving data to be in a normal production state; when the networking of the substation is not detected, the system power supply is not provided and the system is in a shutdown state.
The flow of the system data acquisition, updating and transmission method is shown in figure 4, and the method is totally divided into 5 major steps, through implementation of five major steps, the system can carry out data networking aiming at a plurality of front feeding automatic numerical control lathes, and can realize real-time online acquisition, updating, transmission and final broadcasting of data such as the total number of machining shafts, the number of unqualified products, the work task amount of operators, the execution condition and the like. The details are as follows:
the first step is as follows: substation acquisition equipment basic data
The extension set is mainly responsible for collecting data such as the total number of the processing shafts, the number of unqualified products, the workload of operators, the execution condition and the like, wherein the total number of the processing shafts is realized by a counting sensor; the work task amount is issued and input by a networking network and is confirmed by an operator by swiping a card; the number of unqualified products is manually input by equipment operators; and calculating and displaying the task execution condition of the equipment by the extension machine in real time according to the total amount of the tasks and the total amount of the processing shafts. The method for acquiring the basic data of the equipment by the sub-sites is divided into a plurality of small steps in total, and comprises the following steps:
s1: and powering up and initializing the substation microcontroller. The substation and the numerical control lathe share a power supply, when the numerical control lathe is powered on, the substation is powered on and initialized, and the initialization comprises peripherals such as GPIO (general purpose input/output)/timer/SCI (serial communication interface)/external interrupt/FLASH and the like;
s2: reading FLASH data, configuring the system and updating display screen display. As the system may have a rapid power failure condition, the substation stores the FLASH data by using the battery power of the board itself for later data reading;
s3: and (5) performing self-networking by sites. The sub-sites send instructions to the host computer end, and the host computer immediately replies according to the port numbers of the sub-sites after receiving the instructions; when the substation receives the reply information, networking is successful, otherwise, task networking is failed; if the networking fails, the information needs to be sent again after 60 seconds, the handshake is further carried out, and when the attempts fail for more than 3 times, the alarm prompt is carried out on the display screen.
S4: the substations receive data from the sensor array. The sensor array is used for sensing the shaft parts, sensing when the shaft parts to be machined exist and the shaft parts not to be machined exist can be transmitted, and further counting of the total number of the machining shafts and calculation of other information are achieved;
for the alternating current two-wire sensor FA18-8KB, because the power supply and the signal wire are shared, when metal is in a detection range, the metal is equivalent to short circuit, and the input of the subsequent signal processing circuit is low level; otherwise, it is equivalent to an open circuit, and the input of the subsequent signal processing circuit is a normal ac signal. After signal conditioning, the output of the signal conditioning can be changed into a rectangular wave signal for the microcontroller to collect;
and for the travel switch, the output is a rectangular wave signal during working, and the rectangular wave signal is subjected to amplitude limiting and filtering by a signal processing circuit and then is sent to a microcontroller for acquisition and processing.
The second step is that: comprehensive judgment of extension data
Because the environment of an industrial processing site is noisy, the signal level is more, burr spikes and interference signals exist, if the interference signal level exceeds the limit, the signal level connected to the microcontroller end can be changed, in order to prevent the problem, for a front feeding numerical control lathe, the schematic diagram of the installation position of a sensor is shown in fig. 5. We adopt a three-point counting weighting method for counting the number of machining axes, and the flow chart of the method is shown in fig. 6, which is detailed as follows:
s1: waiting for a signal from the proximity switch 1. The system is inevitably sensed by the proximity switch 1 when feeding, and the system performs timer timing when receiving the sensor signal;
s2: and judging whether a signal of a travel switch exists subsequently. Judging whether a signal of the travel switch exists or not through interruption, and if so, judging that the signal is an effective signal, and judging in the step 3; otherwise, continuously waiting, and once the waiting time is too long, setting the program to be 25S, and considering the signal of the first step as an interference signal, thereby abandoning the counting;
s3: it is determined whether a signal of the proximity switch 2 is present last. Judging whether a signal of the proximity switch 2 exists or not through interruption, and if so, judging that the signal is an effective signal, and judging in the step 3; otherwise, continuously waiting, setting the program to be 20S once the waiting time is too long, considering the signal of the first step as an interference signal, and then giving up the counting;
s4: and counting the total count value of the current machining shaft, calculating the task completion condition and counting the quantity of unqualified products. The total task amount is issued to the sub-sites by the EPR system through the switchboard, then the total task amount is confirmed after an operator swipes a card, and the task completion condition is expressed by percentage. The number of unqualified products is manually input by an operator, and the number of the unqualified products can be increased or reduced one by one through keys on the device.
