CN117270465A - Automatic production control system and method - Google Patents
Automatic production control system and method Download PDFInfo
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- CN117270465A CN117270465A CN202311085786.7A CN202311085786A CN117270465A CN 117270465 A CN117270465 A CN 117270465A CN 202311085786 A CN202311085786 A CN 202311085786A CN 117270465 A CN117270465 A CN 117270465A
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- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41885—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by modeling, simulation of the manufacturing system
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
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Abstract
The invention discloses a production control system and a production control method based on an automatic assembly line, wherein the production control system comprises a production line MES system, a production control system, a production line PLC centralized control system and an automatic assembly line, the production control system is connected with the production line MES system and the PLC centralized control system, receives production task information of the MES system and data information of the production line PLC centralized control system, and performs production management and operation control according to the received data, and quality management, fault treatment and operation and maintenance management of an operation process. According to the invention, through calculating the productivity of the intelligent production line and deducing the productivity, a productivity optimization strategy is generated, and data support is provided for improving the production efficiency of the production line; carrying out statistical analysis on the production defective products, and effectively reducing the defective rate; the equipment fault problem is regulated, a problem method library is formed, the problem disposal efficiency is improved, the equipment fault downtime is reduced, the digitization and the intellectualization of the production line are improved, the cost reduction and the synergy of the enterprise automation assembly line are effectively realized, and the development process of the intelligent power-assisted production line is improved.
Description
Technical Field
The invention belongs to the field of intelligent manufacturing production control, and particularly relates to an automatic-based production control system and method.
Background
Along with the continuous improvement of the intelligent automation level in China and the rapid development of industry, the application of the automatic continuous production line in the industrial aspect in China is also becoming wider, some enterprises are replacing common continuous production lines with the automatic continuous production line, and automatic equipment is adopted in actual production, so that the labor cost is reduced, and the labor productivity and economic benefit of the enterprises are improved.
However, the production control capability of the existing automatic assembly line is generally weak, the factors influencing the performance of the automatic equipment are large, and a unified, efficient and intelligent production control system is lacked, so that the influence of factors such as long time of part of operation procedures, frequent equipment failure and shutdown, long maintenance time, unstable process quality and the like is caused, and the overall production efficiency is always not high.
Disclosure of Invention
The invention aims to solve the technical problem of providing a production management and control system which is reasonable in design, uniform, efficient and intelligent based on an automatic assembly line, aiming at the defects of the prior art.
The invention aims to solve the technical problem of providing a production control method adopting the production control system based on the automatic assembly line aiming at the defects of the prior art.
In order to achieve the above purpose, the present invention adopts the following technical scheme:
the production control system based on automation is characterized by comprising a production line MES system, a production control system, a production line PLC centralized control system and an automation assembly line;
the production management and control system is respectively connected with the production line MES system and the production line PLC centralized control system, receives production task information of the MES system and data information of the production line PLC centralized control system, and monitors and manages the production process according to the received data;
the production management and control system generates a capacity optimization strategy by calculating and deducing the capacity, and provides data support for improving the production efficiency of the production line; carrying out statistical analysis on the production defective products, and effectively reducing the defective rate; and the equipment fault problems are regulated to form a problem method library, so that the problem handling efficiency is improved, and the equipment fault downtime is reduced.
Further, the production management and control system comprises a production management module, a quality management module, a data acquisition module, a data storage module, a fault handling module and an operation and maintenance management module;
the production management module is used for real-time supervision of production states, equipment efficiency and verification of productivity, and an efficiency optimization promotion scheme is generated through deduction and algorithm operation of pre-production;
the quality management module is used for receiving and displaying real-time product quality data of the production line of the automatic equipment, simultaneously carrying out statistics and analysis on the quality data, and storing the result into the database;
the data acquisition module is used for acquiring equipment information and production information of the production line PLC centralized control system and an automatic equipment production line, so as to realize data acquisition of the production control system;
the data storage module is used for storing the contents such as acquisition data, process statistics, analysis data and other input data;
the fault handling module is used for automatically diagnosing possible reasons of faults based on the alarm information, and providing a solution for the possible reasons, and intelligently assisting maintenance personnel in fault handling;
the operation and maintenance management module performs daily maintenance and preventive maintenance work of the production line based on production information and fault information of the production line, improves the performance of equipment and reduces abnormal downtime.
