基于节气门装配线的数据采集与产品性能测试的研究
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摘要
近年来,随着信息技术的发展,数据采集和信息监视被广泛应用于生产管理中,提供了与企业经营决策层和现场控制层的接口,促成生产数据与管理数据的集成,为生产管理的科学决策提供有力的技术支持。本论文以节气门装配线数据采集系统的开发与设计为背景,根据目前博世装配线数据采集及监控的现状,设计了基于节气门装配线的分布式数据采集与产品性能测试系统。
1.分析节气门装配线的工位功能、设备组成、装配流程、数据产生及BPS装配线在数据采集及实时监控中遇到的问题,设计了适用于装配线的数据采集系统,。该系统的硬件结构分为生产数据采集和设备数据采集两部分,根据数据类型不同采取不同的采集方案。对于装配线生产数据,提出了基于XML协议、MSCOMM及I7000系列的采集方法,实现了对PLC触发数据及手动触发数据的采集。对于装配线设备数据,根据装配线设备主要组成及产生故障的原因,重点以装配线普遍使用的压机设备为例,分析设备数据的采集过程,设计了压机运行过程中力和位移的数据采集方案,并用软件优化了原有的数据采集及监视方式。
2.设计节气门性能测试系统,根据其性能要求研究其电压测试(节气门印刷板电路的线性度、同步性及过渡电阻)及功能测试(节气门使用时的电气相响应时间、长回程及短回程响应时间),通过专门设计的电路硬件结构及软件处理来检测产品的性能,并将测试结果作为数据采集系统的一个数据组成部分,以便反应装配线的装配质量。在软件处理过程中,通过改进的小波阈值算法去除测试过程中产生的干扰及噪声,有效地提高了测试数据采集的精度。实验过程中,采用虚拟仪器调用小波去噪模块的方法去除噪声,并对采集到的数据进行相应数值分析,实验证明该测试方法能有效检测出产品性能优劣,提高装配线产出质量。
3.设计了上层监视管理系统ANDON。该系统可以将装配线上采集到的生产数据、设备数据及测试结果进行分析、存储及导出,并在信息板上实时显示装配线的状态,实现了生产过程的实时监视及生产数据的科学管理。
实践证明,这样的数据采集系统可以有效地优化生产流程、快速响应生产异常,为制造型企业的生产信息化、精益化及生产决策提供了有效的技术手段,具有广泛的使用价值及开发前景。
With the development of the information technology in recenet years, data acquisition and monitoring has been widely used in production management area, which provides an interface between enterprise strategy layer and on-site control layer, and also offers strong technical support for scientific strategy of production management. According to the great importance of the data acquisition and mornitoring in production process, this thesis develops a distributed data acquisition and product performance test system for electrical throttle assembly line based on the status of data acquisition and monitoring of Bosch assembly line.
Through analysis of assembling process, station function, equipment composing, data source and the data acquisition problems encountered in Bosch assembly line, the thesis develops an integrated data acquisition system, the hardware of which is designed as two parts: production data acquisition and machine data acquisition, which will be processed in separated ways because of different data types. For assembly production data, the thesis proposes an acquisition method based on XML protocol, MSCOMM component and I-7000 series model.The method realizes the data collection of PLC triggered data and manual triggererd data. For assembly machine data, the thesis analyses the assembly equipment types and its broken-down reasons. Then a representative machinical equipment—press unit is used as example for machine data acquisition research. The force and displacement acquisition solution of the running press unit is designed, and a new software solution is proposed to optimize the traditional solution.
The electrical throttle performance test system is designed mainly focusing on its potentiometer test (The PCB Linearity, synchronization and Transition resistance of electrical throttle) and function test (The actuation time, long return time and short return time of electrical throttle), which are used to detect product performance through customized hardware and software development, and the testing result data will be a part of the data acquisition system. At the same time an improved threshold denoise algorithm is proposed, which can reduce the noise in non-stationary testing enviorment and increase the data acquisition accuracy in test. In experiment the vitual instruction is used to call the wavelet denoise module for reducing the noise. It is proved that the system can efficiently sort out the good part, and improve the quality of assembly line output.
The monitoring and management system—ANODN is designed , which can analyse, store or export all kinds of data collected from assembly line, and the processed data can be shown on the display for showing the assembling status, which will realize the real-time moniring and production data management scientificly.
It is proved that this kind of data acquisition system can optimize the assembling procedure and quickly respose producing abnormity, which offers a solution for lean production, infomationization production and management strategy in manufacture enterprise, and it will also have great value for further research and development, as well as the practical usage.