The third step: data transmission of extension network
Each substation has its own unique port number, and the switchboard also has a unique port number. When networking, each substation sends a 'ready' character to the switchboard, then waits for the switchboard to reply an 'ok' character, if the characters are received within a fixed amount of time, the networking is considered to be successful, otherwise, the networking is considered to be unsuccessful. And aiming at the branch stations and the switchboard which are successfully networked, the switchboard displays the information of each branch station in the network on a display end.
After networking is successful, the sub-sites count information such as processing quantity and the like, and then transmit the information to a main engine end according to a communication protocol format. Because hundreds of substations exist in a workshop, data congestion can be caused by sending information to a switchboard at the same time, and the data sending mode of the substations cannot be determined, for this reason, through repeated design modification and experiments, a data random transmission method is proposed, which is detailed as follows:
s1: firstly, setting a program in a substation microcontroller to generate random numbers, wherein the range of the random numbers is from 0 to 100, and the random numbers are generated every 1S;
s2: if two continuously generated random numbers are the same, namely one random number is an odd number C1, the other generated random number is C2 and is still an odd number, or namely one random number is an even number C1, and the other generated random number is C2 and is still an even number, data transmission is generated; otherwise no data is sent. Through a large number of experimental tests, the time occupied by the sub-site for sending the data once is about 2-12S, and the requirement can be completely met.
The fourth step: the switchboard collects the data and sends the data to the PC client
After receiving the data transmitted from the slave station, the switchboard immediately calculates to extract effective data, stores the effective data in the memory, then carries out SCI serial port communication according to a protocol format, and transmits the data to the PC client. The protocol format is designed as follows:
to the data that EPR needs, numerical control lathe has that the working equipment has three kinds of states at present:
(1) and in a normal working state, the received protocol command indicates a normal working state.
(2) Waiting or maintenance-the device is powered on, sending FE 01100110 EF, indicating that the device is in a work waiting or maintenance state.
(3) And (4) stopping, namely, if the hardware acquisition end has no power supply, the hardware acquisition end does not carry out networking and does not send messages, and the hardware acquisition end is in a stop state.
The fifth step: PC client distributes data over a network
After receiving the instruction data, the PC statistically processes the following information: the working state of the equipment, the total number of the machining shafts of each front feeding numerically controlled lathe, the current task completion amount, the number of unqualified products, the unqualified rate, the operator and other information. And then, the information is subjected to data distribution to an EPR system end in a UDP communication mode through a PC network, and basic data are provided for modernization management of a factory workshop.
Claims (5)
1. A method for updating and transmitting EPR data of an automatic lathe is characterized by comprising the following four steps:
s1: acquiring basic data of equipment in different stations, and acquiring the total number of machining shafts, the number of unqualified products, the workload of operators and execution condition data, wherein the total number of the machining shafts is realized by a counting sensor; the work task amount is issued and input by a networking network and is confirmed by an operator by swiping a card; the number of unqualified products is manually input by equipment operators; the equipment task execution condition is calculated and displayed by the extension in real time according to the total task amount and the total processing shaft amount; the method for acquiring the basic data of the equipment by the station comprises the following steps;
s11: powering up and initializing the site-based microcontroller; the substation and the numerical control lathe share a power supply, and the substation is powered on when the numerical control lathe is powered on to carry out initialization, wherein the initialization comprises GPIO/timer/SCI communication interface/external interrupt/FLASH peripheral;
s12: reading FLASH data, and performing system configuration and updating display screen display; as the system may have a rapid power failure condition, the slave station stores the FLASH data by using the electric quantity of the battery thereof for later data reading;
s13: performing self-networking by sites; the sub-sites send instructions to the host computer end, and the host computer immediately replies according to the port numbers of the sub-sites after receiving the instructions; when the substation receives the reply message, networking is successful, otherwise, the networking task fails; if the networking fails, the information needs to be sent again after 60 seconds, the handshake is further carried out, and when the attempts fail for more than 3 times, the alarm prompt is carried out on the display screen;
s14: the substation receives data from the sensor array; the sensor array is used for sensing the shaft parts, sensing can be realized when the shaft parts to be machined exist and the shaft parts not to be machined are transmitted, and further the counting of the total number of the machining shafts is calculated;