Further, the production line PLC centralized control system receives tasks of the MES system and the production management and control system, and performs centralized management and control on the field automation assembly line based on the programmable controller PLC so as to realize automatic and efficient operation of the production line.
Further, the production management module combines production process information, calculates and calculates theoretical capacity and actual capacity of the production line based on a calculation algorithm of capacity, finds out a capacity lifting point, and improves and optimizes boosting capacity, and an algorithm model of the production management module is specifically as follows:
let n work pieces to be processed, each work piece having q processing steps, the work piece set is represented as { A1, A2,..an }, the processing step set is represented as { C1, C2,..cq }, processing n pieces of work pieces are stopped m times by faults of equipment, wherein h faulty problems occur, the steps Ci correspond to the produced defective products ki, the faulty stop set is { D1, D2,..dm }, the faulty problem set is { W1, W2,..wh }, because the production line is An automated line, the rest time of personnel is not considered:
T g ＝T e -T s
wherein T is g T is the working time of the working procedure s For the job start time, T e The operation ending time;
wherein T is Ci The average operation time of the n workpieces for the ith procedure;
wherein Q is ll For theoretical production capacity, T Z Taking the working time of the start and the end of the operation into consideration as the total working time;
wherein T is cp The operation time wasted for defective products in the production process is shortened;
wherein T is Di For the occupation time of Di fault shutdown, Q sj In order to increase the production yield under the condition of considering equipment faults and defective products, the method can be used as the basis of actual productivity through long-term data accumulation and iteration;
further, the capacity deduction of the production control module in the production control system can manually input and modify data such as working procedure operation time, failure time, defective condition and the like, and can calculate the capacity deduction of the automatic assembly line capacity according to the capacity algorithm model, so as to search for an economic and feasible optimal capacity optimizing path and method.
Further, the fault handling module in the production management and control system diagnoses and analyzes the fault problems, combines a fault handling method library to assist maintenance personnel in fault handling, counts and analyzes the fault problems and the fault influence time, analyzes the fault problems with larger production efficiency, and an algorithm model is as follows:
T D ＝T De -T Ds
wherein T is D For the interruption time of working procedure, T Ds For the job start time, T De The operation ending time;
wherein T is Wmax Wmax is a fault problem that affects the maximum production time in order to affect the maximum production time.
Further, the quality management module in the production management and control system performs statistics and management on the defective product generation procedure, the defective product type and the defective product reason, and assists staff to reduce the defective product rate.
Further, the automatic assembly line comprises various automatic and intelligent devices, and meets the requirements of remote control of networking of the devices and whole-course automatic operation.
The production control method adopting the production control system is characterized by comprising the following steps of:
step 1, a production control system receives an MES system task, reads the starting and ending time of working procedure operation of a PLC centralized control system and automatic assembly line equipment after starting operation, and performs working procedure operation time statistics;
step 2, the production control system reads quality data of the quality inspection equipment, and performs statistics, analysis and data storage on defective products generated in production;
step 3, the production control system receives fault alarm information and downtime information of the field device, performs data processing, and simultaneously diagnoses and analyzes fault problems, and assists maintenance personnel in performing fault treatment according to a fault problem method library;
step 4, the production control system calculates theoretical capacity and actual normal capacity according to collected data such as working procedure operation time, quality data and fault information in the first three steps, an algorithm model and an algorithm model, and generates relevant capacity data, and contents such as fault influence time, fault problem factors, defective rate and the like;
and 5, carrying out capacity improvement deduction by a manager according to capacity data of the production control system through modification and adjustment of related data and indexes, and finding out a reasonable improvement scheme.
