CN108646676B - Production control method of steel structure product - Google Patents
Production control method of steel structure product Download PDFInfo
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- CN108646676B CN108646676B CN201810424226.2A CN201810424226A CN108646676B CN 108646676 B CN108646676 B CN 108646676B CN 201810424226 A CN201810424226 A CN 201810424226A CN 108646676 B CN108646676 B CN 108646676B
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- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 60
- 239000010959 steel Substances 0.000 title claims abstract description 60
- 238000000195 production control method Methods 0.000 title claims description 5
- 238000000034 method Methods 0.000 claims abstract description 77
- 239000000463 material Substances 0.000 claims abstract description 69
- 238000004519 manufacturing process Methods 0.000 claims abstract description 38
- 239000002994 raw material Substances 0.000 claims abstract description 27
- 238000002360 preparation method Methods 0.000 claims abstract description 22
- 238000004381 surface treatment Methods 0.000 claims abstract description 10
- 238000007689 inspection Methods 0.000 claims description 67
- 238000003466 welding Methods 0.000 claims description 35
- 238000004140 cleaning Methods 0.000 claims description 29
- 238000012545 processing Methods 0.000 claims description 22
- 238000007639 printing Methods 0.000 claims description 15
- 238000012790 confirmation Methods 0.000 claims description 14
- 238000010422 painting Methods 0.000 claims description 14
- 238000010276 construction Methods 0.000 claims description 13
- 238000003860 storage Methods 0.000 claims description 13
- 238000000227 grinding Methods 0.000 claims description 11
- 238000004806 packaging method and process Methods 0.000 claims description 10
- 238000013461 design Methods 0.000 claims description 9
- 238000003908 quality control method Methods 0.000 claims description 9
- 238000011960 computer-aided design Methods 0.000 claims description 8
- 238000012937 correction Methods 0.000 claims description 8
- 239000003973 paint Substances 0.000 claims description 6
- 238000012546 transfer Methods 0.000 claims description 6
- 238000005422 blasting Methods 0.000 claims description 5
- 239000012776 electronic material Substances 0.000 claims description 5
- 238000007726 management method Methods 0.000 claims description 5
- 238000010008 shearing Methods 0.000 claims description 4
- 238000005520 cutting process Methods 0.000 claims description 3
- 238000004100 electronic packaging Methods 0.000 claims description 3
- 238000007591 painting process Methods 0.000 claims description 3
- 238000009826 distribution Methods 0.000 claims description 2
- 238000012544 monitoring process Methods 0.000 abstract 1
- 230000032258 transport Effects 0.000 description 3
- 238000001514 detection method Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000005498 polishing Methods 0.000 description 2
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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
- G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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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
- G05B2219/30—Nc systems
- G05B2219/31—From computer integrated manufacturing till monitoring
- G05B2219/31426—Real time database management for production control
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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 discloses a steel structure product production control system and a control method, wherein the control method comprises the following steps: 1) generating a list; 2) generating a material preparation table; 3) compiling a typesetting list; 4) blanking; 5) assembling; 6) surface treatment; 7) and managing raw materials in and out of the warehouse. The invention can realize the real-time monitoring of the production of the steel structural member, greatly improve the production efficiency, improve the production quality and save the labor cost.
Description
The application is a divisional application of an invention patent application with the application number of 201610315657.6, the application date of 2016, 5 and 13 and the name of a steel structure product production control system and a control method.
Technical Field
The invention relates to a steel structure product production control system and method, in particular to a steel structure product quality and production process control system and method.
Background
The steel structure enterprises are different from the traditional discrete manufacturing enterprises, not only are production and manufacturing carried out, but also field construction is carried out simultaneously, and the produced products are different according to different external dimensions and processing techniques of field buildings, so that the steel structure enterprises are difficult to accurately control and check the raw material information, the production process, the quality inspection and other related information of the products, and no universal production control system can meet the industry requirements due to the particularity of the industry at present.
Disclosure of Invention
The invention aims to provide a steel structure product production control system and method, which can inquire the member information of a steel structure enterprise in real time, inquire the quality and the raw material information of the member information, and control the production process and the quality of a product in real time.