for the alternating current two-wire sensor FA18-8KB, because the power supply and the signal wire are shared, when metal is in a detection range, the metal is equivalent to short circuit, and the input of the subsequent signal processing circuit is low level; otherwise, the input of the signal processing circuit is a normal alternating current signal; after signal conditioning, the output of the signal conditioning can be changed into a rectangular wave signal for the acquisition of a microcontroller; for the travel switch, rectangular wave signals with low level of 0V and high level of +24V are output during working, and are subjected to amplitude limiting and filtering by the signal processing circuit and then are sent to the microcontroller for acquisition and processing;
s2: comprehensively judging substation data; for a front feeding numerical control lathe, in the production process of a shaft to be machined, feeding transmission is firstly carried out, an inductive switch can sense a signal of a proximity switch, then workpiece clamping and machining are carried out, and finally discharging transmission is carried out, wherein the following three-point counting weighting method is adopted for counting the number of the machined shafts;
s21: waiting for a signal of the proximity switch 1, wherein the system is inevitably sensed by the proximity switch 1 when feeding, and timing by a timer when receiving a sensor signal;
s22: judging whether a signal of the travel switch exists subsequently, judging whether the signal of the travel switch exists or not through interruption, and if so, considering an effective signal and carrying out step 3 judgment; otherwise, the waiting is continued, and once the waiting time is too long and exceeds 25S, the signal of the S21 is considered as an interference signal, so that the counting is abandoned;
s23: judging whether a signal of the proximity switch 2 exists at last; judging whether a signal of the proximity switch 2 exists or not through interruption, and if so, considering an effective signal and carrying out judgment in the 4 th step; otherwise, the waiting is continued, and once the waiting time is too long to exceed 20S, the signal of S21 is regarded as an interference signal, and the count is discarded,
s24: counting the total count value of the current machining shaft, calculating the task completion condition and counting the number of unqualified products; the total task amount is issued to the sub-sites by an EPR system through a switchboard, then the total task amount is confirmed after an operator swipes a card, and the task completion condition is expressed by percentage; the number of unqualified products is manually input by an operator, and the number of the unqualified products can be increased or reduced one by one through keys on the device;
s3: networking data transmission by sub-sites, wherein each sub-site has a unique port number, and the switchboard also has a unique port number; during networking, each substation sends a 'ready' character to the switchboard, then waits for the switchboard to reply an 'ok' character, if the ok character is received within a fixed time of 10s, the networking is considered to be successful, otherwise, the networking is considered to be unsuccessful; aiming at the sub-sites successfully networked, the switchboard displays the information of each sub-site in the network on a display end; through repeated design modification and experiments, the following data random transmission method is provided;
s31: firstly, setting a program by a microcontroller of a substation to generate random numbers, wherein the range of the random numbers is from 0 to 100, and the random numbers are generated every 1S;
s32: if two continuously generated random numbers are the same, namely one random number is an odd number C1, the other generated random number C2 is still an odd number, or one random number is an even number C1, and the other generated random number C2 is still an even number, data transmission is generated; in other cases, data is not sent, and the time for sending the data by each sub-site is 2-12S; the fourth step: the host computer gathers the data and sends to the PC client, and the host computer calculates immediately after receiving the data that the website transmitted, extracts effective data, stores in the memory, then carries out SCI serial port communication according to the agreement format, sends this data to the PC client, and to the data that EPR needs, the working equipment of numerical control lathe has following three kinds of states:
normal operating state-the received protocol command, indicates a normal operating state;
waiting or maintaining-the equipment is powered on, and sending FE 01100110 EF, which indicates that the equipment is in a work waiting or maintaining state;
stopping, namely, if the hardware acquisition end has no power supply, networking is not carried out, no message is sent, and the hardware acquisition end is in a stopped state;
s4: the PC client distributes data through the network, and after receiving the instruction data, the PC statistically processes the following information: the method comprises the steps of obtaining the working state of the equipment, the total number of machining shafts of each front feeding numerical control lathe, the current task completion amount, the number of unqualified products, the unqualified rate and the information of operators, then distributing the information to an EPR system end in a UDP communication mode through a PC network, and providing basic data for the modernization management of a factory workshop.
