CN116736812A - Tightening system with upper and lower decoupling function and control method thereof - Google Patents

Abstract

The invention discloses a tightening system and a control method that decouple the upper and lower positions. The upper system takes the IOT system as the core and also includes an execution system page, the Andon page, and the MES. The lower system takes the IOT-PLC as the core and also includes the tightening system. Machine PLC and Machine PLC; the tightening JOB+VIN is issued in advance; relying on the corresponding relationship between the JOB and VIN issued in advance, and the VIN queue obtained from the Machine PLC in real time, the real-time VIN is obtained, and then obtained from the tightening machine PLC The cached JOB+VIN relationship issued in advance can be used to obtain the JOB of the current vehicle, so as to continue the tightening operation. Using the above technical solution, a stable and open tightening solution is proposed to overcome the defects and problems caused by the tight coupling of the upper and lower positions, reduce the labor load of workers, increase the factory's workload per unit time, and improve labor productivity.

Description

A tightening system with upper and lower positions decoupled and its control method

Technical field

The invention belongs to the technical field of Internet of Things control for industrial production operations. More specifically, the present invention relates to a tightening system in which upper and lower positions are decoupled. The invention also relates to a control method of the tightening system.

Background technique

In the existing technology, the tightening scheme in the industrial production process has complex upper-level and lower-level couplings. Since the upper-level system is generally deployed in the central computer room, all resources are shared. If a problem occurs at one point, the entire upper-level system will be affected. This kind of strong coupling will cause the lower-level units that are closely related to production to have problems requesting data from the upper-level system, thus causing production to stop, which will greatly affect the production rhythm and efficiency.

Using keywords such as "production; tightening; upper position; lower position" and other keywords to search the literature on the prior art, the search results related to the present invention are as follows

Chinese patent document: "A tightening assembly production system", the patent publication number is 108510023A, and its technical solution is as follows:

The system "includes a server and at least one workstation. The workstation includes a host computer, a lower computer and an electric tool, as well as a background server program and a workstation client program; the electric tool is connected to the lower computer through a field bus, and the upper computer is connected to the lower computer through the lower computer. Control electric tools and obtain feedback data; the background server program provides a configuration module for users to configure to form workstation task information or product task information; the workstation client program is used to obtain the current workpiece from the background server program based on the barcode information on the current workpiece The work station task information of the current work station is then notified to the lower computer of the work station to control the electric tool to perform the task according to the work station task information;

The technical effects recorded are as follows:

"It can be configured accordingly according to the brand and model of the electric tightening tool. It has high versatility, and the production line switching efficiency is very high when the product is changed. If the electric tool fails, it can be easily replaced."

However, after a detailed analysis of this document, it was found that this technical solution failed to solve the problem in the existing technology that "strong coupling will cause the lower-level units that are strongly related to production to request data from the upper-level system, resulting in The production line is stopped, which will greatly affect the production rhythm and efficiency" problems and defects.

Contents of the invention

The invention provides a tightening system in which the upper position and the lower position are decoupled, with the purpose of reducing workers' labor load and improving production efficiency.

In order to achieve the above objects, the technical solutions adopted by the present invention are:

The upper-level and lower-level decoupling tightening system of the present invention includes an upper-level system and a lower-level system; the upper-level system takes the IOT system as the core, and also includes execution system pages, Andon pages, and MES; the lower-level system uses the IOT-PLC As the core, it also includes the tightening machine PLC and the machine PLC; the tightening JOB+VIN is issued in advance; with the corresponding relationship between the JOB and VIN issued in advance, and the VIN queue obtained from the machine PLC in real time, real-time VIN is obtained. Then, the JOB of the current vehicle is obtained from the JOB+VIN relationship cached in the tightening machine PLC, and the tightening operation continues.

The number of VIN+JOBs issued in advance depends on the number of sliders or spreaders between the painting offline point and the final assembly 10th online point.

In order to achieve the same inventive purpose as the above technical solution, the present invention also provides a control method for the above-mentioned upper and lower decoupled tightening system, and the process is:

1). The IOT system sends the start position and stop position percentage of the execution system to IOT-PLC;

2), Jiyun PLC gives IOT-PLC the percentage of sliding into the workstation and the VIN queue;

3). When the percentage of sliding warps entering the workstation reaches the starting position set by the workstation, IOT-PLC takes out the vehicle VIN of the current workstation from the VIN queue of the machine PLC, and uses this VIN to request the workstation from the superior. Corresponding JOB number;

4) After IOT-PLC obtains the VIN+JOB number, it transmits this information to the tightening machine PLC, and the tightening machine starts working;

5) The tightening machine PLC works based on this JOB and uploads the tightening results to IOT-PLC;

6) When the percentage of the sliding warp entering the station does not reach the stop position and the tightening OK result has been obtained, the IOT-PLC will send a direction signal to the machine PLC, otherwise no interaction will be performed.

