CN111176223A - A production line safety management system and method - Google Patents
A production line safety management system and method Download PDFInfo
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- CN111176223A CN111176223A CN201911005217.0A CN201911005217A CN111176223A CN 111176223 A CN111176223 A CN 111176223A CN 201911005217 A CN201911005217 A CN 201911005217A CN 111176223 A CN111176223 A CN 111176223A
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- G05B19/02—Programme-control systems electric
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- G05B19/02—Programme-control systems electric
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Abstract
The embodiment of the invention discloses a production line safety management system and a method, wherein the system comprises: an equipment control system and a security management system; the equipment control system is in communication connection with the safety management system; wherein: the equipment control system is used for controlling all equipment in the production line; the safety management system is used for monitoring, protecting and managing safety accident triggering events in the production process of the production line. The technical scheme of the embodiment of the invention can realize automatic safety management of the production line so as to improve the timeliness and intelligence of the safety management of the production line.
Description
Technical Field
The embodiment of the invention relates to the technical field of safety management, in particular to a production line safety management system and a production line safety management method.
Background
An emergency stop button is typically provided in the equipment at the production line site. Once the production line is abnormal or a safety accident triggering event occurs on the production line site, the production line can be stopped by operating the emergency stop button.
In the prior art, the emergency stop button is usually operated by a field operator.
In the process of implementing the invention, the inventor finds that the prior art has the following defects: the operation condition of the emergency stop button can not be traced in real time by field operators, so that the emergency stop events in the production line field can not be arranged and summarized in time. In addition, for some safety accident triggering events, such as events that personnel are detained in a safety protection area or the personnel illegally enter the safety protection area when the safety door is closed, the mode of manually operating the emergency stop button cannot provide effective safety protection measures in time. Therefore, the safety management method for manually controlling the emergency stop button cannot meet the modern production requirements in the aspects of timeliness and intelligence.
Disclosure of Invention
The embodiment of the invention provides a production line safety management system and a production line safety management method, which are used for realizing automatic safety management of a production line so as to improve timeliness and intelligence of production line safety management.
In a first aspect, an embodiment of the present invention provides a production line safety management system, including: an equipment control system and a security management system; the equipment control system is in communication connection with the safety management system; wherein:
the equipment control system is used for controlling all equipment in the production line;
the safety management system is used for monitoring, protecting and managing safety accident triggering events in the production process of the production line.
In a second aspect, an embodiment of the present invention further provides a production line safety management method, including:
the equipment control system controls all equipment in the production line;
the safety management system monitors, protects and manages safety accident triggering events in the production process of the production line, and controls all equipment in the production line according to the safety accident triggering events in cooperation with the equipment control system.
According to the embodiment of the invention, all equipment in the production line is controlled by the equipment control system in the production line safety management system, and the safety accident triggering event in the production process of the production line is monitored, protected and managed by the safety management system, so that the problem that the production requirement cannot be met in the existing production line safety management mode is solved, the automatic safety management of the production line is realized, and the timeliness and the intelligence of the production line safety management are improved.
Drawings
FIG. 1 is a schematic diagram of a production line safety management system according to an embodiment of the present invention;
fig. 2 is a schematic structural diagram of an apparatus control system according to an embodiment of the present invention;
fig. 3 is a schematic structural diagram of a control subsystem according to an embodiment of the present invention;
fig. 4 is a schematic structural diagram of a security management system according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of a partial hardware structure layout of a production line safety management system according to an embodiment of the present invention;
FIG. 6 is a schematic flow chart of a process for safety management of a production line according to an embodiment of the present invention;
fig. 7 is a flowchart of a production line safety management method according to a second embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to the accompanying drawings and examples. It is to be understood that the specific embodiments described herein are merely illustrative of the invention and are not limiting of the invention.
It should be further noted that, for the convenience of description, only some but not all of the relevant aspects of the present invention are shown in the drawings. Before discussing exemplary embodiments in more detail, it should be noted that some exemplary embodiments are described as processes or methods depicted as flowcharts. Although a flowchart may describe the operations (or steps) as a sequential process, many of the operations can be performed in parallel, concurrently or simultaneously. In addition, the order of the operations may be re-arranged. The process may be terminated when its operations are completed, but may have additional steps not included in the figure. The processes may correspond to methods, functions, procedures, subroutines, and the like.