Compared with the prior art, the invention has the following technical effects:
firstly, through data acquisition, data analysis and statistics of an automatic assembly line, the timely treatment of the abnormality of field equipment and the comprehensive control of the production operation condition are realized;
secondly, generating a capacity optimizing strategy through a capacity algorithm model, capacity factor analysis and capacity deduction, and assisting in providing data support for production line production efficiency improvement;
thirdly, carrying out statistical analysis on the production defective products, analyzing the reasons of the defective products, and assisting operators in effectively reducing the defective rate;
fourth, the equipment fault problem is regulated and the process is iterated, so that a problem disposal method library is formed, the problem disposal efficiency is improved, and the equipment fault downtime is reduced.
Through the intelligent means and the software function, the digitization and intelligent level of the production line is improved, the cost reduction and synergy of an enterprise automation assembly line are effectively realized, and a real value gain is provided for enterprises.
Drawings
FIG. 1 is a schematic diagram of a production control system architecture based on an automated pipeline of the present invention;
FIG. 2 is a flow chart of steps of a production control method based on an automated pipeline according to the present invention.
Detailed Description
The following description of the embodiments of the present invention will be made clearly and completely with reference to the accompanying drawings, in which it is apparent that the embodiments described are only some embodiments of the present invention, but not all embodiments.
Referring to fig. 1, a production control system based on an automated assembly line includes a production line MES system, a production control system, a production line PLC centralized control system, and an automated assembly line;
the production management and control system is respectively connected with the production line MES system and the production line PLC centralized control system, receives production task information of the MES system and data information of the production line PLC centralized control system, and monitors and manages the production process according to the received data;
more specifically, the production control system generates a capacity optimization strategy by calculating and deducing the capacity, and provides data support for improving the production efficiency of the production line; carrying out statistical analysis on the production defective products, and effectively reducing the defective rate; and the equipment fault problems are regulated to form a problem method library, so that the problem handling efficiency is improved, and the equipment fault downtime is reduced.
The production management and control system comprises a production management module, a quality management module, a data acquisition module, a data storage module, a fault handling module and an operation and maintenance management module;
the production management module is used for real-time supervision of production states, equipment efficiency and verification of productivity, and an efficiency optimization promotion scheme is generated through deduction and algorithm operation of pre-production;
the quality management module is used for receiving and displaying real-time product quality data of the production line of the automatic equipment, simultaneously carrying out statistics and analysis on the quality data, and storing the result into the database;
the data acquisition module is used for acquiring equipment information and production information of the production line PLC centralized control system and an automatic equipment production line, so as to realize data acquisition of the production control system;
the data storage module is used for storing the contents such as acquisition data, process statistics, analysis data and other input data;
the fault handling module is used for automatically diagnosing possible reasons of faults based on the alarm information, and providing a solution for the possible reasons, and intelligently assisting maintenance personnel in fault handling;
the operation and maintenance management module performs daily maintenance and preventive maintenance work of the production line based on production information and fault information of the production line, improves the performance of equipment and reduces abnormal downtime.
The production line PLC centralized control system receives tasks of the MES system and the production management and control system, and performs centralized management and control on the field automation assembly line based on the programmable controller PLC so as to realize automatic and efficient operation of the production line.
