CN117055492B - A production line remote diagnosis and early warning device and method - Google Patents

Abstract

The present invention relates to the technical field of automated production lines, and in particular to a production line remote diagnosis and early warning device and method. The present invention provides a production line remote diagnosis and early warning device and method, which solves the technical problem that the conveying equipment used for the production line in the prior art has no early warning function, causing other automated equipment to easily malfunction. A production line remote diagnosis and early warning device, including an actuator and a controller that controls the operation of the actuator, is provided with a micro switch, and the micro switch is provided between a first extreme position and a second extreme position, and the actuator is between the first extreme position and the second extreme position. The micro switch can monitor the actual position of the actuator, so that the actual operating parameters of the actuator can be monitored before the actuator reaches the second extreme position, thereby playing an early warning function.

Description

A production line remote diagnosis and early warning device and method

Technical Field

The present invention relates to the technical field of automated production lines, and in particular to a production line remote diagnosis and early warning device and method.

Background Art

A production line refers to an industrial production process in which the medium to be processed flows from one end to the other according to process steps or process conditions, and when the medium to be processed flows from one end to the other, each process step is completed between the two ends. Usually, the medium to be processed completes at least two process steps on a single production line to improve the production efficiency of the product.

For production lines with a high degree of automation, automated equipment is usually used to complete each process step. Therefore, the medium to be processed needs to have a high transmission accuracy when flowing from one end to the other end to prevent the automated equipment from malfunctioning when completing the process steps.

The production line in the prior art is generally long, and a conveyor belt is usually used to transport the medium to be processed, especially a production line for producing solar cells. This production line is usually long and has many intermediate process steps. In order to improve the transmission accuracy of the conveyor belt, the conveyor belt is usually driven by a servo motor, and the position of the conveyor belt is determined by monitoring the output angle of the servo motor. Although this monitoring method can monitor the displacement state of the conveyor belt, this monitoring method has low monitoring accuracy and no early warning function, and cannot accurately determine the position of the medium to be produced on the conveyor belt.

Summary of the invention

The invention provides a production line remote diagnosis and early warning device and method, which solves the technical problem in the prior art that the conveying equipment used in the production line has no early warning function, causing other automated equipment to easily malfunction.

Some implementation plans adopted to solve the above technical problems include:

In the first aspect: a production line remote diagnosis and early warning device, comprising an actuator and a controller for controlling the operation of the actuator, the actuator comprising a servo motor and an actuator component driven by the servo motor and outputting a linear motion, the controller comprising a pulse power supply for outputting a pulse current to the servo motor and a displacement detector for detecting a motion parameter of the actuator component, the displacement detector communicating with the controller, and the controller controlling the pulse power supply to output a pulse current according to the parameters detected by the displacement detector;

The production line remote diagnosis and early warning device also includes an alarm, and the alarm is controlled by the controller;

The displacement detector includes an encoder for detecting the rotation angle of the output shaft of the servo motor, the actuator includes a first limit position and a second limit position, a micro switch is provided between the first limit position and the second limit position, there is at least one micro switch, the micro switch communicates with the controller, and the micro switch is triggered by the actuator; wherein:

The controller controls the pulse power supply to output pulse current according to the displacement stroke of the actuator, and the encoder monitors the rotation state of the output shaft of the servo motor. When the output shaft of the servo motor rotates to an angle that causes the actuator to trigger the micro switch and the micro switch is not triggered by the actuator, the controller controls the alarm to operate.

Preferably, the actuator further comprises an active roller and a driven roller, the active roller being driven by the output shaft of the servo motor, the actuator being a conveyor belt arranged between the active roller and the driven roller, wherein the output shaft of the servo motor and the active roller are an integrated structure.

Preferably, the actuator further comprises a support frame, the conveyor belt forms a ring, the support frame is located within the ring formed by the conveyor belt, and the micro switch is arranged on the support frame.

Preferably, the micro switch is an inductive switch, the actuator is provided with an inductive sensor sensed by the micro switch, the inductive sensor is bonded to the actuator, and the inductive sensor is not in contact with the micro switch.

Preferably, there are at least two micro switches, and the two micro switches are evenly distributed between the first limit position and the second limit position along the length direction of the support frame.

In the second aspect: a production line remote diagnosis and early warning method, comprising the following steps:

Determine a first limit position, a process position, and a second limit position of the actuator, wherein the process position is located between the first limit position and the second limit position;

According to the first limit position, the process position and the second limit position of the actuator, determine the angles that the driving component needs to output respectively when the actuator moves from the first limit position to the process position and the second limit position;

Monitor the angle of the drive component output and the displacement state of the actuator, and determine whether the actuator is displaced from the first limit position and the process position to the second limit position in sequence according to the angle of the drive component output and the displacement state of the actuator. When the actuator passes through the first limit position, the process position and the second limit position in sequence, the drive component and the actuator work normally; when the actuator does not pass through the first limit position, the process position and the second limit position in sequence, an alarm signal is issued.