In the above 1), the start position and stop position percentage are stored in the DB block of IOT-PLC; as permanent storage, after one delivery is completed, if no adjustment is made, there is no need to deliver it again.

In the above 2), the percentage of the work station is from 1% to 100%; every 1% increase must be given to the IOT-PLC once; it reflects the percentage of the slipper entering the work station; among them, 50% represents The sliding center coincides with the workstation center;

In the above 2), the VIN queue is obtained through RFID; RFID is installed at the entry and exit of the final assembly and at the upper and lower lines of each line; the VIN is identified through RFID, thereby updating the VIN queue of the machine PLC in real time.

In the above 5), whether the tightening work is OK is passed to IOT-PCL.

When all tightening at the station is OK, the tightening machine PLC will transmit the tightening result as OK to the IOT-PLC, otherwise no information will be transmitted.

When the upper system has a problem and crashes, 3) in the process will not be realized, that is, the current JOB number cannot be obtained; at this time, the IOT-PLC detects that the upper system cannot ping or the information is severely squeezed, and then sends a flag to the tightening machine PLC. , directly use the VIN given by the machine PLC, and obtain the JOB of the vehicle from the VIN+JOB relationship cached in the tightening machine PLC, and then proceed to the subsequent 4), 5), and 6) processes without affecting production.

The cached data buys more than 2-3 hours for the upper position to be repaired; if the upper position is still not restored at this time, the on-site tightening machine enters manual mode by swiping the card. At this time, there is no JOB issued, and the workers need to rely on experience to perform the tightening operation. The machine PLC will record the tightening process data of each vehicle and finally provide it to the quality department for review. Finally, the quality gate of the final assembly will confirm whether the vehicle has reached the stage of being released and can enter the subsequent process.

The present invention adopts the above technical solution and proposes a stable and open tightening scheme to overcome the defects and problems caused by the tight coupling of the upper and lower positions, reduce the labor load of workers, increase the factory's workload per unit time, and improve labor productivity.

Description of drawings

A brief description of the content shown in the attached figure is as follows:

Figure 1 is a schematic diagram of the structure and basic data flow of the upper and lower systems of the present invention;

Figure 2 is a schematic diagram of the transmission protocol and interface of the present invention;

Figure 3 is a basic schematic diagram of the cache data of the present invention (the concept of the location of the workshop);

Figure 4 is the tightening control diagram of the coating line;

Figure 5 is a schematic diagram of the tightening process under normal conditions.

Detailed ways

The specific implementation modes of the present invention will be further described in detail below by describing the embodiments with reference to the accompanying drawings, so as to help those skilled in the art have a more complete, accurate and in-depth understanding of the inventive concepts and technical solutions of the present invention.

The technical terms involved in this invention include:

VIN: Abbreviation of Vehicle Identification Number;

JPH: workload per unit time;

PLC: It is a programmable controller;

IOT system: Internet Of Things, Internet of Things operating system;

Andon: Also known as "dark light", the Andon system is an acousto-optical multimedia multiple automation control system;

RESTFUL: It is a design style and development method for network applications;

MES: Production information management system for the execution level of manufacturing enterprise workshops;

OTT: The abbreviation of "Over The Top" refers to Internet companies bypassing operators and developing various video and data service businesses based on the open Internet;

RFID: The abbreviation of Radio Frequency Identification, which is radio frequency identification technology;

Ping: Network diagnostic tool.

As shown in Figures 1 and 2, the structure of the present invention is a stable and open tightening system with upper and lower decoupling, including an upper system and a lower system.

In order to solve the problems existing in the existing technology and overcome its defects, and achieve the invention purpose of reducing the labor load of workers and improving production efficiency, the technical solution adopted by the present invention is:

As shown in Figures 1 and 2, the upper-level and lower-level tightening systems of the present invention are decoupled. The upper-level system takes the IOT system as the core and also includes an execution system page, the Andon page, and MES; the lower-level system uses the IOT system as the core. -PLC is the core, and also includes the tightening machine PLC and the machine PLC; the tightening JOB+VIN is issued in advance; with the corresponding relationship between the JOB and VIN issued in advance, and the VIN queue obtained from the machine PLC in real time, real-time VIN, and then obtain the JOB of the current vehicle from the relationship of JOB+VIN cached in the tightening machine PLC and issued in advance, so as to continue the tightening operation.