The production management module combines production process information, performs statistics and accounting on the theoretical capacity and the actual capacity of the production line based on a calculation algorithm of the capacity, finds out a key influence node of the capacity, improves and optimizes the boosting capacity, and an algorithm model of the production management module specifically comprises the following steps:
let n work pieces to be processed, each work piece having q processing steps, the work piece set is represented as { A1, A2,..an }, the processing step set is represented as { C1, C2,..cq }, processing n pieces of work pieces are stopped m times by faults of equipment, wherein h faulty problems occur, the steps Ci correspond to the produced defective products ki, the faulty stop set is { D1, D2,..dm }, the faulty problem set is { W1, W2,..wh }, because the production line is An automated line, the rest time of personnel is not considered:
T g ＝T e -T s
wherein T is g T is the working time of the working procedure s For the job start time, T e The operation ending time;
wherein T is Ci The average operation time of the n workpieces for the ith procedure;
wherein Q is ll For theoretical production capacity, T Z Taking the working time of the start and the end of the operation into consideration as the total working time;
wherein T is cp The operation time wasted for defective products in the production process is shortened;
wherein T is Di For the occupation time of Di fault shutdown, Q sj In order to increase the production yield under the condition of considering equipment faults and defective products, the method can be used as the basis of actual productivity through long-term data accumulation and iteration;
the production capacity deduction of the production control module in the production control system can manually input and modify data such as working procedure operation time, fault time, defective condition and the like, and carry out production capacity deduction operation on the production capacity of an automatic assembly line according to a production capacity algorithm model so as to search for an economic and feasible optimal production capacity optimizing path and method.
The fault handling module in the production management and control system is used for diagnosing and analyzing the fault problems, combining with a fault handling method library, assisting maintenance personnel in carrying out fault handling, simultaneously carrying out statistics and analysis on the fault problems and fault influence time, analyzing the fault problems with larger production efficiency, and an algorithm model is as follows:
T D ＝T De -T Ds
wherein T is D For the interruption time of working procedure, T Ds For the job start time, T De The operation ending time;
wherein T is Wmax Wmax is a fault problem that affects the maximum production time in order to affect the maximum production time.
And the quality management module in the production management and control system performs statistics and management on the defective product generation procedure, the defective product type and the defective product reason, and assists staff to reduce the defective product rate.
The automatic assembly line comprises various automatic and intelligent equipment, and meets the requirements of remote control of equipment networking and whole-course automatic operation.
Referring to fig. 2, a production control method using the above production control system includes the following steps:
step 1, a production control system receives an MES system task, reads the starting and ending time of working procedure operation of a PLC centralized control system and automatic assembly line equipment after starting operation, and performs working procedure operation time statistics;
step 2, the production control system reads quality data of the quality inspection equipment, and performs statistics, analysis and data storage on defective products generated in production;
step 3, the production control system receives fault alarm information and downtime information of the field device, performs data processing, and simultaneously diagnoses and analyzes fault problems, and assists maintenance personnel in performing fault treatment according to a fault problem method library;
step 4, the production control system calculates theoretical capacity and actual normal capacity according to the collected data of the first three steps and by combining an algorithm model, and generates relevant capacity data, and contents such as fault influence time length, fault problem factors, defective rate and the like;
and 5, carrying out capacity improvement deduction by a manager according to capacity data of the production control system through modification and adjustment of related data and indexes, and finding out a reasonable improvement scheme.
The invention is further illustrated below with reference to examples.
Examples
In this embodiment, the production control system is applied to a full-automatic production line for processing ship pipes, and interacts with an MES system, a siemens 1200PLC centralized control system and a pipe processing automation line through an industrial switch, and collects various data information on site through an internet of things collection gateway.
The production line PLC centralized control system receives tasks of an MES system and a production management control system, and performs centralized management control on a field automation assembly line based on a Programmable Logic Controller (PLC) to realize automatic efficient operation of the production line, wherein the automatic assembly line for pipe processing comprises a pipe conveying system, an automatic cutting machine, a laser coding machine, a visual detection system, a robot automatic assembly and a robot welding system, and works such as automatic pipe processing, assembly welding and the like are realized; the types of the pipes which can be processed comprise carbon steel and stainless steel, the diameter of the pipes is within 600mm, and the pipes also comprise a vertical warehouse system, a machine vision detection system, an automatic grinding machine, a logistics conveying system and the like.