Example one
Fig. 1 is a schematic diagram of a production line safety management system according to an embodiment of the present invention, and as shown in fig. 1, the production line safety management system may include: a device control system 10 and a security management system 20; the equipment control system 10 is in communication connection with the safety management system 20; wherein:
the equipment control system 10 is used for controlling all equipment in the production line; the safety management system 20 is used for monitoring, protecting and managing safety accident triggering events in the production process of the production line.
In the embodiment of the present invention, the structure of the production line safety management system may specifically include two main system structures, i.e., the device control system 10 and the safety management system 20. The equipment control system 10 may be used to control all equipment in the production line, i.e., the equipment control system 10 may control the operation of the entire production line. The safety management system 20 operates independently of the equipment control system 10 and is used for monitoring, protecting and managing safety accident triggering events in the production process of the production line. The safety accident triggering event includes but is not limited to the situation that when the safety door is closed, a person stays in the safety protection area, the person illegally enters the safety protection area, the emergency stop button acts, the safety sensor senses the like. The safety management system 20 can develop the application of the intelligent safety management system based on the equipment internet of things cloud platform, so as to meet the application requirements of performing advance monitoring prompt, real-time protection in the process and timely closed-loop solution of the problem after the process in the production line safety production process.
Therefore, the safety management system which operates independently is matched with the equipment control system of the production line, so that the automatic management of the production line can be realized, and when the safety accident triggering event is monitored, the protection and management measures can be automatically provided, thereby meeting the modern production requirement.
Fig. 2 is a schematic structural diagram of an apparatus control system according to an embodiment of the present invention, and in an alternative embodiment of the present invention, as shown in fig. 2, the apparatus control system 10 includes a control subsystem 110, a first server 120, and a second server 130; the control subsystem 110, the first server 120 and the second server 130 are communicatively connected; wherein: the control subsystem 110 is used for acquiring and processing signals of associated equipment in the production line and controlling the output action of an actuating mechanism in the production line; the first server 120 is used for performing standardized and unified conversion on the communication interface of the field device in the production line, and acquiring and processing target data according to a set acquisition frequency; wherein the target data is the device data required by the security management system; the second server 130 is used for centralized storage management of the target data.
As shown in fig. 2, in particular, the device control system may include at least a control subsystem 110, a first server 120, and a second server 130. The control subsystem 110 may control all devices in the production line, specifically, may collect and process signals of associated devices in the production line, and control output actions of actuators in the production line. The associated devices include, but are not limited to, production line sensors, stand-alone devices, dedicated devices, and the like. The control subsystem 110 acts as a site control hub for the production line equipment and controls the output actions of the various actuators of the production line according to program logic instructions. The first server 120 may be a data acquisition server, and specifically may perform standardized and unified conversion on communication interfaces of field devices such as a control subsystem, a Radio Frequency Identification (RFID) industrial personal computer, a video monitoring server, and the like, calibrate various device data required by the security management system as target data according to occurrence time, and periodically acquire the target data according to a set acquisition Frequency and perform compression processing. The set acquisition frequency may be set according to actual requirements, which is not limited in the embodiments of the present invention. The second server 130 may be an industrial time series library server, which is a data center for the equipment production process. The second server 130 may centrally store and manage target data that may be collected by each plant, i.e., each production line, via the first server 120. When other platforms and applications need to exchange data with the field equipment of the production line, target data acquired in real time in the industrial time sequence library can be in data butt joint with each platform machine application requesting data, so that equipment downtime caused by the fact that a plurality of platforms or applications simultaneously send and receive data requests to the equipment is avoided.
Fig. 3 is a schematic structural diagram of a control subsystem according to an embodiment of the present invention, and in an alternative embodiment of the present invention, as shown in fig. 3, the control subsystem may include a main control unit 111, an information input unit 112, a driving unit 113, a first clamping servo flipping unit 114, and a second clamping servo flipping unit 115; the control unit 111, the display unit 112, the driving unit 113, the first clamping and holding servo overturning unit 114 and the second clamping and holding servo overturning unit 115 are in communication connection; wherein: the main control unit 111 is used for controlling all the devices in the production line according to the control information input by the operation object; the information input unit 112 is used for receiving control information input by the operation object; the driving unit 113 is used for driving the operating equipment in the production line; the first clamping and holding servo turning unit 114 and the second clamping and holding servo turning unit 115 are used for turning the product.