Preferably, the method further includes the following steps: determining the angle that the driving component needs to output during the process of the actuator moving from the second extreme position to the first extreme position, and monitoring the angle output by the driving component, and issuing a first alarm signal when the angle output by the driving component causes the actuator to move from the second extreme position to the first extreme position and the actuator has not moved to the first extreme position.

Preferably, when the actuator does not pass through the first limit position, the process position and the second limit position in sequence, an alarm signal is issued, and the alarm signal is a second alarm signal.

Preferably, there are at least two process positions, and the time required for the actuator to move between two adjacent process positions is determined based on the angle required for the driving component to output when the actuator moves between the two adjacent process positions, and the time taken for the actuator to move between the two adjacent process positions is monitored, and a third alarm signal is issued when the time taken for the actuator to move between the two adjacent process positions is greater than the time required for the actuator to move between the two adjacent process positions.

Preferably, the driving component comprises a servo motor, and the output angle of the servo motor is monitored by an encoder.

Compared with the prior art, the present invention has the following beneficial effects:

1. By setting a micro switch, and the micro switch is set between the first limit position and the second limit position, and the actuator is between the first limit position and the second limit position, the micro switch can monitor the actual position of the actuator, so that the actual operating parameters of the actuator can be monitored before the actuator reaches the second limit position, thereby improving the position monitoring accuracy of the actuator, and when the actuator does not trigger the micro switch under reasonable conditions, the alarm will sound, thereby playing a warning function.

2. Usually the actuator is used to trigger the micro switch, which can directly monitor the movement position of the actuator, so that more accurate position parameters can be output to the controller, improving the position monitoring accuracy of the micro switch.

3. By monitoring the rotation angle of the output shaft of the servo motor and the movement position of the actuator through the micro switch, the position monitoring structure of the actuator is simplified. There is no need to set a position monitoring device such as a grating ruler between the first limit position and the second limit position. The actuator can have a longer stroke, reducing the use cost of the production line.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of explanation, several embodiments of the present invention technology are described in the following figures. The following figures are incorporated into this text and constitute a part of the specific embodiment. In some cases, well-known structures and components are shown in block diagram form to avoid obscuring the concept of the present invention subject technology.

FIG. 1 is a schematic diagram showing a case where the actuator is a conveyor belt.

FIG. 2 is an exploded view of FIG. 1 .

FIG. 3 is a schematic diagram of the middle support frame of FIG. 2 .

FIG4 is a flow chart of a method for remote diagnosis and early warning of a production line.

In the figure:

1. Active roller, 2. Driven roller, 3. Servo motor, 4. Conveyor belt, 5. Support frame, 6. Micro switch.

Implementation

The specific embodiments shown below are intended to be descriptions of various configurations of the subject technology of the present invention, and are not intended to represent the only configuration that the subject technology of the present invention can be put into practice. The specific embodiments include specific details intended to provide a thorough understanding of the subject technology of the present invention. However, it will be clear and obvious to those skilled in the art that the subject technology of the present invention is not limited to the specific details shown herein, and can be put into practice without these specific details.

Referring to FIGS. 1 to 3 , in the first aspect: a production line remote diagnosis and early warning device comprises an actuator and a controller for controlling the operation of the actuator, wherein the actuator comprises a servo motor 3 and an actuator component driven by the servo motor 3 and outputting a linear motion, wherein the controller comprises a pulse power supply for outputting a pulse current to the servo motor 3 and a displacement detector for detecting a motion parameter of the actuator component, wherein the displacement detector communicates with the controller, and the controller controls the pulse power supply to output a pulse current according to the parameter detected by the displacement detector;

The pulse power supply is one of the commonly used accessories of the servo motor 3. Its structure and working principle refer to the prior art and will not be described in detail here.

The controller is usually a control device with program execution capability. The controller is widely used in production lines. Its working principle is referred to in the prior art and will not be described in detail here.

The production line remote diagnosis and early warning device also includes an alarm, and the alarm is controlled by the controller;

The displacement detector includes an encoder for detecting the rotation angle of the output shaft of the servo motor 3, the actuator includes a first limit position and a second limit position, a micro switch 6 is provided between the first limit position and the second limit position, there is at least one micro switch 6, the micro switch 6 communicates with the controller, the micro switch 6 is triggered by the actuator, the encoder and the alarm are conventional electronic components in the prior art, wherein the alarm can be a sound alarm or a light alarm or an audible and visual alarm; wherein:

The controller controls the pulse power supply to output pulse current according to the displacement stroke of the actuator, and the encoder monitors the rotation state of the output shaft of the servo motor 3. When the output shaft of the servo motor 3 rotates to an angle that causes the actuator to trigger the micro switch 6 and the micro switch 6 is not triggered by the actuator, the controller controls the alarm to work.