This invention proposes a stable and open solution for the most complex core business of final assembly in automobile manufacturing: tightening, which can reduce worker load and improve factory JPH.

The present invention adopts a decoupling scheme for the upper and lower positions. Since the tightened JOB+VIN is issued in advance, when a problem occurs at the upper position, although the real-time request for the JOB interface fails, the JOB+VIN issued in advance can be used. The corresponding relationship between JOB and VIN, and the VIN queue obtained from the machine PLC in real time, get the real-time VIN, and then obtain the JOB of the current vehicle from the relationship of JOB+VIN cached in the tightening machine PLC and issued in advance, and then continue Carry out tightening operation.

The number of VIN+JOBs issued in advance depends on the number of skids (also called "skids", production line conveying equipment) or spreaders between the painting offline point and the final assembly line point 10.

Generally speaking, there will be dozens or even hundreds of sliders or spreaders on the production line. If calculated according to JPH = 40, this part of the cached data will be available for 2-3 hours. During this time, tightening is still in efficient automatic mode. running, which provides enough time to repair the upper system.

After this period of time, if the upper position is still not repaired, the manual tightening operation will be performed.

The upper-level system is based on the IOT system as the core, including the IOT system, Andon page, MES (production information management for the manufacturing enterprise workshop execution layer) system, execution system page, etc.; the lower-level system is based on the IOT-PLC as the core, including the IOT- PLC, tightening machine PLC, machine PLC, etc.

The upper-level system mainly provides data sources and control, while the lower-level system mainly provides execution.

Andon is also called "dark light". The Andon system is just a light. It is an acousto-optic multimedia multiple automation control system. It is an information management and control system specially designed for automobile production and assembly lines. It has become an indispensable part of the complete automobile production line. The Andon system can collect relevant equipment and quality management information on the production line, process it, and control the lighting and sound alarm systems distributed throughout the workshop.

The execution system mainly configures the entire system, such as the configuration of basic information, issuance of instructions, etc. What is more important here is the configuration and issuance of important parameters. The start and stop positions of each workstation can be configured in the execution system, and Send to IOT-PLC;

The MES system mainly provides data sources for IOT, such as JOB+VIN information, material information, etc. The IOT system provides it with vehicle passing information during final assembly, which facilitates MES to continuously monitor and retain files; the Andon screen mainly accepts information from the IOT system Alarm and line shutdown information are displayed on the large screen in the workshop in real time, allowing on-site leaders and process personnel to coordinate resources and solve on-site problems in a timely manner.

IOT-PLC is the lower execution core. All cache information and control information from the upper level are gathered into IOT-PLC. The control lines that are crucial to the scene are logically judged here;

Jiyun PLC mainly calculates the beat data in real time (data obtained through the number of rotations of the motor and the length of the slip) and provides it to the IOT-PLC to obtain the line control or release signal and control whether to stop the line;

The tightening machine PLC is the core component of the tightening gun. It mainly caches JOB+VIN information, obtains JOB information in real time, transfers the JOB to the tightening gun for work, and then feeds back the tightening results of the tightening gun to IOT-PLC.

as shown in picture 2;

The upper system transmits data through the Restful interface. The upper and lower systems use the OPCUA protocol for transmission. Since the lower systems are all Siemens PLCs, they use the S7 protocol (as shown in the figure).

RESTFUL is a design style and development method for web applications. It is based on HTTP and can be defined in XML format or JSON format.

OTT, the abbreviation of "Over The Top", refers to Internet companies bypassing operators and developing various video and data service businesses based on the open Internet.

RESTFUL is suitable for scenarios where mobile Internet manufacturers serve as business interfaces to implement the function of third-party OTTs calling mobile network resources. The action types are adding, changing, and deleting the called resources.

As shown in Figure 3, it is mainly used to illustrate the basic principles of caching data and is a conceptual diagram of a location in the workshop.

The painting workshop and the general assembly workshop are divided by the coating line point, and then enter the general assembly workshop after a certain distance. When entering the general assembly workshop at 10 o'clock, the work report is carried out, and then the general assembly related operations of each station begin.

