CN117666451A - Multi-process-based chip mounter main control system and method - Google Patents
Multi-process-based chip mounter main control system and method Download PDFInfo
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- CN117666451A CN117666451A CN202410143288.1A CN202410143288A CN117666451A CN 117666451 A CN117666451 A CN 117666451A CN 202410143288 A CN202410143288 A CN 202410143288A CN 117666451 A CN117666451 A CN 117666451A
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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
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/04—Programme control other than numerical control, i.e. in sequence controllers or logic controllers
- G05B19/042—Programme control other than numerical control, i.e. in sequence controllers or logic controllers using digital processors
- G05B19/0428—Safety, monitoring
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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
- G05B2219/00—Program-control systems
- G05B2219/20—Pc systems
- G05B2219/24—Pc safety
- G05B2219/24024—Safety, surveillance
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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Abstract
The invention relates to the technical field of chip mounter control, and particularly discloses a chip mounter main control system and method based on multiple processes, wherein the system comprises a main control board and a software system, the software system comprises a main process and a plurality of subprocesses, and the main process is communicated with the main control board; the plurality of subprocesses are communicated with a main process, the plurality of subprocesses firstly send data or instructions issued to the main control board to the main process for verification and management, and then the main process issues the data or instructions to the main control board, and the plurality of subprocesses are not communicated with each other; the main control board is used for receiving data or instructions from the main process and returning equipment state information to the main process. The scheme can effectively avoid the problem that the whole chip mounter main control system runs when a subsystem is in problem due to the implementation mechanism of the same process.
Description
Technical Field
The invention relates to the technical field of chip mounter control, in particular to a chip mounter main control system and method based on multiple processes.
Background
The chip mounter main control system software comprises the following subsystems: the control system is used for setting a control strategy for element mounting coordination and multi-axis system motion control; the real-time monitoring system is used for monitoring software and hardware data communication, equipment real-time state, error information feedback and the like; the database and log system stores real-time data and important historical information; a man-machine interface for providing visual monitoring and operation interface for users; the system also comprises a system diagnosis function module, a parameter management function module and the like. The subsystems and the functional modules are not single, are interwoven together and work in coordination, so that the diversity of software functions of the chip mounter main control system and the complexity of the system can be seen.
The running efficiency and reliability of the chip mounter main control system software directly influence the efficiency and reliability of the whole chip mounter. Because the chip mounter main control system software is different from the software development (such as database software, file editing software and the like) in the conventional sense, the design of the chip mounter main control system software needs to meet the following requirements: emphasis is placed on real-time and excellent reliability, not only requiring good human-computer interaction management required by conventional software, but also requiring underlying hardware operation and control capabilities, etc.
If the chip mounter main control system adopts the conventional implementation mechanisms such as control management, real-time monitoring, man-machine interaction and the like by using the same process, when a certain subsystem of the chip mounter is caused to have a problem by the mechanism, the whole chip mounter main control system can run through, namely other subsystems which normally run are forced to be closed along with running, and all unsaved data can be lost.
Disclosure of Invention
The invention aims to solve the problems in the prior art, and provides a chip mounter main control system and method based on multiple processes, which can effectively avoid the problem that the whole chip mounter main control system runs when a subsystem is in a problem due to the implementation mechanism of the same process.
In order to achieve the above object, a first aspect of the present invention provides a chip mounter master control system based on multiple processes, which is characterized by comprising a master control board and a software system,
the software system comprises a main process and a plurality of subprocesses, wherein the main process is communicated with the main control board; the plurality of subprocesses are communicated with a main process, the plurality of subprocesses firstly send data or instructions issued to the main control board to the main process for verification and management, and then the main process issues the data or instructions to the main control board, and the plurality of subprocesses are not communicated with each other;
the main control board is used for receiving data or instructions from the main process and returning equipment state information to the main process.
The second aspect of the invention provides a real-time feedback method based on a multi-process chip mounter, which is realized based on the system and comprises the following steps:
s31, creating mounting flow instruction data by a production flow control subprocess of the system, and transmitting the mounting flow instruction data to equipment for execution;
s32, after the execution of the identification instruction of the production flow control subprocess is successful, the image processing subprocess obtains an image shot by a camera, identifies according to parameters, and sends an identification result to the main process;
S33, subscribing the identification result by the production process control subprocess, and correcting the mounting instruction according to the identification result when the element is successfully identified; when the element identification fails, executing the element throwing action;
s34, the equipment of the system monitors and feeds back the feeding command of the flyer in the sub-process subscription event bus in real time, records the length of the flyer material belt, updates the length of the material belt corresponding to the flyer number when one feeding command of the flyer is monitored, and executes the cutter action when the maximum length of the material belt is greater than the length of the material belt preset in the machine parameter;
s35, the equipment monitors and feeds back the state of the sub-process subscription conveying track in real time, and when a substrate is arranged at the entrance of the track and the mounting position is free of the substrate, the substrate is conveyed in and the production mounting is started; transferring the substrate to downstream equipment when one substrate is mounted;
s36, subscribing an element mounting instruction by a production process control subprocess, recording current information of the mounted element of the PCB, and when the mounting process is stopped halfway and restarted, continuing to produce the unfinished mounting data according to the recorded information;
and S37, the equipment monitors and feeds back control subprocess monitoring shaft movement instructions, shaft return origin instructions, shaft state information and shaft movement to static information in real time, and when detecting that the difference between the final position of the shaft and the target position of the movement instructions exceeds a threshold value, the equipment feeds back error information to the main process when the difference between the final position of the shaft and the target position of the movement instructions exceeds the threshold value.