Specifically, as shown in fig. 3, the control subsystem controls all the devices in the production line by the main control unit 111 according to the control information input by the operation object. The main control unit may be any type of device having a control function, such as a PLC (Programmable Logic Controller) or an industrial personal computer, and the embodiment of the present invention does not limit the specific device type of the main control unit. The operation object may be an operation worker of the production line, or may also be a control instruction sent by the safety management system to the equipment control system, such as a shutdown instruction or a reset instruction. The information input unit 112 may be an information input device such as a touch screen, and may be used for an operator to manually input control information. The control information includes, but is not limited to, information for controlling operation of the device and information for controlling an output target parameter, where the target parameter may be information such as yield or capacity, and the embodiment of the present invention does not limit this. The driving unit 113 may drive an operating device in the production line, for example, robot driving in the driving unit 113 is performed on a robot device in the production line. It should be noted that the driving unit 113 may further include a remote driving module, which is used to provide a data relay function for the target device. Wherein the target device may be a device that is remote from the main control unit 111. The first clamping and holding servo turning unit 114 and the second clamping and holding servo turning unit 115 may be two clamping and holding servo turning units which are oppositely arranged, and are specifically configured to turn over related products in a production line. It should be noted that in some production lines where the product is not required to be turned, the first clamping and servo turning unit 114 and the second clamping and servo turning unit 115 may be omitted.
Fig. 4 is a schematic structural diagram of a security management system according to an embodiment of the present invention, and in an alternative embodiment of the present invention, as shown in fig. 4, the security management system may include a device internet of things cloud 210, a first core switch 220, a second core switch 230, and at least one data collector 240; wherein: the equipment internet of things cloud 210 is in communication connection with the first core switch 220, and is used for acquiring data of the first core switch 220 and making a decision according to the acquired data; the device internet of things cloud 210 comprises a database 211 for storing acquired data; the first core switch 220 is communicatively connected to the second core switch 230, and is configured to forward data sent by the second core switch 230; the second core switch 230 is communicatively connected to the data collector 240, and is configured to forward data sent by the data collector 240; the data collector 240 is used to collect the associated data generated in the control subsystem 110.
Specifically, as shown in fig. 4, the security management system may be constructed based on the device internet of things cloud 210. The device internet of things cloud 210 may include a database 211, and optionally, the database 211 may be an industrial time sequence database, which is mainly used for storing acquired data. The device internet of things cloud 210 may make a decision according to the data forwarded by the first core switch 220, such as sending an emergency shutdown or reset instruction to the device control system. The first core switch 220 may receive data transmitted by the second core switch 230, and the number of the second core switches 230 may be plural. For example, each individual factory may configure an individual second core switch 230, and all data of the second core switch 230 is forwarded to the device cloud 210 via the first core switch 220. The number of the data collector 240 may be plural, and is mainly used for collecting the associated data generated in the control subsystem 110. For example, different devices may be configured with independent data collectors 240 for collecting associated data, and for example, a pre-assembly line, a hoist or a storage bin may be configured with the data collectors 240 for collecting data. Each collected data may be used as associated data.
In an alternative embodiment of the present invention, as shown in FIG. 2, the device control system may further include a portrait recognition system 140; the portrait recognition system 140 is communicatively connected to the second server 130 for recognizing the operation object.
The operation object is a worker who operates the equipment control system.
It is understood that an operation can only be performed if the operation object has operation rights to an operation flow in the device production process of the production line. Therefore, the authority of the operation object is confirmed through the portrait recognition system, and the operation object is allowed to execute startup operation after the fact that the authority is matched with the operator information which is pre-recorded by the system is confirmed, so that an operator can operate normal equipment according to the standard, and the specialty and the safety of the operation process are guaranteed.
In an optional embodiment of the present invention, the security management system may further include a monitoring device; the monitoring device is in communication connection with the safety management system and is used for acquiring the abnormal conditions of the target monitoring area of the production line in real time.
Optionally, the safety camera shooting holder can be used as a monitoring device to perform safety monitoring on the target monitoring area. Wherein the target monitoring area may be a safety protection area in the production line field. In the embodiment of the invention, the safety management system can capture and snapshot sudden abnormal conditions in the safety protection area in real time through the monitoring device, such as safety accident triggering events of illegal personnel entry, preparation of starting production of a production line when the personnel are detained, emergency shutdown, illegal opening of a safety door and the like.
