CN-121742405-B - Process control method and system for automatic production line

CN121742405BCN 121742405 BCN121742405 BCN 121742405BCN-121742405-B

Abstract

The invention discloses a process control method and a system for an automatic production line, which relate to the technical field of automatic production and comprise the following steps of projecting a discrete control state of a current original process into a continuous physical process starting state based on a continuous physical process state expression model; the method comprises the steps of constructing a physical process attraction domain of a target process in a state expression model based on a process corresponding to the target intelligent building unit, generating a continuous transition process path based on a physical process starting state and the physical process attraction domain, carrying out sectional migration on control authorities based on the sequence of differential transition processes, and re-projecting the continuous physical process state of a current product into a discrete control state corresponding to the target process as an initial control state of the target intelligent building unit. The invention realizes the smooth control transition of the intelligent making unit on-line in-out through the mapping of the continuous physical process state and the discrete control state and the generation of the continuous transition path, and effectively eliminates the fault between the physical state and the control system.

Inventors

LI QI
WANG YU

Assignees

北京奇步自动化控制设备有限公司

Dates

Publication Date: 20260508
Application Date: 20260226

Claims (5)

1. Process control method for an automated production line, characterized in that it comprises the following steps: When the intelligent making unit triggers online listing or listing, based on a continuous physical process state expression model, projecting a discrete control state of the current original working procedure into a continuous physical process starting state; the continuous physical process state expression model is specifically constructed by collecting temperature, clamping stress and surface process state information at each process node of a product, and fusing the information to form corresponding temperature state components, stress state components and process state components; the multi-dimensional continuous state vector is used as a state variable to establish a differential equation of each continuous state component, and a coupling relation between heat-force-process states is introduced into the differential equation to form a continuous physical process state expression model; Based on the corresponding procedure of the target intelligent building unit, a physical process attraction domain of the target procedure is built in a continuous physical process state expression model, specifically, a continuous physical process state time sequence corresponding to the target procedure is generated by collecting a temperature state component, a clamping stress state component and a process state component of a product under the target procedure; Determining the continuous state point set as a physical process attraction domain corresponding to a target process; Based on the initial state of the physical process and the physical process attraction domain, generating a continuous transition process path and decomposing the continuous transition process path into a plurality of differential transition processes, wherein the physical process attraction domain is used as a target convergence interval by taking the initial state of the physical process as an initial node, and a continuous state evolution search space pointed to the physical process attraction domain by the initial state of the physical process is constructed under the constraint of a continuous physical process state expression model; in the search space, taking the comprehensive weighted offset values of the temperature state variable quantity, the stress state variable quantity and the process state variable quantity as a state disturbance cost function, carrying out cost evaluation on each candidate continuous state evolution path according to a minimum state disturbance principle, and screening out a continuous state evolution path with the minimum comprehensive disturbance cost as the continuous transition process path; the method comprises the steps of dividing a continuous physical process state into a plurality of differential transition processes, namely sampling the continuous physical process state along a continuous transition process path, segmenting the continuous transition process path according to the continuous state change rate, dividing a corresponding continuous state change interval into the same continuous sub-process when the continuous state change rate falls into the same threshold interval, respectively determining each continuous sub-process into a differential transition process, and extracting a corresponding temperature state correction amount, clamping stress correction amount and process state correction amount for each differential transition process to form a group of control parameter correction amounts which can be independently executed; Based on the sequence of differential transition procedures, the control authority between the original intelligent making unit and the target intelligent making unit is transferred in a segmented mode, specifically, according to the execution sequence of the differential transition procedures, control parameter correction amounts corresponding to the current differential transition procedure are sequentially read and used as control transition instructions of the current stage; in the execution period corresponding to the current differential transition procedure, based on a control transition instruction, the control output weight of the original intelligent making unit is adjusted downwards according to a preset decreasing proportion, and meanwhile, the control output weight of the target intelligent making unit is adjusted upwards according to an increasing proportion corresponding to the decreasing proportion, so that double-unit cooperative control weight distribution of the current stage is formed; And after the segment migration is completed, the initial state of the continuous physical process of the current product is reprojected into the discrete control state corresponding to the target procedure to serve as the initial control state of the target intelligent manufacturing unit.
2. The process control method for an automated production line according to claim 1, wherein the projecting the discrete control state of the current raw process as a continuous physical process start state is specifically: when detecting that the intelligent making unit generates an online in-line or out-line trigger event, reading discrete control state parameters corresponding to the original working procedure to form a discrete control state parameter set of the current original working procedure; converting the spindle rotation speed and the feed quantity into temperature initial distribution according to a preset mapping relation between the discrete control state parameters and the continuous physical process state expression model, mapping the clamping instruction into a clamping stress initial value, mapping the process segment number into a process state component, and generating initial assignment of each continuous state component; substituting the initial assignment parameters into a state differential equation of the continuous physical process state expression model to obtain a continuous physical process initial state vector.
3. The process control method for an automated production line of claim 1, wherein the screening out a set of consecutive status points that can be reverted to a set of steady state constraints is: Taking a steady-state average value of each continuous state component in the steady-state physical state constraint set as a disturbance center, and applying disturbance of a preset amplitude along the direction of each continuous state component to generate a plurality of groups of disturbance initial state points; Substituting each disturbance initial state point into a continuous physical process state expression model one by one to carry out evolution calculation so as to obtain a corresponding continuous state evolution track; regression judgment is carried out on each continuous state evolution track, and when the continuous state reenters the range of the steady-state physical state constraint set in the preset evolution time, the corresponding disturbance initial point is judged to be a regressive state point; and collecting all disturbance continuous state initial points which are judged to be regressible state points into a continuous state point set, and taking the continuous state point set as a physical process attraction domain corresponding to the target process.
4. The process control method for an automated production line according to claim 1, wherein the reprojecting the current continuous physical process start state of the work-in-process to a discrete control state corresponding to the target process is specifically: when the target intelligent making unit prepares to take over control, collecting the current continuous physical process state vector of the product; Judging whether the continuous state falls into a physical process suction domain corresponding to the target procedure, and triggering the reprojection of the continuous state to the discrete control state if the continuous state meets the condition; calculating a discrete control set value reversely by combining the continuous physical process state vector based on a standard control parameter interval of a target process; Combining the discrete control set value with the corresponding process segment number to form a complete discrete control state parameter set under the target process; And taking the discrete control state parameter set as an initial control state of the target intelligent manufacturing unit, so that the target intelligent manufacturing unit directly enters a stable production control state.
5. A process control system for an automated production line, applied to the process control method for an automated production line according to any one of claims 1 to 4, comprising a continuous physical process start state generation module, an attraction domain construction module, a differential transition process decomposition module, a control authority segment migration module, and a target process discrete control state initialization module: The system comprises a continuous physical process starting state generating module, a continuous physical process starting state generating module and a control module, wherein the continuous physical process starting state generating module is used for projecting a discrete control state of a current original process into a continuous physical process starting state based on a continuous physical process state expression model when an intelligent making unit triggers online listing or listing; the attraction domain construction module is used for constructing a physical process attraction domain of the target process in the continuous physical process state expression model based on the corresponding process of the target intelligent building unit; The differential transition procedure decomposition module is used for generating a continuous transition procedure path based on the starting state of the continuous physical procedure and the physical procedure attraction domain and decomposing the continuous transition procedure path into a plurality of differential transition procedures; The control authority segmented migration module is used for carrying out segmented migration on the control authority between the original intelligent making unit and the target intelligent making unit based on the sequence of the differential transition procedure; And the target process discrete control state initializing module is used for re-projecting the initial state of the continuous physical process of the current product into the discrete control state corresponding to the target process after the segment migration is completed, and taking the initial state as the initial control state of the target intelligent making unit.