As shown in Figure 4:

When a vehicle comes off the painting line on a skid or spreader, the vehicle VIN at this time is obtained through the VIN queue of the painting MES system. At this time, the IOT system will use this VIN as the basis to request follow-up requests from the MES system. JOBs of all tightening machine jobs, and VIN+JOB are sent to the PLC points of all tightening machines after going online at 10 o'clock, so as to achieve the purpose of caching.

As shown in Figure 5:

In order to achieve the same inventive purpose as the above technical solution, the present invention also provides a control method for the above-mentioned upper and lower decoupled tightening system, and the process is:

1). The IOT system sends the start position and stop position percentage of the execution system to IOT-PLC;

2), Jiyun PLC gives IOT-PLC the percentage of sliding into the workstation and the VIN queue;

3). When the percentage of sliding warps entering the workstation reaches the starting position set by the workstation, IOT-PLC takes out the vehicle VIN of the current workstation from the VIN queue of the machine PLC, and uses this VIN to request the workstation from the superior. What is the corresponding JOB number;

4) After IOT-PLC obtains the VIN+JOB number, it transmits this information to the tightening machine PLC, and the tightening machine starts working;

5) The tightening machine PLC works based on this JOB and uploads the tightening results to IOT-PLC;

6) When the percentage of the sliding warp entering the station does not reach the stop position and the tightening OK result has been obtained, the IOT-PLC will send a direction signal to the machine PLC, otherwise no interaction will be performed.

In the above 1), the start position and stop position percentage are stored in the DB block (data block) of IOT-PLC; as permanent storage, after one delivery is completed, if no adjustment is made, there is no need to deliver it again.

In the above 2), the percentage of the workstation is from 1% to 100%; every 1% increase must be given to the IOT-PLC once; it reflects the percentage of the slipper (car above) entering the workstation; Among them, 50% means that the slip center coincides with the center of the workstation;

In the above 2), the VIN queue is obtained through RFID; RFID is installed at the entry and exit of the final assembly and at the upper and lower lines of each line; the VIN is identified through RFID, thereby updating the VIN queue of the machine PLC in real time.

It should be noted that so many RFIDs are deployed because the vehicle may be pulled in and out when changing lines. (RFID is radio frequency identification technology, the abbreviation of Radio Frequency Identification.)

In the above 5), whether the tightening work is OK is passed to IOT-PCL.

What needs to be explained here is that the manufacturer of the tightening machine PLC needs to cache the corresponding JOBs in advance: the number of tightening points, the upper and lower limits of torque, and the upper and lower limits of angle; whether the worker succeeds in tightening each time will be displayed on the tightening screen, and the tightening gun will also have Lighted display.

When the green light is on, it means that the angle and torque of this tightening have reached the requirements. This tightening is OK, and the next position can be tightened according to the process requirements;

When tightening NOK, you must immediately rework and retighten. You cannot proceed with subsequent tasks until the tightening is OK.

When all tightening at the station is OK, the tightening machine PLC will transmit the tightening result as OK to the IOT-PLC, otherwise no transmission will be made.

What needs to be emphasized is that the Jiyun PLC controls the line by default. If no release signal is obtained, the Jiyun PLC controls the line and displays the relevant line control reasons, workstation information, etc. on the andon screen for the preparation of relevant personnel. Quick fix.

When the upper system has a problem and crashes, 3) in the process will not be realized, that is, the current JOB number cannot be obtained; at this time, the IOT-PLC detects that the upper system cannot ping or the information is severely squeezed, and then sends a flag to the tightening machine PLC. , directly use the VIN given by the machine PLC, and obtain the JOB of the vehicle from the VIN+JOB relationship cached in the tightening machine PLC, and then proceed to the subsequent 4), 5), and 6) processes without affecting production.

Caching data can buy more than 2-3 hours for repairing the upper level; if the upper level still has not been restored at this time, the on-site tightening machine will enter manual mode by swiping the card. At this time, there is no JOB issued, and workers need to rely on experience to perform tightening operations. The tightening machine PLC will record the tightening process data of each vehicle and eventually provide it to the quality department for review. Finally, the quality gate of the final assembly will confirm whether the vehicle has reached the stage of being released and can enter the subsequent process.

Test examples of the present invention:

This invention is applied in the assembly workshops of multiple automobile manufacturing companies, and increases the JPH from less than 30 to more than 60. With the application of this automated system, workers' workload is greatly reduced, and labor costs can be saved by about 20%.