2. An apparatus based on the method for updating and transmitting EPR data of an automatic lathe as claimed in claim 1, which comprises a substation, a switchboard and a PC client,
the sub-stations are responsible for collecting the total number of the processing shafts, the number of unqualified products, the workload of operators and the collection of execution condition data on each front feeding automatic numerical control lathe;
the switchboard is responsible for summarizing the data transmitted by the substation according to a certain format and transmitting the summarized data to the PC client, and the substation and the switchboard are in wireless communication;
and the PC client summarizes the received information of each sub-site and finally broadcasts the information through a UDP network according to the client requirement format.
3. An apparatus according to claim 2, characterized in that: the substation is composed of a microcontroller, a power supply conversion module, a wireless transmission module, an RFID module, a counting sensor array, a sensor signal processing circuit module, a display module and a keyboard input module; the sub-station can be set to automatically jump when the sub-station is possibly far away from the switchboard, and can be used as a wireless transmitting module and a relay station of other sub-stations, so that transmission at a larger distance is completed through relay jumping;
the microcontroller adopts an ARM 32-bit Cortex-M3 processor, and is matched with a crystal oscillator circuit, a reset circuit and a download circuit to form a minimum working system which is responsible for the operation, data acquisition, information input and display tasks of the substation device;
the power conversion module adopts standard devices L7815, L7809, L7805 and LM1117-3.3 chips and is responsible for converting a +24v power supply in a weak electric box of a machine tool into +15v, +9v, +5v in three stages, so that the +5v and +3.3v power supplies required by the system are realized;
the wireless transmission module adopts a commercially available DL-LN33 wireless ad hoc network multi-hop module, is connected through a serial port, can realize receiving and sending automatic multi-hop to complete communication relay, and is also provided with a 1024-byte receiving and sending buffer area, so that the receiving and sending of multiple data can be realized without overflow;
the RFID module is based on an MFRC-522 chip, and can realize information reading and writing of a radio frequency card by matching with part of peripheral circuit design;
the counting sensor array adopts 2 alternating current two-wire inductive proximity switches FA18-8KB and 1 travel switch YBLX-ME/8104, the former adopts 90V-220V alternating current for power supply, is directly connected to an alternating current contactor, has the sensing distance of 8mm and is used for counting the detection of a shaft to be processed on the numerical control lathe at the transmission ends of two sides; the latter adopts an ohm dragon travel switch which is used for counting workpieces when the spindle to be machined is assembled and clamped on the machining main shaft;
the sensor signal processing circuit module is used for realizing the processing and conversion of sensor signals so as to facilitate the signal acquisition of the microcontroller;
the display module and the keyboard input module are man-machine interaction equipment used for system setting, information input and display.
4. An apparatus according to claim 2, characterized in that: the switchboard consists of a microcontroller, a power supply conversion module, a wireless transmission module, a display module and a keyboard input module;
the microcontroller adopts an ARM 32-bit Cortex-M3 processor, and is matched with a crystal oscillator circuit, a reset circuit and a download circuit to form a minimum working system which is responsible for the operation, data acquisition, information input and display tasks of the substation device;
the power conversion module adopts standard devices L7815, L7809, L7805 and LM1117-3.3 chips and is responsible for converting a +24v power supply in a weak electric box of a machine tool into +15v, +9v, +5v in three stages, so that the +5v and +3.3v power supplies required by the system are realized;
the wireless transmission module adopts a commercially available DL-LN33 wireless ad hoc network multi-hop module, is connected through a serial port, can realize automatic multi-hop of receiving and sending, and completes communication relay, and is also provided with a 1024-byte receiving and sending buffer area, so that the receiving and sending of multiple data can be realized without overflow;
the display module and the keyboard input module are man-machine interaction equipment used for system setting, information input and display.
5. An apparatus according to claim 2, characterized in that: the PC client automatically receives data signals from each substation end aiming at the received information of each substation, the microcontroller immediately transmits the information to the PC client through the SCI serial communication interface at a certain baud rate after receiving the information, meanwhile, statistics is carried out on forwarded data, whether data transmission of each substation is overtime is analyzed, and when the data transmission is overtime, an alarm is given on the display module and the data is transmitted to the PC client for the EPR system to display; the working state of the equipment is provided by the host, and if the host considers that networking of the substation is received but data of the substation is never received, the equipment is considered to be in a standby state at present; normally receiving data to be in a normal production state; when the networking of the substation is not detected, the system power supply is not provided and the system is in a shutdown state.
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