Assume that there is a micro switch 6 between the first limit position and the second limit position, and that the actuator needs to output 2N pulse currents when it moves from the first limit position to the second limit position, and that the actuator needs N pulse currents when it moves from the first limit position to the position where the micro switch 6 is triggered. When the actuator is at the first limit position, the controller controls the pulse power supply to output N pulse currents and the encoder starts to monitor the rotation angle of the output shaft of the servo motor 3. Assume that the servo motor 3 rotates M angles to make the actuator move from the first limit position to the position that triggers the micro switch 6. When the pulse power supply outputs N pulse currents and the servo motor 3 rotates M angles, the micro switch 6 is not triggered. At this time, the controller controls the alarm to work and sends out an alarm signal.

Specifically, the alarm can send out different alarm signals according to the situation: for example, when the pulse power supply outputs N pulse currents, the encoder does not detect that the servo motor 3 rotates M angles and the micro switch 6 is not triggered, then, a first type of alarm signal can be sent out.

When the pulse power supply outputs N pulse currents, the encoder detects that the servo motor 3 rotates M angles and the micro switch 6 is not triggered, then a second type of alarm signal can be issued.

When the pulse power supply does not output N pulse currents, the encoder detects that the servo motor 3 rotates M angles and the micro switch 6 is not triggered, then a third type of alarm signal may be issued.

The first to third category alarm signals can be independent alarm codes, that is, each independent alarm code can represent a situation, and each situation can determine that a certain device or a certain type of device is damaged, so that maintenance personnel can quickly determine the fault location according to the alarm code, which is convenient for maintenance of the production line.

In some embodiments, the actuator further comprises an active roller 1 and a driven roller 2, wherein the active roller 1 is driven by the output shaft of the servo motor 3, and the actuator is a conveyor belt 4 disposed between the active roller 1 and the driven roller 2, wherein the output shaft of the servo motor 3 and the active roller 1 are an integrated structure. The active roller 1 and the driven roller 2 are both rotatably connected to a frame or other components. The output shaft of the servo motor 3 and the active roller 1 are an integrated structure, and the servo motor 3 and the active roller 1 have a higher transmission accuracy.

In some embodiments, the actuator further includes a support frame 5 , the conveyor belt 4 forms a ring, the support frame 5 is located in the ring formed by the conveyor belt 4 , and the micro switch 6 is disposed on the support frame 5 .

The micro switch 6 is an inductive switch, and the actuator is provided with an inductive element that is sensed by the micro switch 6 . The inductive element is bonded to the actuator, and the inductive element is not in contact with the micro switch 6 .

There are at least two micro switches 6 , and the two micro switches 6 are evenly distributed between the first limit position and the second limit position along the length direction of the support frame 5 .

That is, there can be multiple sensing switches and one sensed object, and the sensed object is sensed by the multiple sensing switches in sequence to determine the position of the actuator.

The inductive switch may also be replaced by other electronic components having similar functions.

Both the first limit position and the second limit position can be determined by the induction switch, that is, the installation position of the induction switch determines the positions of the first limit position and the second limit position.

As shown in FIG4 , in the second aspect: a production line remote diagnosis and early warning method, applicable to the production line remote diagnosis and early warning device disclosed in the first aspect, comprises the following steps:

Determine a first limit position, a process position, and a second limit position of an actuator, wherein the process position is between the first limit position and the second limit position, the actuator may be a conveyor belt 4, the first limit position may be a position close to the active roller 1, and the second limit position may be a position close to the driven roller 2;

The controller determines the angles that the driving component needs to output respectively when the actuator moves from the first limit position to the process position and the second limit position according to the first limit position, the process position and the second limit position of the actuator;

The displacement detector monitors the angle of the drive component output and the displacement state of the actuator, and determines whether the actuator is displaced from the first limit position and the process position to the second limit position in sequence according to the angle of the drive component output and the displacement state of the actuator. When the actuator passes through the first limit position, the process position and the second limit position in sequence, the drive component and the actuator work normally; when the actuator does not pass through the first limit position, the process position and the second limit position in sequence, an alarm signal is issued.