1.分析节气门装配线的工位功能、设备组成、装配流程、数据产生及BPS装配线在数据采集及实时监控中遇到的问题,设计了适用于装配线的数据采集系统,。该系统的硬件结构分为生产数据采集和设备数据采集两部分,根据数据类型不同采取不同的采集方案。对于装配线生产数据,提出了基于XML协议、MSCOMM及I7000系列的采集方法,实现了对PLC触发数据及手动触发数据的采集。对于装配线设备数据,根据装配线设备主要组成及产生故障的原因,重点以装配线普遍使用的压机设备为例,分析设备数据的采集过程,设计了压机运行过程中力和位移的数据采集方案,并用软件优化了原有的数据采集及监视方式。
2.设计节气门性能测试系统,根据其性能要求研究其电压测试(节气门印刷板电路的线性度、同步性及过渡电阻)及功能测试(节气门使用时的电气相响应时间、长回程及短回程响应时间),通过专门设计的电路硬件结构及软件处理来检测产品的性能,并将测试结果作为数据采集系统的一个数据组成部分,以便反应装配线的装配质量。在软件处理过程中,通过改进的小波阈值算法去除测试过程中产生的干扰及噪声,有效地提高了测试数据采集的精度。实验过程中,采用虚拟仪器调用小波去噪模块的方法去除噪声,并对采集到的数据进行相应数值分析,实验证明该测试方法能有效检测出产品性能优劣,提高装配线产出质量。
3.设计了上层监视管理系统ANDON。该系统可以将装配线上采集到的生产数据、设备数据及测试结果进行分析、存储及导出,并在信息板上实时显示装配线的状态,实现了生产过程的实时监视及生产数据的科学管理。
实践证明,这样的数据采集系统可以有效地优化生产流程、快速响应生产异常,为制造型企业的生产信息化、精益化及生产决策提供了有效的技术手段,具有广泛的使用价值及开发前景。
With the development of the information technology in recenet years, data acquisition and monitoring has been widely used in production management area, which provides an interface between enterprise strategy layer and on-site control layer, and also offers strong technical support for scientific strategy of production management. According to the great importance of the data acquisition and mornitoring in production process, this thesis develops a distributed data acquisition and product performance test system for electrical throttle assembly line based on the status of data acquisition and monitoring of Bosch assembly line.
Through analysis of assembling process, station function, equipment composing, data source and the data acquisition problems encountered in Bosch assembly line, the thesis develops an integrated data acquisition system, the hardware of which is designed as two parts: production data acquisition and machine data acquisition, which will be processed in separated ways because of different data types. For assembly production data, the thesis proposes an acquisition method based on XML protocol, MSCOMM component and I-7000 series model.The method realizes the data collection of PLC triggered data and manual triggererd data. For assembly machine data, the thesis analyses the assembly equipment types and its broken-down reasons. Then a representative machinical equipment—press unit is used as example for machine data acquisition research. The force and displacement acquisition solution of the running press unit is designed, and a new software solution is proposed to optimize the traditional solution.
The electrical throttle performance test system is designed mainly focusing on its potentiometer test (The PCB Linearity, synchronization and Transition resistance of electrical throttle) and function test (The actuation time, long return time and short return time of electrical throttle), which are used to detect product performance through customized hardware and software development, and the testing result data will be a part of the data acquisition system. At the same time an improved threshold denoise algorithm is proposed, which can reduce the noise in non-stationary testing enviorment and increase the data acquisition accuracy in test. In experiment the vitual instruction is used to call the wavelet denoise module for reducing the noise. It is proved that the system can efficiently sort out the good part, and improve the quality of assembly line output.
The monitoring and management system—ANODN is designed , which can analyse, store or export all kinds of data collected from assembly line, and the processed data can be shown on the display for showing the assembling status, which will realize the real-time moniring and production data management scientificly.
It is proved that this kind of data acquisition system can optimize the assembling procedure and quickly respose producing abnormity, which offers a solution for lean production, infomationization production and management strategy in manufacture enterprise, and it will also have great value for further research and development, as well as the practical usage.