The third aspect of the present invention provides an error handling method based on a multi-process chip mounter, which is implemented based on a main process of the above system, and includes the following steps:
when the hardware submodule has abnormal conditions, the hardware submodule directly enters an error state, an instruction to be executed is emptied, and a corresponding error code is sent to a main control board of the system at the same time:
outputting a fault code when the maintenance is improper or the operation is wrong due to the operator;
when detecting that the submodule has errors, automatically clearing all the subsequent instructions which are not executed, cutting off the power line of the equipment, ensuring that the equipment is not allowed to act in an error state, and feeding an error code back to the upper computer;
when receiving the error from the hardware module, recording the error type, error time, error generating module and error content, pushing the error information to the event bus, broadcasting the error information to the subprocesses of the system by the IPC communication module, and processing after the subprocesses receive the error information.
According to the technical scheme, corresponding program processes are developed for the main control system software of the large chip mounter according to different functions, a specific design scheme is provided from two aspects of a hardware structure and a software framework, the complex main control system software is divided into a plurality of mutually non-communication sub-processes, the sub-processes and the main process work cooperatively to complete the overall function of the system software, the different sub-processes run in the respective independent memory spaces, one process cannot directly access the data of other processes, so that the sub-processes cannot interfere with each other, running of a certain sub-process cannot influence other processes, the main control system software of the chip mounter has good real-time performance, reliability, stable running and effective monitoring, and effective guarantee is provided for the chip mounter.
Drawings
FIG. 1 is a schematic diagram of a master control system of the present invention;
FIG. 2 is a schematic diagram of a component sub-process in a multi-process architecture of the master control system of the present invention;
FIG. 3 is a diagram of a log system architecture according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a multi-process architecture of a software system running on a device PC according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of the creation steps of the production flow instruction of 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. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.
Corresponding program processes are developed according to different functions aiming at the main control system software of the large-scale chip mounter, and all the processes work cooperatively to complete the overall functions of the system software. Different processes run in independent memory spaces, one process cannot directly access data of other processes, so that the processes cannot interfere with each other, and running of a certain subprogram cannot affect other processes. Therefore, the chip mounter main control system software based on multiple processes can effectively solve various problems in practice. Based on this, a first aspect of the embodiment of the present invention provides a chip mounter master control system based on multiple processes, including a master control board and a software system,
The software system comprises a main process and a plurality of subprocesses, wherein the main process is communicated with the main control board; the plurality of subprocesses are communicated with a main process, the plurality of subprocesses firstly send data or instructions issued to the main control board to the main process for verification and management, and then the main process issues the data or instructions to the main control board, and the plurality of subprocesses are not related to each other;
the main control board is used for receiving data or instructions from the main process and returning equipment state information to the main process.
The chip mounter main control system based on the multiple processes comprises a hardware structure and a software framework, specifically, as shown in fig. 1, on an equipment layer, the hardware structure comprises a main control board and a plurality of image acquisition cards, the main control board and the image acquisition cards are connected with an upper computer through PCIe interfaces, the requirements of large data volume and high-speed data interaction can be met at the same time, the main control board comprises reading and writing of software, reading and writing of component instructions such as shaft motion and the like and reading of state information of equipment, the image acquisition cards collect images of cameras on the equipment, and the collected images are processed by the upper computer. The main control board runs the logic control of the components of the chip mounter and monitors the states of the components, such as the axial movement and the activation/deactivation states of the sensors, so that the accurate control of the actions is realized.
The chip mounter main control system is functionally decomposed from two aspects of a hardware structure and a software framework, a plurality of multi-processes which have clear functions and are related to each other are formed, each process realizes independent and complete functions, the influence on other processes is avoided when a certain subprocess is abnormal, the cutting-off effect is well achieved, the reliability of the chip mounter main control system software is effectively improved, and a visualized interaction system such as a main interface subprocess is provided for users.
In the actual design process, more complex data interaction conditions are often required to be considered, and the types of data involved in interaction are more, such as operation control data, calculation result data and the like, in the interaction process, how to ensure the accuracy and the instantaneity of data transmission is required to be considered, so that a proper multi-process architecture and a data interaction mode are required to be designed for completion.
Therefore, further, the interaction mode of the main process and the plurality of sub-processes for data and task communication in the embodiment of the invention is as follows: creating a virtual shared memory by each sub-process connected with a main process of main control software, determining the size of the shared memory, notifying the main process of a unique handle of the shared memory after the creation is completed, completing the reading and writing of the shared memory data by the main process, immediately completing the reading and writing of the shared memory by each sub-process, and releasing the virtual memory after the sub-process exits.
After the shared memory is mapped to the process space, a unique handle for identifying the shared memory exists, and if other processes use the same object handle, data can be directly read and written from the shared memory. Therefore, user mode/kernel mode switching and data copying of a user space and a kernel space, which are necessary for other inter-process communication mechanisms, are avoided, the throughput of data interaction is greatly improved, and the response time delay is reduced.
The communication between the processes is a preset established protocol, each subprocess judges whether the read instruction is an instruction interested in the process or not, if so, the corresponding operation is executed according to the instruction protocol, and if not, the process ignores the instruction. The inter-process data interaction is carried out by adopting a shared memory mode, the communication among the processes is standard and clear, the storage authority of the inter-process data interaction is clear, the misoperation rate is reduced, the inter-process loose coupling connection mode is realized, and the flexibility and the instantaneity of the inter-process communication are improved.