In an optional embodiment of the present invention, the security management system may further comprise a display device; the display device is in communication connection with the safety management system and is used for displaying target information; the target information comprises fault information, monitoring picture information and production line associated information.
The production line related information includes, but is not limited to, portrait identification information, production line equipment running state information, and the like.
Optionally, the large visual screen may be used as a display device of the security management system to display the target information in real time. The display device can display and control the production line equipment to alarm and fault in a panoramic visual manner, and can display target information such as a safety production management and control flow, monitoring picture information, production safety start and stop and the like. The display mode of the display device may be split-screen display, and the embodiment of the present invention does not limit the specific content displayed by the display device and the display mode used.
In an optional embodiment of the present invention, the control subsystem is configured to control the apparatus to start operation when it is determined that the safety emergency warning signal does not exist after the portrait recognition system successfully recognizes the operation object.
The safety emergency pre-warning signal may be a signal caused by a safety accident triggering event.
In an optional embodiment of the present invention, the safety management system is configured to send a shutdown instruction to the equipment control system when the safety accident triggering event is monitored, so that the equipment control system controls equipment to shutdown; and after receiving the accident reason information, auditing the accident reason information, unlocking the safety accident information after the auditing is passed, and sending a reset instruction to the equipment control system so that the equipment control system controls equipment to start operation again under the condition that the safety emergency early warning signal does not exist.
Fig. 5 is a schematic diagram of a partial hardware structure layout of a production line safety management system according to an embodiment of the present invention, and fig. 6 is a schematic diagram of a flow of production line safety management according to an embodiment of the present invention.
In one specific example, as shown in fig. 5 and 6, the device control system confirms the power-on operator authority based on the portrait recognition system. After the system is allowed to be started, the control subsystem such as a PLC carries out safety diagnosis and self-checks whether safety emergency early warning signals exist or not, such as signals of emergency stop action, safety sensor induction, safety door opening and the like, and when the safety management system is associated with the equipment control system, namely communication connection is kept, safety accident linkage signals of the safety management system also need to be detected. And if the PLC confirms that the signals are not abnormal, the equipment starts to operate according to a normal management mechanism. Otherwise, the start-up or control of the emergency shutdown is not allowed.
Through monitoring device, like the cloud platform condition of making a video recording of safety in real time monitoring production line safety protection district and key capture system in preset incident trigger event, like illegal entering safety protection district, emergency exit close personnel are detained, emergency stop action, events such as security sensor response and emergency exit open. When a safety accident triggering event occurs, the camera shoots immediately. When the safety management system is associated with the equipment control system, namely, the communication connection is kept, the safety management system can send out a safety accident notification to related responsible persons, so that the time delay caused by artificial emergency stop equipment is reduced, and the injury degree to personnel in the moment of the accident is reduced. Meanwhile, the safety management system can also send a safety accident interlocking signal and an emergency stop instruction to the equipment control system, so that the equipment control system controls the production line equipment to stop immediately. And solving the problems and filling the reasons on line by the related responsible persons, unlocking the safety accident information after the approval process of the safety management system passes, simultaneously sending a reset instruction to the equipment control system so as to enable the equipment control system to control the equipment to carry out emergency shutdown reset, carrying out safety scanning again, and restarting the equipment to operate or carrying out other operations after confirming that no safety emergency early warning information exists. Through monitoring device real time monitoring and snapshot production line violation or the accident that the hourglass arouses, fall to the minimum with the injury that production line incident caused, utilize system flow closed loop management simultaneously, through the accident problem record that safety management system will often take place in with safety in production and form the analysis table, discharge the potential safety hazard, reduce the high problem of sending out of incident to improve the prevention consciousness of on-the-spot production personnel and managers safety in production operation.
According to the embodiment of the invention, all equipment in the production line is controlled by the equipment control system in the production line safety management system, and the safety accident triggering event in the production process of the production line is monitored, protected and managed by the safety management system, so that the problem that the production requirement cannot be met in the existing production line safety management mode is solved, the automatic safety management of the production line is realized, and the timeliness and the intelligence of the production line safety management are improved.
Example two
Fig. 7 is a flowchart of a production line safety management method according to a second embodiment of the present invention, which can be applied to the production line safety management system according to the first embodiment of the present invention to automatically and intelligently perform production line safety management. Accordingly, as shown in fig. 7, the method includes the following operations:
and S110, controlling all equipment in the production line by the equipment control system.