引文
[1] 陈虹,唐鸿儒,杨胭.企业信息化进程和趋势:[自动化博览]. 2002, 4:323
[2] Bosch Production System. [Bosch Inner Website]. RBAC-AE.2007
[3] 胡彦锁.汽车部件压入装配与检测集成系统的研究:[硕士学位论文].四川:四川大学,2006:1-3
[4] K Hubert. Rampersad. Bottlenecks & development tendencies in robotics assembIy, Robotics Today.1995, 8(3):1-6
[5] DanieIE. Whitney. The Potential assembly modeling in Product development and manufacturing.MIT.1996
[6] TDC3000.Basic Totel Distributed System
[7] L.E.Moser, P.O.Melliar-Syteith, V.Agrawala.Processor Membership in Asynchronous Distributed System. IEEE PDS.1994, 5(5): 459-473
[8] JCS车间信息集成技术在缸盖生产线中的应用 [International Mould Network]2006
[9] 夏心骏.生产及设备数据自动采集系统通讯技术的研究:[硕士学位论文].上海:上海同济大学,2005,8-12
[10] 生产线远程自动化监控数据采集系统 [三门峡科技成果网] 2006
[11] http://smx.hnkjcg.com/system/techtrans/provide/showinfo.asp?infoid=8850
[12] 赵军. 微动开关装配自动线的设计.组合机床与自动化加工技术 2003(2): 66~ 67
[13] 王彤彤.汽车综合性能检测新技术和新装备的发展与应用 [中国汽保网] 2006
[14] 马明建.数据采集与处理技术:西安交通大学出版社,2002:1-6
[15] 王亚民,陈青,刘畅生.王水平.组态软件设计与开发.西安电子科技大学出版社.2003:8-12
[16] Production control system OpCon general information and productions. [Inner reference] Germany, PA-ATMO1.2004:1-5
[17] OpCon Server Operation of OpCon Databases (Oracle). [Inner reference] Germany, PA-ATMO.2003:4-7
[18] 机房监控系统成功案例 [阿尔泰科技网] 典型案例 2007 http://www.art-control.com/caseNewsInfo.aspid=34
[19] H.Sari, G.Karam,I. Jeanclaude. Transmission Techniques for Digital Terrestrial TV Broascasting. IEEE Comm. Mag.,1995,Vol.33 (2):100～109
[20] RS-485总线理论及实际应用 [机电专业技术网].2007
[21] 王家桢,王俊杰.传感器和变送器. 北京:清华大学出版社,2003
[22] National Instrument.SCXI Chassis User Manual.Austin USA: National Instrument Corporation, 2006
[23] National Instruments . Instrumentation Reference and Catalogue . Austin USA: National Instrument Corporation, 2003
[24] 雷振山.LabVIEW7 Express 实用技术教程.北京:中国铁道出版社,2004.4
[25] 罗鹏飞,杨世海,朱国富等译.数字信号处理实践方法(第二版).北京:电子工业出版社,2004.11
[26] Frank Markert. Introduction to IEC 61131 with IndraLogic.[inner reference]
[27] Germany, PA-ATMO1, 2004National Instrument . SCXI Chassis User Manual. Austin USA: National Instrument Corporation, 2006
[28] 陈建业 , 许飞云.机械设备数据采集与状态监测系统的研制 ,[PLC&FA], 2005.11:95-96
[29] RS-232、RS-422与RS-485标准及应用 [机电专业技术网-业通信]. 2007
[30] Tox-Powerpackage, Tox pressotechnik GmbH & Co.KG
[31] ATEQ F510 User Manual,Version 1.16
[32] Burster Br?zisionsme?technik GmbH & co kg.DIGIFORCE 9310 Operation Manual, 2004
[33] 毛六平,王耀南.基于模糊小波基函数神经网络的电子节气门控制:电气传动 2005年, 第35卷 第9期:35-37
[34] McKay, D., ET a1. Delphi Electronic Throtde Control Systems for Model Year 2000;Driver Features,Systems Security,an d OEM Benefits. ETC forthe Mass Market.SAE 2000-01-0556
[35] National Instruments NI PCI 6259 User Manual. 2007
[36] Test and Assembly Procedures Throttle Fixtures 节气门 and RKL-E1 (Main Part) [inner reference] Germany, GS-AM/ENG7.2004:7-8
[37] 吴正国,夏立,尹为民.现代信号处理技术. 武汉:武汉大学出版社, 2003
[38] 魏明果.实用小波分析. 北京:北京理工大学出版社. 2005.9
[39] Sohn H, Park G. Wavelet-based active sensing for delamination detection in composite structures. Smart Materials and Structures, 2004:153-168
[40] 陈武凡.小波分析及其在图像处理中的应用IM],北京:科学出版社,2002。
[41] 张贤达.现代信号处理 [M].北京:清华大学出版社,1995。
[42] 张贤达、保铮.非平稳信号分析与处理 [M].北京:国防工业出版社,1998。