Further, as shown in fig. 1, on the functional layer, the software system includes a main process and a plurality of sub-processes, and the functional modules do not directly interact with each other, and all use event bus intermediaries to interact with each other. The software system architecture is shown in fig. 2, and the several sub-processes comprise a device initialization sub-process, a production flow control sub-process, a device real-time monitoring and feedback control sub-process, a camera drawing sub-process, an image processing sub-process, a main interface sub-process, a teaching sub-process and an image dynamic display sub-process. The main functions of each sub-process are as follows:
The production flow control sub-process is used for controlling the mounting flow of the execution element and mainly comprises a production flow state management module, a mounting data creation module, an interactive instruction analysis module, an instruction data verification module, a mounting flow creation module and a mounting error compensation module. The interactive instruction analysis module is used for interacting with the main process information and comprises receiving a production control instruction from the main process and sending a production completion signal to the main process; the mounting data creation module is used for reading the substrate file data and the machine parameter information and creating a mounting data set; the mounting process creation module is used for creating a production mounting instruction set according to the mounting data set; the mounting error compensation module is used for receiving the marking points and the element identification results sent by the image identification software and correcting the mounting error according to the identification results; the command data checking module is used for checking the production mounting command and judging whether the command has the conditions of shaft target position overrun limit, command parameter error and the like; the production flow state management module is used for managing the mounting flow execution steps, realizing the switching of actions such as substrate mark point identification, element suction identification, mounting and the like, and terminating production when errors occur.
The camera image collecting sub-process image acquisition card is connected through PCIe and is responsible for acquiring image data in the image acquisition card, arranging the image data into one or more complete images, and packaging and sending the image information to a main process of main control software;
the device real-time monitoring and feedback control subprocess is used for monitoring the state of the device and controlling the action of the device parts, and sending error information to the main process when the state of the device is abnormal. Comprises a cutter control module, a transmission rail production control module and an automatic tray control module. The cutter control module monitors the feeding command of the flyer, and executes the cutter strip cutting action when the flyer strip reaches a specified length; the conveying track production control module is used for controlling the substrate to be conveyed on a production line in a production process, and comprises the steps of conveying the substrate from upstream equipment to a mounting position and conveying the substrate out to downstream equipment when one substrate is mounted; the automatic tray control module is used for monitoring the state of the automatic tray, feeding back information to the main process when the tray cabinet door is opened, and controlling the automatic tray exchange in the production process; the shaft position monitoring module is used for monitoring shaft movement instructions and shaft state information, and reporting errors when detecting that the phase difference between the final position of the shaft and the target position of the movement instructions exceeds a threshold value;
And the device initialization subprocess is used for carrying out initialization configuration on the device when the software is started. The device comprises a device startup self-checking module, a hardware parameter configuration module, a shafting return module and a warming module. The device power-on self-checking module is used for confirming whether each hardware module of the device is successfully connected or not and checking the version number information of each module; the hardware parameter configuration module is used for issuing initialization configuration parameters of each module of the equipment when the self-checking is successful; the shafting return module is used for executing the complete machine return action flow of the equipment when receiving the equipment return instruction; the warming-up module is used for executing a device warming-up action flow when receiving a device warming-up instruction;
the image processing subprocess is used for identifying the element image shot by the camera in the production process and sending an identification result to the main process, wherein the identification result comprises coordinate deviation and element angle of the element relative to the center of the image and is used for correcting the mounting error by the production process control subprocess;
and the main interface subprocess provides a UI interface capable of interacting with the equipment and mainly comprises a production design UI module, a device component UI module, a tool UI module and a history UI module. The production design UI module is used for setting the running speed of equipment, confirming the type of a suction nozzle, issuing an original shafting return and warm-up instruction, loading a substrate file and calling a substrate file editing App to edit the substrate file; the device component UI module is used for checking the device component state and controlling the device component action; the tool UI module is used for setting a production mode and confirming a production state; the resume UI module is used for checking production statistics information, including the number of completed production, the number of times of absorption and mounting, the average CPH value and the like;
The teaching subprocess is used for correcting the substrate file used for production through the reference camera and comprises a substrate origin teaching module, a suction position teaching module, a mounting position teaching module, a tray interval teaching module, an element adjusting module and a mark adjusting module. The substrate origin teaching is used for correcting origin coordinates of the substrate; the suction position teaching confirms whether the coordinates of the suction position of the element are correct, and when deviation exists, the software provides a correction function for the coordinates; the mounting position teaching is used for checking whether the position and angle information of the mounting point of the substrate have deviation or not and confirming the actual mounting effect; the tray interval teaching module is used for teaching the interval of the tray elements through the reference camera; the component adjustment is used for sucking and identifying the components used in production, confirming whether the feeding function and sucking action can be normally executed or not, and identifying whether the components are correctly identified by the identification parameters or not; the marking point teaching is used for confirming whether the coordinates of the substrate marking points are correct or not and whether the identification parameters can identify the marking points correctly or not;
and the image dynamic display subprocess is used for acquiring the image data from the main process and displaying the image data in real time.