And S120, monitoring, protecting and managing a safety accident triggering event in the production process of the production line by the safety management system, and controlling all equipment in the production line by matching the equipment control system according to the safety accident triggering event.
In the embodiment of the invention, when monitoring a safety accident triggering event in the production process of a production line, a safety management system sends a shutdown instruction to an equipment control system so as to enable the equipment control system to control equipment to be shut down; and after the accident reason information is received, auditing the accident reason information, unlocking the safety accident information after the auditing is passed, and sending a reset instruction to the equipment control system so that the equipment control system controls equipment to start running again.
Specifically, the equipment control system confirms the authority of the startup operator according to the portrait recognition system. After the equipment control system is allowed to be started, a control subsystem in the equipment control system carries out safety diagnosis and self-checks whether safety emergency early warning signals exist or not, such as signals of emergency stop action, safety sensor induction, safety door opening and the like, and when the safety management system is in communication connection with the equipment control system, safety accident linkage signals of the safety management system need to be detected. And if the control subsystem confirms that the signals are not abnormal, the equipment starts to operate according to a normal management mechanism. Otherwise, the start-up or control of the emergency shutdown is not allowed.
The method comprises the steps of monitoring the conditions of a safety protection area of a production line in real time through a monitoring device in a safety management system and mainly capturing preset safety accident triggering events in the system, such as events of illegal entry into the safety protection area, retention of personnel for closing a safety door, emergency stop action, induction of a safety sensor, opening of the safety door and the like. When a safety accident triggering event occurs, the camera shoots immediately. When the safety management system is in communication connection with the equipment control system, the safety management system can send out a safety accident notification to related responsible persons, so that the time delay caused by manual emergency stop equipment is reduced, and the injury degree to personnel in the moment of accident occurrence is reduced. Meanwhile, the safety management system can also send a safety accident interlocking signal and an emergency stop instruction to the equipment control system, so that the equipment control system controls the production line equipment to stop immediately. And solving the problems and filling the reasons on line by the related responsible persons, unlocking the safety accident information after the approval process of the safety management system passes, simultaneously sending a reset instruction to the equipment control system so as to enable the equipment control system to control the equipment to carry out emergency shutdown reset, carrying out safety scanning again, and restarting the equipment to operate or carrying out other operations after confirming that no safety emergency early warning information exists. Through monitoring device real time monitoring and snapshot production line violation or the accident that the hourglass arouses, fall to the minimum with the injury that production line incident caused, utilize system flow closed loop management simultaneously, through the accident problem record that safety management system will often take place in with safety in production and form the analysis table, discharge the potential safety hazard, reduce the high problem of sending out of incident to improve the prevention consciousness of on-the-spot production personnel and managers safety in production operation.
According to the embodiment of the invention, all equipment in the production line is controlled by the equipment control system, and the safety accident triggering event in the production process of the production line is monitored, protected and managed by the safety management system, so that the problem that the production requirement cannot be met in the existing production line safety management mode is solved, the automatic safety management of the production line is realized, and the timeliness and the intelligence of the production line safety management are improved.
It is to be noted that the foregoing is only illustrative of the preferred embodiments of the present invention and the technical principles employed. It will be understood by those skilled in the art that the present invention is not limited to the particular embodiments described herein, but is capable of various obvious changes, rearrangements and substitutions as will now become apparent to those skilled in the art without departing from the scope of the invention. Therefore, although the present invention has been described in greater detail by the above embodiments, the present invention is not limited to the above embodiments, and may include other equivalent embodiments without departing from the spirit of the present invention, and the scope of the present invention is determined by the scope of the appended claims.
Claims (10)
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| CN111633324A (en) * | 2020-06-08 | 2020-09-08 | 松山湖材料实验室 | A kind of turbine blade manufacturing method, device and monitoring system based on monitoring system |
| CN112126908A (en) * | 2020-08-31 | 2020-12-25 | 佛山市博顿光电科技有限公司 | Coating control system and coating equipment |
| CN112309091A (en) * | 2020-11-04 | 2021-02-02 | 爱珂勒电子元器件（珠海）有限公司 | Production alarm system with remind function |
| CN113946141A (en) * | 2020-07-16 | 2022-01-18 | 青岛海尔工业智能研究院有限公司 | Network system for production demonstration line and control method |
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