The production management module combines production process information, performs statistics and accounting on the theoretical capacity and the actual capacity of the production line based on a calculation algorithm of the capacity, finds out a key influence node of the capacity, improves and optimizes the boosting capacity, and an algorithm model of the production management module specifically comprises the following steps:
let n work pieces to be processed, each work piece having q processing steps, the work piece set is represented as { A1, A2,..an }, the processing step set is represented as { C1, C2,..cq }, the processing of n work pieces is stopped m times by a failure of equipment, wherein h failure problems occur, the steps Ci correspond to the produced defective products ki, the failure stopping set is { D1, D2,..dm }, the failure problem set is { W1, W2,..wh }, because the production line is An automated line, the rest time of personnel is not considered, and therefore:
T g ＝T e -T s
wherein T is g T is the working time of the working procedure s For the job start time, T e The operation ending time;
wherein T is Ci The average operation time of the n workpieces for the ith procedure;
wherein Q is ll For theoretical production capacity, T Z For the total duration of the job, the working time of the start and end of the job is considered, the circulation time of the end-to-end products is deducted on the basis of the total duration of the job, max (T C1 ,T C2 ,...T Cq ) The operation procedure of (2) is a key procedure, and the production efficiency is improved preferentially;
wherein T is cp The operation time wasted for defective products in the production process is shortened;
wherein T is Di For the occupation time of Di fault shutdown, Q sj In order to consider the production yield under the condition of equipment faults and inferior products, the circulation time of the head and tail products, the accumulated time of fault shutdown and the influence time of inferior product operation are deducted on the basis of the total operation time, and the system data is basically close to the actual productivity through long-time accumulation and iteration and can be used as the basis of production scheduling;
in the embodiment, the quality data is derived from a field visual detection system, the quality of the pipe in the operation engineering is detected, and main indexes comprise the data of the pipe size, the appearance, the code printing, the welding quality and the like, and the quality and the defective quality are judged according to a user-set threshold value; the equipment fault problems comprise equipment failure, mechanical limitation failure, non-brightness of a limit switch, motor fault and the like.
The production capacity deduction of the production control module in the production control system can manually input and modify data such as working procedure operation time, fault time, defective condition and the like, and carry out production capacity deduction operation on the production capacity of an automatic assembly line according to a production capacity algorithm model so as to search for an economic and feasible optimal production capacity optimizing path and method.
Claims (8)
1. The production control system based on the automatic assembly line is characterized by comprising a production line MES system, a production control system, a production line PLC centralized control system and an automatic assembly line;
the production management and control system is respectively connected with the production line MES system and the production line PLC centralized control system, receives the production task information of the production line MES system and the data information of the production line PLC centralized control system, monitors and manages the production process according to the received data,
the production line PLC centralized control system receives tasks of a production line MES system and a production management and control system, and performs centralized management and control on a field automation assembly line based on a Programmable Logic Controller (PLC) so as to realize automatic and efficient operation of the production line;
the production control system generates a capacity optimization strategy by calculating and deducing the capacity, and provides data support for improving the production efficiency of the production line; carrying out statistical analysis on the production defective products, and effectively reducing the defective rate; and the equipment fault problems are regulated to form a problem method library, so that the problem handling efficiency is improved, and the equipment fault downtime is reduced.
2. The automated pipeline-based production control system of claim 1, wherein the production control system comprises a production management module, a quality management module, a data acquisition module, a data storage module, a fault handling module, and an operation and maintenance management module;
the production management module is used for real-time supervision of production states, equipment efficiency and verification of productivity, and an efficiency optimization promotion scheme is generated through deduction and algorithm operation of pre-production;
the quality management module is used for receiving and displaying real-time product quality data of the production line of the automatic equipment, simultaneously carrying out statistics and analysis on the quality data, and storing the result into the database;
the data acquisition module is used for acquiring equipment information and production information of the production line PLC centralized control system and an automatic equipment production line, so as to realize data acquisition of the production control system;
the data storage module is used for storing the contents such as acquisition data, process statistics, analysis data and other input data;
the fault handling module is used for automatically diagnosing possible reasons of faults based on the alarm information, and providing a solution for the possible reasons, and intelligently assisting maintenance personnel in fault handling;
the operation and maintenance management module performs daily maintenance and preventive maintenance work of the production line based on production information and fault information of the production line, improves the performance of equipment and reduces abnormal downtime.