As shown in fig. 2, the main process is responsible for data interaction with the main control board hardware and management and data interaction of each sub-process, and the core functional module comprises a data checking module, a device real-time information module, a log module, an exception handling module, an IPC communication module, a main control board driving module and an event bus. The data verification module is used for verifying and checking the instruction written into the main control board and checking whether the instruction parameter error or the instruction length error exists or not; the equipment real-time information module is used for reading equipment real-time information from the main control board and sending the information to the upper computer; the log module is used for recording all instruction information written into the main control board and all generated error information into a log file, so that problems can be conveniently checked when abnormal conditions occur; the exception handling module is used for handling the write instruction error and the error from the main control board, and broadcasting error codes and error information to each subprocess; the IPC communication module is used for communicating with each subprocess, receiving a control instruction sent by the subprocess, writing the control instruction into the main control board after data verification, and broadcasting the equipment state information obtained by the equipment real-time information module to the subprocess; the main control board driving module is responsible for data interaction between the upper computer and the main control board, wherein the main function is divided into two parts, namely, the main control board driving module is responsible for receiving the command which is checked by the data checking module and confirmed to be correct, serializing the command and finally writing the command into the main control board; secondly, the method is responsible for processing the data reading request of the upper computer and the interrupt information generated by the main control board, reading the required binary data from the register of the main control board according to different reading requests and interrupt contents, analyzing the binary data and sending the binary data to the real-time information module of the equipment; the event bus is used for searching whether subscribers of the type of event exist when the event occurs, if so, traversing all subscribers and sending event information.
The event bus module is used for organizing and managing all events in one sub-process, and adopts a publisher/subscriber mode, so that after a publisher publishes an event, a subscriber can subscribe to the event and execute related operations when the event occurs. As shown in fig. 1, for the device state information event, the IPC communication module, the production process control sub-process, the exception processing module of the main process and other sub-modules subscribe the device state information event from the event bus to be subscribers; the main control board driving module distributes the equipment state information read from the main control board equipment to an event bus to be a publisher; similarly, for the equipment control event, each sub-module is a publisher, and the main control board driving module is a subscriber. When the main control board driving module issues equipment state information to the event bus, all sub-modules can receive corresponding events and respectively perform relevant processing; after each sub-module issues a device control event to the event bus, the main control board driving module can receive the device control event through the event bus and write the device control event into the main control board device.
The core function module of the software system is used for producing a process control sub-process, a device real-time monitoring and feedback control sub-process and an event bus mechanism, and as shown in fig. 5, the process control sub-process decomposes a mounting process into a plurality of functional points and packages the functional points into process nodes, wherein the process nodes comprise 4 process nodes in total of file data analysis, mounting process creation, instruction data verification and instruction execution. As shown in fig. 1, the system is divided into a functional layer (software system) and a device layer (main control board device) which can interact with each other, and convenience such as logically clear project reading and debugging is provided for a developer. The equipment real-time monitoring and feedback control sub-process is convenient for checking the running condition of the system, timely finding out the abnormality of the system, and carrying out early warning when the abnormality occurs in the running of the system. The event bus mechanism is as follows: searching whether subscribers of the type of event exist when the event occurs, and if so, traversing all subscribers to send event specific information; the event bus combines the functional modules together to form a larger and more complete structure, while maintaining the flexibility and efficiency of the structure, and solving the problem of coupling of the functional modules from the structural aspect of the program.
In the embodiment of the invention, the multiprocess adopts a plug-in-like software framework, as shown in fig. 4, all the subprocesses are communicated with the main control software main process through the IPC communication module, other subprocesses are not related to each other, and all the subprocesses form a complete system together. In addition, the subprocess and the main process have a set of standards and protocols which cooperate to coordinate the subprograms of different sources with each other. The unique interface between the main process of the main control software and the hardware of the main control board is used as the unique communication channel of the software system and the hardware equipment, other subprocesses are not communicated with the hardware of the main control board, and data or instructions issued to the hardware by other subprocesses are checked and managed by the main control board, so that read-write conflicts of a plurality of subprocesses are avoided. The camera image receiving subprocess is connected with PCIe image acquisition card hardware and is used for receiving, checking and managing image data from equipment and finally transmitting the complete image to a main control software main process. The main process and the camera drawing subprocess are adopted to independently interact with the hardware main control board, so that the problem that the hardware is possibly operated by multiple processes simultaneously is reduced.
Further, the production process control sub-process is used for controlling the mounting process of the execution element specifically as follows:
S11, an interactive instruction analysis module analyzes the substrate file and the machine parameter file to obtain substrate file data and various machine parameter information, and a mounting data creation module creates substrate file data and various machine parameter information and a mounting data set;
s12, a mounting flow creation module creates production mounting flow instruction data according to the mounting data set obtained in the step S11, and then sequentially combines the created mounting flow instruction data into an executable mounting flow instruction set;
s13, the instruction data checking module performs data checking on the mounting flow instruction set obtained in the step S12, and judges whether the axle movement instruction exceeds a limit range, whether the instruction data is correct or whether the axle interlocking error is caused;
s14, if the step S13 is used for checking that the instruction has errors, the production flow state management module terminates the mounting flow and pushes error codes to an event bus of the main process; if no error exists, writing the mounting flow instruction set obtained in the step S12 into a flow executor, and pushing the mounting flow instruction set to an event bus;
s15, the IPC communication module sends the instruction set pushed to the event bus in the step S14 to the main process, and the main process writes the instruction set into a main control board for execution;
S16, the mounting error compensation module pastes and binds the recognition result from the image processing subprocess, calculates the substrate inclination error and the element suction error according to the recognition result, and corrects the coordinates of the mounting instruction to realize error compensation;
s17, the production flow state management module monitors the execution state of each step of the production flow, controls the execution of the next production step when the execution of the production action is completed, subscribes to error codes at the same time, and terminates the production flow when the occurrence of errors is detected.