Description

Process control method and system for automatic production line Technical Field The present invention relates to the field of automated production technology, and more particularly, to a process control method and system for an automated production line. Background With the development of industrial automation and modular smart manufacturing, modern production lines are increasingly built with modular smart manufacturing units to achieve flexible and scalable production organizations. In the production line, all intelligent making units perform cooperative operation through standard interfaces, so that multi-working-in-process and online circulation of products are realized. However, since the thermal state, the stress state, the clamping state and the process evolution state of the product are all continuously variable physical processes, the control system usually switches the process by discrete stations and discrete control instructions, and when the intelligent building unit is online in-line or out-line, the control system recognizes the process state and generates a time continuity fault between the actual physical state of the product. The fault can cause process mutation at the moment of in-line or out-line of the product, and further causes the problems of unstable processing, quality fluctuation, discretization of processing results and the like. In the prior art, an effective mapping relation is difficult to establish between discrete control switching and continuous physical processes, so that smooth transition and process consistency of the physical state of the product cannot be ensured when the intelligent building unit is dynamically switched. Therefore, how to realize high-precision mapping between continuous physical process states and discrete control states on an automatic production line and keep stable transition of the process when intelligent building units are in-line or out-of-line is a key technical problem to be solved in the current automatic production process management and control. The present invention proposes a solution to the above-mentioned problems. Disclosure of Invention In order to overcome the above-mentioned drawbacks of the prior art, embodiments of the present invention provide a process control method and system for an automated production line, which establishes a mapping relationship between discrete control states and continuous physical process states of a product, and predicts a control transition path based on physical process state evolution, so as to implement continuous transition and smooth control authority switching of an intelligent building unit during online enqueuing or dequeuing, so as to solve the problems set forth in the background art. In order to achieve the above purpose, the present invention provides the following technical solutions: A process control method for an automatic production line comprises the following steps of projecting discrete control states of a current original process into a continuous physical process starting state based on a continuous physical process state expression model when intelligent building units trigger online on-line or off-line, constructing a physical process attraction domain of a target process in the continuous physical process state expression model based on a target intelligent building unit corresponding process, generating a continuous transition process path based on the continuous physical process starting state and the physical process attraction domain and decomposing the continuous transition process path into a plurality of differential transition processes, carrying out sectional migration on control authorities between the original intelligent building unit and the target intelligent building unit based on the sequence of the differential transition processes, and re-projecting the continuous physical process starting state of the current product into a discrete control state corresponding to the target process after the sectional migration is completed to serve as an initial control state of the target intelligent building unit. In a preferred embodiment, the continuous physical process state expression model is specifically constructed by collecting temperature, clamping stress and surface process state information at each process node of a product, fusing the information to form corresponding temperature state components, stress state components and process state components, combining the continuous state components into multi-dimensional continuous state vectors for representing the instantaneous physical process state of the product, taking the multi-dimensional continuous state vectors as state variables, establishing differential equations of the continuous state components, and introducing coupling relations among thermal-force-process states in the differential equations to form the continuous physical process state expression model. In a preferred embodiment, the projection o