3. The production control system based on the automated assembly line according to claim 2, wherein the production management module performs statistics and accounting on theoretical capacity and actual capacity of the production line based on a calculation algorithm of capacity by combining production process information, and finds a capacity lifting point, boosting capacity lifting and optimizing, and an algorithm model thereof specifically comprises:
let n work pieces to be processed, each work piece having q processing steps, the work piece set is represented as { A1, A2,..an }, the processing step set is represented as { C1, C2,..cq }, processing n pieces of work pieces are stopped m times by faults of equipment, wherein h faulty problems occur, the steps Ci correspond to the produced defective products ki, the faulty stop set is { D1, D2,..dm }, the faulty problem set is { W1, W2,..wh }, because the production line is An automated line, the rest time of personnel is not considered:
T g ＝T e -T s
wherein T is g T is the working time of the working procedure s For the job start time, T e The operation ending time;
wherein T is Ci The average operation time of the n workpieces for the ith procedure;
wherein Q is ll For theoretical production capacity, T Z Taking the working time of the start and the end of the operation into consideration as the total working time;
wherein T is cp The operation time wasted for defective products in the production process is shortened;
wherein T is Di For the occupation time of Di fault shutdown, Q sj In order to consider the production yield under the conditions of equipment failure and defective products, the method can be used as the basis of actual productivity through long-term data accumulation and iteration.
4. The production control system based on the automatic assembly line according to claim 2, wherein the capacity deduction of the production control module in the production control system is performed by manually inputting and modifying the working time, the fault time and the defective condition of the working procedure, and the capacity deduction operation is performed on the capacity of the automatic assembly line according to the capacity algorithm model, so as to seek an economical and feasible optimal capacity optimizing path and method.
5. The production control system based on the automated assembly line according to claim 2, wherein a fault handling module in the production control system diagnoses and analyzes the fault problem, and combines with a fault handling method library to assist maintenance personnel in fault handling, and simultaneously performs statistics and analysis on the fault problem and the fault influence time length, and analyzes the fault problem with larger production efficiency, and an algorithm model is as follows:
T D ＝T De -T Ds
wherein T is D For the interruption time of working procedure, T Ds For the job start time, T De The operation ending time;
wherein T is Wmax Wmax is a fault problem that affects the maximum production time in order to affect the maximum production time.
6. The production control system based on the automatic assembly line according to claim 2, wherein the quality management module in the production control system performs statistical management on the defective product generation procedure, the defective product type and the defective product cause, and assists staff in reducing defective product rate.
7. The production control system based on the automatic assembly line according to claim 1, wherein the automatic assembly line comprises various automatic and intelligent devices on the production line, and meets the requirements of remote control of networking of the devices and whole-course automatic operation.
8. A production control method employing the production control system based on an automated pipeline as claimed in any one of claims 1 to 7, comprising the steps of:
step 1, a production management and control system receives a production line MES system task, reads working procedure operation starting and ending time of a production line PLC centralized control system and automatic assembly line equipment after starting operation, and performs working procedure operation time statistics;
step 2, the production control system reads quality data of the quality inspection equipment, and performs statistics, analysis and data storage on defective products generated in production;
step 3, the production control system receives fault alarm information and downtime information of the field device, performs data processing, and simultaneously diagnoses and analyzes fault problems, and assists maintenance personnel in performing fault treatment according to a fault problem method library;
step 4, the production control system calculates theoretical capacity and actual normal capacity according to the acquired data of the first three steps, and generates relevant capacity data, fault influence time length, fault problem factors and defective rate;
and 5, carrying out capacity improvement deduction by a manager according to capacity data of the production control system through modification and adjustment of related data and indexes, and finding out a reasonable improvement scheme.
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