The device real-time monitoring and feedback control subprocess is used for monitoring the state of the device and controlling the action of the device parts, and sending error information to the main process when the state of the device is abnormal is specifically as follows:
s21, a cutter control module subscribes to the feeding command of the flyer in the event bus, records the length of the flyer material belt, updates the material belt length corresponding to the flyer number when one of the flyer feeding commands is monitored, and executes the cutter action when the maximum material belt length is greater than the preset material belt length in the machine parameter;
s22, the automatic conveying module of the conveying track subscribes to the state of the conveying track, and when a substrate is arranged at the inlet of the track and the mounting position is free of the substrate, the substrate is conveyed in and the production mounting is started; transferring the substrate to downstream equipment when one substrate is mounted;
S23, subscribing an element mounting instruction by the production flow state management module, recording the current information of the mounted element of the PCB, and when the mounting flow is stopped halfway and restarted, continuing to produce the unfinished mounting data according to the recorded information;
s24, an automatic tray control module monitors tray and shaft state information, and when detecting that the shaft state is from moving to static or a cabinet door knob is in an open state, the automatic tray control module controls to open the cabinet door lock, otherwise controls to close the cabinet door lock; when the cabinet door is detected to be in an open state, a prompt message is fed back to the main process, and a dialog box is popped up from the main interface for display;
and S25, a shaft position monitoring module monitors a shaft movement instruction, a shaft return origin instruction, shaft state information and shaft movement to static information, and when detecting that the difference between the final position of the shaft and the target position of the movement instruction exceeds a threshold value (such as 45 micrometers), the shaft movement error is overlarge, and an error message is fed back to a main process.
The specific architecture of the log module is shown in fig. 3, the log module subscribes to all control instructions in the event bus of the main process, maintains an event queue of a lock-free queue for storing received control instruction data, and simultaneously creates a sub-thread for writing the log into a file in event circulation, wherein the main thread in fig. 3 is an event circulation working thread in the main process. The specific process is as follows:
Pushing the control command to an event bus when the main process IPC module receives the control command;
the log module receives control instruction information through subscription and puts the control instruction into a queue;
the sub-thread of the log module circularly acquires a control instruction from the lock-free queue and writes the control instruction into a log file;
the log module writes control instructions issued by all software into a log file, so that problems can be conveniently checked when abnormal conditions occur; because the lock-free queue and the sub-thread are used, the execution efficiency is improved.
The error handling mechanism of the exception handling module is specifically: the invention provides a set of feasible solutions for dividing errors into hardware errors and software errors by a chip mounter main control software system, and the error processing method specifically comprises the following steps:
each sub-module of the hardware can realize an error processing mechanism, when abnormal clearing occurs, such as an error instruction is received, the instruction fails to execute, the instruction overtime is not completed, and the module state is abnormal, the error state is directly entered, the instruction to be executed is cleared, and meanwhile, a specific error code is sent to the main control board, wherein the error code comprises a sub-module number, an error occurring object and a specific error fault code;
the misoperation or misoperation of the maintenance of operators can also cause the failure code of the electric control failure self-diagnosis system to be output wrong;
When the main control board detects that errors occur in the submodules, all subsequent instructions which are not executed are automatically emptied, meanwhile, the power line of the equipment is cut off, the equipment is ensured not to be allowed to act in an error state, and meanwhile, error codes are fed back to the upper computer;
when the main process receives the error from the hardware module, the error type, the error time, the error module and the specific error content are recorded, the main process broadcasts the error information, the main interface subprocess pops up an error dialog box after receiving the error information, the specific error content is displayed, and meanwhile, the buzzer sounds for a long time and the indicator light turns red;
when the main interface subprocess receives the error report from the software system, the main process broadcasts the error information and the main interface pops up an error dialog box for display, and the error report of the software system has no influence on the main control board and the subprotoblock;
the error handling mechanism of the exception handling module has the advantages that: because the quick movement of the chip mounter, communication noise, communication disconnection and other faults are inevitable and accidental events of the chip mounter, and wrong data information transmission or program is permanently waited, the monitoring failure and system breakdown of a main control system of the chip mounter can be finally caused, and even serious potential safety hazards are brought. The invention realizes a sound error processing mechanism and an accurate fault positioning warning function.
In the embodiment of the invention, the communication between the processes is a predetermined protocol, and only the determined protocol can communicate with each other, so that the probability of error data or tasks is reduced to the minimum, and the running reliability of the system is effectively improved.
The chip mounter main control system software architecture adopted by the embodiment of the invention can reduce the coupling between modules, improve the software reusability, adopts a modularized software design method to functionally decompose task system software, divides a plurality of different processes to form a multi-process software architecture, and when a certain process is abnormal due to different address spaces of the plurality of processes, an operating system can limit the abnormality in the process in a single process, thereby avoiding affecting other processes, playing a cutting-off role well and improving the software reliability effectively.