[43] 刘晓石,陈鸿建,何腊梅.概率论与数理统计[M],北京:科学出版社,2000。
[2] Bosch Production System. [Bosch Inner Website]. RBAC-AE.2007
[3] 胡彦锁.汽车部件压入装配与检测集成系统的研究:[硕士学位论文].四川:四川大学,2006:1-3
[4] K Hubert. Rampersad. Bottlenecks & development tendencies in robotics assembIy, Robotics Today.1995, 8(3):1-6
[5] DanieIE. Whitney. The Potential assembly modeling in Product development and manufacturing.MIT.1996
[6] TDC3000.Basic Totel Distributed System
[7] L.E.Moser, P.O.Melliar-Syteith, V.Agrawala.Processor Membership in Asynchronous Distributed System. IEEE PDS.1994, 5(5): 459-473
[8] JCS车间信息集成技术在缸盖生产线中的应用 [International Mould Network]2006
[9] 夏心骏.生产及设备数据自动采集系统通讯技术的研究:[硕士学位论文].上海:上海同济大学,2005,8-12
[10] 生产线远程自动化监控数据采集系统 [三门峡科技成果网] 2006
[11] http://smx.hnkjcg.com/system/techtrans/provide/showinfo.asp?infoid=8850
[12] 赵军. 微动开关装配自动线的设计.组合机床与自动化加工技术 2003(2): 66~ 67
[13] 王彤彤.汽车综合性能检测新技术和新装备的发展与应用 [中国汽保网] 2006
[14] 马明建.数据采集与处理技术:西安交通大学出版社,2002:1-6
[15] 王亚民,陈青,刘畅生.王水平.组态软件设计与开发.西安电子科技大学出版社.2003:8-12
[16] Production control system OpCon general information and productions. [Inner reference] Germany, PA-ATMO1.2004:1-5
[17] OpCon Server Operation of OpCon Databases (Oracle). [Inner reference] Germany, PA-ATMO.2003:4-7
[18] 机房监控系统成功案例 [阿尔泰科技网] 典型案例 2007 http://www.art-control.com/caseNewsInfo.aspid=34
[19] H.Sari, G.Karam,I. Jeanclaude. Transmission Techniques for Digital Terrestrial TV Broascasting. IEEE Comm. Mag.,1995,Vol.33 (2):100～109
[20] RS-485总线理论及实际应用 [机电专业技术网].2007
[21] 王家桢,王俊杰.传感器和变送器. 北京:清华大学出版社,2003
[22] National Instrument.SCXI Chassis User Manual.Austin USA: National Instrument Corporation, 2006
[23] National Instruments . Instrumentation Reference and Catalogue . Austin USA: National Instrument Corporation, 2003
[24] 雷振山.LabVIEW7 Express 实用技术教程.北京:中国铁道出版社,2004.4
[25] 罗鹏飞,杨世海,朱国富等译.数字信号处理实践方法(第二版).北京:电子工业出版社,2004.11
[26] Frank Markert. Introduction to IEC 61131 with IndraLogic.[inner reference]
[27] Germany, PA-ATMO1, 2004National Instrument . SCXI Chassis User Manual. Austin USA: National Instrument Corporation, 2006
[28] 陈建业 , 许飞云.机械设备数据采集与状态监测系统的研制 ,[PLC&FA], 2005.11:95-96
[29] RS-232、RS-422与RS-485标准及应用 [机电专业技术网-业通信]. 2007
[30] Tox-Powerpackage, Tox pressotechnik GmbH & Co.KG
[31] ATEQ F510 User Manual,Version 1.16
[32] Burster Br?zisionsme?technik GmbH & co kg.DIGIFORCE 9310 Operation Manual, 2004
[33] 毛六平,王耀南.基于模糊小波基函数神经网络的电子节气门控制:电气传动 2005年, 第35卷 第9期:35-37
[34] McKay, D., ET a1. Delphi Electronic Throtde Control Systems for Model Year 2000;Driver Features,Systems Security,an d OEM Benefits. ETC forthe Mass Market.SAE 2000-01-0556
[35] National Instruments NI PCI 6259 User Manual. 2007
[36] Test and Assembly Procedures Throttle Fixtures 节气门 and RKL-E1 (Main Part) [inner reference] Germany, GS-AM/ENG7.2004:7-8
[37] 吴正国,夏立,尹为民.现代信号处理技术. 武汉:武汉大学出版社, 2003
[38] 魏明果.实用小波分析. 北京:北京理工大学出版社. 2005.9
[39] Sohn H, Park G. Wavelet-based active sensing for delamination detection in composite structures. Smart Materials and Structures, 2004:153-168
[40] 陈武凡.小波分析及其在图像处理中的应用IM],北京:科学出版社,2002。
[41] 张贤达.现代信号处理 [M].北京:清华大学出版社,1995。
[42] 张贤达、保铮.非平稳信号分析与处理 [M].北京:国防工业出版社,1998。
[43] 刘晓石,陈鸿建,何腊梅.概率论与数理统计[M],北京:科学出版社,2000。