In some embodiments, the following steps are also included: determining the angle that the driving component needs to output during the process of the actuator moving from the second extreme position to the first extreme position, and monitoring the angle output by the driving component. When the angle output by the driving component causes the actuator to move from the second extreme position to the first extreme position and the actuator has not moved to the first extreme position, a first alarm signal is issued.

When the execution component does not pass through the first limit position, the process position and the second limit position in sequence, an alarm signal is issued, and the alarm signal is the second alarm signal.

In this embodiment, the alarm signals are classified, and the fault location can be quickly determined according to the category of the alarm signal, so that the production line is easy to maintain.

In some embodiments, there are at least two process positions, and the time required for the actuator to move between two adjacent process positions is determined based on the angle required for the driving component to output when the actuator moves between the two adjacent process positions. The time taken for the actuator to move between the two adjacent process positions is monitored, and a third alarm signal is issued when the time taken for the actuator to move between the two adjacent process positions is greater than the time required for the actuator to move between the two adjacent process positions.

A time monitoring scheme is introduced in this embodiment, that is, by monitoring the time, it is determined whether the actuator reaches a certain position within a certain time. Since the linear speed of the conveyor belt 4 is certain when the servo motor 3 drives the transmission to work, the time required for a certain position on the conveyor belt 4 to move from one position to another is also certain, so that time can be used to determine whether the conveyor belt 4 is working normally.

The introduction of the time monitoring solution can monitor the movement state of the conveyor belt 4 from more dimensions, thereby improving the execution accuracy of the execution components.

In some embodiments, the driving component includes a servo motor 3, and the output angle of the servo motor 3 is monitored by an encoder.

The above is an introduction to the subject technical solution of the present invention and the corresponding details. It can be understood that the above introduction is only some implementation plans of the subject technical solution of the present invention, and some details can be omitted during the specific implementation.

In addition, in some embodiments of the above invention, multiple embodiments may be implemented in combination, and various combinations are not listed one by one due to space limitations. Those skilled in the art can freely combine and implement the above embodiments as needed in specific implementation to obtain a better application experience.

When implementing the subject technical solution of the present invention, those skilled in the art can obtain other detailed configurations or drawings based on the subject technical solution of the present invention and the drawings. Obviously, these details still fall within the scope covered by the subject technical solution of the present invention without departing from the subject technical solution of the present invention.

Claims (5)

1. The utility model provides a but production line remote diagnosis early warning device which characterized in that: the device comprises an actuator and a controller for controlling the actuator to work, wherein the actuator comprises a servo motor (3) and an execution part which is driven by the servo motor (3) and outputs linear motion, the controller comprises a pulse power supply for outputting pulse current to the servo motor (3) and a displacement detector for detecting motion parameters of the execution part, the displacement detector is communicated with the controller, and the controller controls the pulse power supply to output the pulse current according to the parameters detected by the displacement detector;

The production line remote diagnosis early warning device also comprises an alarm, wherein the alarm is controlled to work by the controller;

The displacement detector comprises an encoder for detecting the rotation angle of an output shaft of the servo motor (3), the execution part comprises a first limit position and a second limit position, a micro switch (6) is arranged between the first limit position and the second limit position, at least one micro switch (6) is arranged, the micro switch (6) is communicated with the controller, and the micro switch (6) is triggered by the execution part; wherein:

the controller controls the pulse power supply to output pulse current according to the displacement stroke of the executing component, the encoder monitors the rotation state of the output shaft of the servo motor (3), and when the output shaft of the servo motor (3) rotates to an angle enabling the executing component to trigger the micro switch (6) and the micro switch (6) is not triggered by the executing component, the controller controls the alarm to work.

2. The production line remotely diagnosable early warning device of claim 1, wherein: the actuator further comprises a driving roller (1) and a driven roller (2), the driving roller (1) is driven by an output shaft of the servo motor (3), the actuating component is a conveyor belt (4) arranged between the driving roller (1) and the driven roller (2), and the output shaft of the servo motor (3) and the driving roller (1) are of an integrated structure.

3. The production line remotely diagnosable early warning device of claim 2, wherein: the actuator further comprises a supporting frame (5), the conveyor belt (4) is surrounded into a ring shape, the supporting frame (5) is positioned in the ring shape surrounded by the conveyor belt (4), and the micro switch (6) is arranged on the supporting frame (5).

4. The line remotely diagnosable early warning device of claim 3, further comprising: the micro switch (6) is an inductive switch, the executing component is provided with a sensed device sensed by the micro switch (6), the sensed device is adhered to the executing component, and the sensed device is not contacted with the micro switch (6).

5. The production line remotely diagnosable early warning device of claim 4, wherein: at least two micro switches (6) are arranged, and the two micro switches (6) are uniformly distributed between the first limit position and the second limit position along the length direction of the supporting frame (5).