Based on the same inventive concept, a second aspect of the embodiment of the present invention provides a real-time feedback method based on a multi-process chip mounter, the method being implemented based on the above system, comprising the steps of:
s31, creating mounting flow instruction data by a production flow control subprocess of the system, and transmitting the mounting flow instruction data to equipment for execution;
s32, after the execution of the identification instruction of the production flow control subprocess is successful, the image processing subprocess obtains an image shot by a camera, identifies according to parameters, and sends an identification result to the main process;
S33, subscribing the identification result by the production process control subprocess, and correcting the mounting instruction according to the identification result when the element is successfully identified; when the element identification fails, executing the element throwing action;
s34, the equipment of the system monitors and feeds back the feeding command of the flyer in the sub-process subscription event bus in real time, records the length of the flyer material belt, updates the length of the material belt corresponding to the flyer number when one feeding command of the flyer is monitored, and executes the cutter action when the maximum length of the material belt is greater than the length of the material belt preset in the machine parameter;
s35, the equipment monitors and feeds back the state of the sub-process subscription conveying track in real time, and when a substrate is arranged at the entrance of the track and the mounting position is free of the substrate, the substrate is conveyed in and the production mounting is started; transferring the substrate to downstream equipment when one substrate is mounted;
s36, subscribing an element mounting instruction by a production process control subprocess, recording current information of the mounted element of the PCB, and when the mounting process is stopped halfway and restarted, continuing to produce the unfinished mounting data according to the recorded information;
and S37, the equipment monitors and feeds back control subprocess monitoring shaft movement instructions, shaft return origin instructions, shaft state information and shaft movement to static information in real time, and when detecting that the difference between the final position of the shaft and the target position of the movement instructions exceeds a threshold value, the equipment feeds back error information to the main process when the difference between the final position of the shaft and the target position of the movement instructions exceeds the threshold value.
Based on the same inventive concept, a third aspect of the embodiment of the present invention provides an error processing method based on a multi-process chip mounter, based on a main process implementation of the above system, including the following steps:
when the hardware submodule has abnormal conditions, the hardware submodule directly enters an error state, an instruction to be executed is emptied, and a corresponding error code is sent to a main control board of the system at the same time:
outputting a fault code when the maintenance is improper or the operation is wrong due to the operator;
when detecting that the submodule has errors, automatically clearing all the subsequent instructions which are not executed, cutting off the power line of the equipment, ensuring that the equipment is not allowed to act in an error state, and feeding an error code back to the upper computer;
when receiving the error from the hardware module, recording the error type, error time, error generating module and error content, pushing the error information to the event bus, broadcasting the error information to the subprocesses of the system by the IPC communication module, and processing after the subprocesses receive the error information.
When the main interface subprocess receives the error report from the software system, the main process broadcasts the error information and the main interface pops up the error dialog box for display, and the error report of the software system has no influence on the main control board and the subprotoblock.
In summary, the technical scheme of the invention functionally decomposes the chip mounter main control system from two aspects of a hardware structure and a software framework, so that a plurality of multi-processes which have definite functions and are related to each other are formed, each process realizes independent and complete functions, the influence on other processes is avoided when an abnormality occurs in a certain sub-process, the cutting-off effect is well achieved, the reliability of the chip mounter main control system software is effectively improved, and a visual interaction system is provided for users. The inter-process data interaction is carried out by adopting a shared memory mode, the communication among the processes is standard and clear, the storage authority of the inter-process data interaction is clear, the misoperation rate is reduced, the inter-process loose coupling connection mode is realized, and the flexibility and the instantaneity of the inter-process communication are improved. And secondly, the established fault processing mechanism, the real-time feedback control mechanism and the log system can finish the management, analysis and control of the monitoring data, and further improve the real-time performance and reliability index of the system.
The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited thereto. Within the scope of the technical idea of the invention, a number of simple variants of the technical solution of the invention are possible, including the combination of the individual specific technical features in any suitable way. The various possible combinations of the invention are not described in detail in order to avoid unnecessary repetition. Such simple variations and combinations are likewise to be regarded as being within the scope of the present disclosure.
Claims (12)
1. A chip mounter master control system based on multiple processes is characterized by comprising a master control board and a software system,
the software system comprises a main process and a plurality of subprocesses, wherein the main process is communicated with the main control board; the plurality of subprocesses are communicated with a main process, the plurality of subprocesses firstly send data or instructions issued to the main control board to the main process for verification and management, and then the main process issues the data or instructions to the main control board, and the plurality of subprocesses are not communicated with each other;
the main control board is used for receiving data or instructions from the main process and returning equipment state information to the main process.
2. The system of claim 1, wherein the main process and the plurality of sub-processes communicate to interact data and instructions in the following manner: creating a virtual shared memory by each sub-process, determining the size of the shared memory, notifying the main process of a unique handle of the shared memory after the creation is completed, completing the reading and writing of the shared memory data by the main process, immediately completing the reading and writing of the shared memory by each sub-process, and releasing the virtual memory after the sub-process exits.
3. The system of claim 1, wherein the communication between the plurality of sub-processes and the main process is a predetermined protocol, so that each sub-process determines whether the read instruction is an instruction of interest to the process, if so, the corresponding operation is performed according to the instruction protocol, and if not, the process ignores the read instruction.
4. The system of claim 1, wherein the plurality of sub-processes includes a production flow control sub-process for controlling an actuator mounting process; the production process control sub-process comprises a production process state management module, a mounting data creation module, an interactive instruction analysis module, an instruction data verification module, a mounting process creation module and a mounting error compensation module,
the mounting data creation module is used for reading the substrate file data and the machine parameter information and creating a mounting data set; the interactive instruction analysis module is used for interacting with the main process information and comprises receiving a production start control instruction from the main process and sending a production completion signal to the main process; the mounting process creation module is used for creating a mounting process instruction set according to the mounting data set; the mounting error compensation module is used for receiving the identification results of the element image and the mark point image and correcting the mounting error according to the identification results; the production flow state management module is used for managing the mounting flow execution step so as to realize the switching of the mounting flow and terminate the mounting flow when an error occurs; the instruction data checking module is used for checking the mounting flow instructions and judging whether error conditions occur.