The present invention has been exemplarily described above in conjunction with the accompanying drawings. It is obvious that the specific implementation of the present invention is not limited by the above-mentioned manner, as long as various non-substantive improvements are made using the method concepts and technical solutions of the present invention, or without improvement. Direct application of the concepts and technical solutions of the present invention to other situations shall fall within the protection scope of the present invention.

Claims (10)

1. A decoupling tightening system between the upper and lower positions, including an upper system and a lower system, characterized in that: the upper system takes the IOT system as the core, and also includes an execution system page, an Andon page, and MES; the lower system The system is based on IOT-PLC as the core, and also includes tightening machine PLC and machine operation PLC; the tightening JOB+VIN is issued in advance; with the corresponding relationship between the JOB and VIN issued in advance, and the VIN queue obtained from the machine operation PLC in real time, Get the real-time VIN, and then get the JOB of the current vehicle from the JOB+VIN relationship cached in the tightening machine PLC, and then continue the tightening operation. 2. The upper-position and lower-position decoupling tightening system according to claim 1, characterized in that: the number of VIN+JOB issued in advance depends on the slippage or spreader between the coating line point and the various points of the final assembly line. quantity. 3. The control method of the upper and lower decoupled tightening system according to claim 1 or 2, characterized in that: the process of the control method is: 1) The IOT system sends the start position and stop position percentage of the execution system to IOT-PLC; 2), Jiyun PLC gives IOT-PLC the percentage of sliding into the workstation and the VIN queue; 3). When the percentage of sliding warps entering the workstation reaches the starting position set by the workstation, IOT-PLC takes out the vehicle VIN of the current workstation from the VIN queue of the machine PLC, and uses this VIN to request the workstation from the superior. Corresponding JOB number; 4) After IOT-PLC obtains the VIN+JOB number, it transmits this information to the tightening machine PLC, and the tightening machine starts working; 5) The tightening machine PLC works based on this JOB and uploads the tightening results to IOT-PLC; 6) When the percentage of the sliding warp entering the station does not reach the stop position and the tightening OK result has been obtained, the IOT-PLC will send a direction signal to the machine PLC, otherwise no interaction will be performed. 4. The control method of the upper and lower decoupled tightening system according to claim 3, characterized in that: in said 1), the start position and the stop position percentage are stored in the DB block of the IOT-PLC; as Permanent storage. After one delivery is completed, if no adjustments are made, there is no need to deliver it again. 5. The control method of the upper and lower decoupled tightening system according to claim 3, characterized in that: in 2), the percentage of work stations is from 1% to 100%; for every 1% increase, It must be given to IOT-PLC once; it reflects the percentage of slippage entering the workstation; among them, 50% means that the center of the slippage coincides with the center of the workstation. 6. The control method of the upper and lower decoupled tightening system according to claim 5, characterized in that: in said 2), the VIN queue is obtained through RFID; at the entry and exit of the final assembly position, each line RFID is installed at both the upper and lower line locations; VIN is identified through RFID, thereby updating the VIN queue of Jiyun PLC in real time. 7. The control method of the upper and lower decoupled tightening system according to claim 3, characterized in that in said 5), whether the tightening work is OK is transmitted to IOT-PCL. 8. The control method of the upper and lower decoupled tightening system according to claim 7, characterized in that: the tightening machine PLC needs to cache the corresponding JOBs in advance: the number of tightening points, the upper and lower limits of torque, and the upper and lower limits of angle; workers The success of each tightening will be displayed on the tightening screen, and the tightening gun will also have a light display. 9. The control method of the upper-level and lower-level decoupled tightening system according to claim 3, characterized in that: when the upper-level system collapses due to problems, 3) in the process will not be realized, that is, the current JOB number cannot be obtained; At this time, IOT-PLC detects that the host system cannot ping or the information is severely squeezed, and then sends a flag to the tightening machine PLC. It directly uses the VIN given by the machine PLC and obtains the relationship between VIN+JOB cached in the tightening machine PLC. JOB of the car, and then proceed to the subsequent processes 4), 5), and 6) without affecting production. 10. The control method of the upper and lower decoupled tightening system according to claim 9, characterized in that: the cached data buys more than 2-3 hours for repairing the upper position; if the upper position is still not restored at this time, the on-site The tightening machine enters manual mode by swiping the card. At this time, there is no JOB issued. Workers need to rely on experience to perform tightening operations. The tightening machine PLC will record the tightening process data of each vehicle and eventually provide it to the quality department for review, and finally in the final assembly. The quality gate confirms whether the vehicle can be released to the subsequent process.