5. The system of claim 4, wherein the production process control sub-process is configured to control an actuator mounting process specifically to:
s11, an interaction instruction analysis module analyzes the substrate file and the machine parameter file to obtain substrate file data and various machine parameter information, and a mounting data creation module creates a mounting data set according to the substrate file data and the various machine parameter information;
s12, a mounting flow creation module creates production mounting flow instruction data according to the mounting data set obtained in the step S11, and then sequentially combines the created mounting flow instruction data into an executable mounting flow instruction set;
s13, the instruction data checking module performs data checking on the mounting flow instruction set obtained in the step S12, and judges whether the axle movement instruction exceeds a limit range, whether the instruction data is correct or whether the axle interlocking error is caused;
s14, if the step S13 is used for checking that the instruction has errors, the production flow state management module terminates the mounting flow and pushes error codes to an event bus of the main process; if no error exists, writing the mounting flow instruction set obtained in the step S12 into a flow executor, and pushing the mounting flow instruction set to an event bus;
S15, the IPC communication module sends the instruction set pushed to the event bus in the step S14 to the main process, and the main process writes the instruction set into a main control board for execution;
s16, the mounting error compensation module pastes and binds the recognition result from the image processing subprocess, calculates the substrate inclination error and the element suction error according to the recognition result, and corrects the coordinates of the mounting instruction to realize error compensation;
s17, a production flow state management module monitors the execution state of each step of the production flow, controls the execution of the next production step when the execution of the production action is completed, subscribes an error code at the same time, and terminates the production flow when the occurrence of the error is detected;
s18, the production flow state management module subscribes to the component mounting instruction, records the current information of the mounted components of the PCB, and can only continue to produce the unfinished mounting data according to the recorded information when the mounting flow is stopped halfway and restarted.
6. The system of claim 1, wherein the plurality of sub-processes includes a device real-time monitoring and feedback control sub-process for monitoring a device state and controlling a device component action, and transmitting error information to the main process when an abnormality occurs in the device state;
The equipment real-time monitoring and feedback control subprocess comprises a cutter control module, a conveying track production control module, an automatic tray control module and a shaft position monitoring module; the cutter control module is used for monitoring the feeding command of the flyer, and executing the cutter strip cutting action when the flyer strip reaches the specified length; the conveying track production control module is used for controlling the substrate to be conveyed on a production line in a mounting process; the automatic tray control module is used for monitoring the state of the automatic tray, feeding back information to the main process when the tray cabinet door is opened, and controlling the automatic tray exchange in the production process; the shaft position monitoring module is used for monitoring shaft movement instructions and shaft state information, and reporting errors when detecting that the phase difference between the final position of the shaft and the target position of the movement instructions exceeds a threshold value.
7. The system of claim 6, wherein the device monitors and feeds back the control sub-process in real time, is configured to monitor a device status and control a device component to act, and send error information to the main process when an abnormality occurs in the device status, specifically:
s21, a cutter control module subscribes to the feeding command of the flyer in the event bus, records the length of the flyer material belt, updates the material belt length corresponding to the flyer number when one of the flyer feeding commands is monitored, and executes the cutter action when the maximum material belt length is greater than the preset material belt length in the machine parameter;
S22, the automatic conveying module of the conveying track subscribes to the state of the conveying track, and when a substrate is arranged at the inlet of the track and the mounting position is free of the substrate, the substrate is conveyed in and the production mounting is started; transferring the substrate to downstream equipment when one substrate is mounted;
s23, an automatic tray control module monitors tray and shaft state information, and when detecting that the shaft state is from moving to static or a cabinet door knob is in an open state, the automatic tray control module controls to open the cabinet door lock, otherwise controls to close the cabinet door lock; when the cabinet door is detected to be in an open state, a prompt message is fed back to the main process, and a dialog box is popped up from the main interface for display;
and S24, the shaft position monitoring module monitors a shaft movement instruction, a shaft return original point instruction, shaft state information and shaft movement to static information, and when detecting that the difference between the final position of the shaft and the target position of the movement instruction exceeds a threshold value, the shaft movement error is overlarge, and error information is fed back to the main process.
8. The system of claim 1, wherein the plurality of sub-processes includes a camera view sub-process, an image processing sub-process, an image dynamic display sub-process, a device initialization sub-process, a main interface sub-process, and a teaching sub-process,
The camera image receiving subprocess is connected with the image acquisition card through PCIe and is used for acquiring image data in the image acquisition card, finishing the image data into one or more complete images and packaging and sending the image information to the main process;
the image processing subprocess is used for identifying the element image and the mark point image which are shot by the camera in the production process and sending the identification result to the main process;
the image dynamic display subprocess is used for acquiring image data from the main process and displaying the image data in real time;
the equipment initialization subprocess is used for carrying out initialization configuration on equipment when the software system is started;
the main interface subprocess is used for providing a UI interface which can interact with the equipment; the main interface subprocess comprises a production design UI module, a device component UI module, a tool UI module and a history UI module, wherein the production design UI module is used for setting the running speed of equipment, confirming the type of a suction nozzle, issuing a shafting return and warm-up instruction, loading a substrate file and calling a substrate file editing App to edit the substrate file; the device component UI module is used for checking the state of the device component and controlling the action of the device component; the tool UI module is used for setting a production mode and confirming a production state; the resume UI module is used for checking production statistical information;
The teaching subprocess is used for correcting the substrate file used for production; the teaching subprocess comprises a substrate origin teaching module, a suction position teaching module, a mounting position teaching module, a tray interval teaching module, an element adjusting module and a mark adjusting module; the substrate origin teaching module is used for correcting origin coordinates of the substrate; the sucking position teaching module is used for confirming whether the sucking position coordinates of the element are correct or not, and when deviation exists, the software provides a correction function for the coordinates; the mounting position teaching module is used for checking whether the position and angle information of the mounting point of the substrate have deviation or not and confirming the actual mounting effect; the tray interval teaching module is used for teaching the interval of tray elements through the reference camera; the component adjusting module is used for sucking and identifying components used for production, confirming whether a feeding function and sucking action can be normally executed or not and identifying whether the components are correctly identified by the identification parameters or not; the marking point teaching module is used for confirming whether the coordinates of the marking points of the substrate are correct or not and whether the identification parameters can identify the marking points correctly or not.
9. The system of any of claims 1-7, wherein the master process comprises a data verification module, a device real-time information module, a log module, an exception handling module, an IPC communication module, a master board driver module, and an event bus;
The data checking module is used for checking and checking the instruction written in the main control board and checking whether the instruction parameter error or the instruction length error exists or not;
the equipment real-time information module is used for reading equipment real-time information from the main control board and sending the equipment real-time information to the upper computer;
the log module is used for recording all instruction information written in the main control board and all generated error information to a log file, so that problems can be conveniently checked when abnormal conditions occur;
the exception handling module is used for handling write instruction errors or errors from a main control board, and broadcasting error codes and error information to each subprocess;
the IPC communication module is used for communicating with each subprocess, receiving a control instruction sent by the subprocess, writing the control instruction into the main control board after data verification, and broadcasting the equipment state information obtained by the equipment real-time information module to the subprocess;
the main control board driving module is responsible for receiving the command which is checked by the data checking module and confirmed to be correct, serializing the command and finally writing the command into the main control board; or the data reading request of the upper computer and the interrupt information generated by the main control board are processed, and the required binary data is read from the main control board according to different reading requests and interrupt contents and analyzed and sent to the equipment real-time information module;
The event bus is used for searching whether subscribers of the type of event exist when the event occurs, if so, traversing all subscribers and sending event information.
10. The system of claim 9, wherein the log module is configured to record all control instruction information written in the main control board and all generated error information to a log file specifically: the log module subscribes to all control instructions in the main process event bus, maintains a lock-free queue to store the received control instruction information, and creates a sub-thread to cyclically write the log into the log file.
11. A real-time feedback method based on a multi-process chip mounter, which is realized based on the system as claimed in any one of claims 1 to 10, and comprises the following steps:
s31, creating mounting flow instruction data by a production flow control subprocess of the system, and transmitting the mounting flow instruction data to equipment for execution;
s32, after the execution of the identification instruction of the production flow control subprocess is successful, the image processing subprocess obtains an image shot by a camera, identifies according to parameters, and sends an identification result to the main process;
s33, subscribing the identification result by the production process control subprocess, and correcting the mounting instruction according to the identification result when the element is successfully identified; when the element identification fails, executing the element throwing action;
S34, the equipment of the system monitors and feeds back the feeding command of the flyer in the sub-process subscription event bus in real time, records the length of the flyer material belt, updates the length of the material belt corresponding to the flyer number when one feeding command of the flyer is monitored, and executes the cutter action when the maximum length of the material belt is greater than the length of the material belt preset in the machine parameter;
s35, the equipment monitors and feeds back the state of the sub-process subscription conveying track in real time, and when a substrate is arranged at the entrance of the track and the mounting position is free of the substrate, the substrate is conveyed in and the production mounting is started; transferring the substrate to downstream equipment when one substrate is mounted;
s36, subscribing an element mounting instruction by a production process control subprocess, recording current information of the mounted element of the PCB, and when the mounting process is stopped halfway and restarted, continuing to produce the unfinished mounting data according to the recorded information;
and S37, the equipment monitors and feeds back control subprocess monitoring shaft movement instructions, shaft return origin instructions, shaft state information and shaft movement to static information in real time, and when detecting that the difference between the final position of the shaft and the target position of the movement instructions exceeds a threshold value, the equipment feeds back error information to the main process when the difference between the final position of the shaft and the target position of the movement instructions exceeds the threshold value.
12. An error handling method based on a multi-process chip mounter, characterized in that the method is implemented based on a main process of the system according to any of claims 1-10, and comprises the following steps:
when the hardware submodule has abnormal conditions, the hardware submodule directly enters an error state, an instruction to be executed is emptied, and a corresponding error code is sent to a main control board of the system at the same time:
outputting a fault code when the maintenance is improper or the operation is wrong due to the operator;
when detecting that the submodule has errors, automatically clearing all the subsequent instructions which are not executed, cutting off the power line of the equipment, ensuring that the equipment is not allowed to act in an error state, and feeding an error code back to the upper computer;
when receiving the error from the hardware module, recording the error type, error time, error generating module and error content, pushing the error information to the event bus, broadcasting the error information to the subprocesses of the system by the IPC communication module, and processing after the subprocesses receive the error information.
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| 陈辉, 蔡妍艳, 高红霞, 张燕忠: "基于高速高精度贴片机的几种图像并行处理方法研究", 广东自动化与信息工程, no. 01, 30 March 2005 (2005-03-30) * |
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