In order to realize the purpose of the invention, the following technical scheme is adopted for realizing the purpose:
a production quality control method of a steel structure product comprises the following steps:
(1) making a list: receiving a CAD (computer-aided design) design drawing of a steel structure product, inputting all part information of each component of the steel structure product in the drawing into a database, generating a list of the steel structure product, further forming a complete blanking list, a material list and a delivery list of the drawing, and generating a unique identification code of each component according to the delivery list;
(2) generating a material preparation table: according to the delivery list, inquiring the raw material inventory condition in the database, calculating the required purchase amount of the raw materials, and generating a material preparation table;
(3) compiling a typesetting list: making a typesetting list according to the blanking list, a material preparation table and the stock condition of raw materials;
(4) blanking: raw materials are taken according to the typesetting list, blanking is carried out on each component after the blanking is finished, and the box-type beam column is transferred to a main assembly process after the blanking of parts is finished; assembling H-shaped and cross-shaped beams and columns, and transferring to a main assembly process after the assembling is finished;
the following steps are completed before transferring to the main assembly process: generating a one-dimensional bar code of a component to be transferred, printing the bar code on a sticker, pasting the one-dimensional bar code on the component to be transferred, submitting for inspection, inputting confirmation information into a database by scanning the one-dimensional bar code after inspection, inputting handover information into the database after scanning the one-dimensional bar code during handover, and finally forwarding the component to be transferred to an assembly process;
(5) scanning the received one-dimensional code of the component and inputting the received information into a database, then performing door welding on the component, reporting and checking after the door welding is completed, and inputting the checking information into the database by scanning the one-dimensional bar code after the door welding is completed, and assembling; before assembly, scanning a one-dimensional code to complete receiving, then assembling the component, reporting and checking after the assembly is completed, inputting inspection information into a database by scanning the one-dimensional bar code after the inspection information is input into the database, then welding the component, welding a connecting piece on the component after the one-dimensional code is scanned before the welding is completed, reporting and checking after the inspection is completed, inputting the inspection information into the database by scanning the one-dimensional bar code after the inspection information is input into a cleaning and grinding machine, starting cleaning and grinding after the one-dimensional code is scanned before the cleaning and grinding machine completes receiving, reporting and checking after the inspection is completed, performing quality inspection confirmation by scanning the one-dimensional code, inputting confirmation information into the database, generating the one-dimensional bar code of the component of the process, printing the bar code, pasting the one-dimensional bar code on the component, and;
(6) surface treatment, comprising the following two steps:
(6.1) surface pretreatment: firstly, scanning a one-dimensional bar code of an anchor component to receive component information and input the received information into a database, performing shot blasting on the component after receiving, cleaning steel grit, reporting inspection after the completion, inputting inspection information into the database by scanning the one-dimensional bar code after the inspection, cleaning the component by using an air pipe, reporting inspection after the cleaning is completed, inputting the inspection information into the database by scanning the one-dimensional bar code after the inspection, and transferring to a painting process;
(6.2) painting: and (3) painting the component with the pretreated surface, generating and printing a finished product label containing the one-dimensional code and the two-dimensional code after painting is finished, checking, adhering the finished product label to the component after the painting is dried, and after checking, inputting the checking information into a database by scanning the one-dimensional code bar code on the finished product label and then delivering the goods.
The method for controlling the production quality of a steel structural product according to claim 1, preferably further comprising the steps of:
(7) and (4) delivery: and receiving a delivery notice and delivering.
The production quality control method of the steel structure product is preferably characterized in that the specific steps of manufacturing the list are as follows:
receiving a steel structure product CAD design drawing provided by a design department, sequentially inputting the name, thickness, width, length, quantity, material and weight of all parts of each component of the steel structure product in the drawing into a database, after the input is finished, generating a steel structure product list comprising information of all the parts by the database, and generating a blanking list, a material list and a delivery list of the drawing.
The production quality control method of the steel structure product is preferable, wherein the blanking list comprises the following information: part name, part size, plate required by the part, part cutting and shearing information; the bill of materials includes the following information: the type, model and quantity of raw materials required by the steel structure product; the delivery list comprises a finished product list of steel structure products, and the finished product list comprises component types, names, specifications, quantities, weights and area codes.
Preferably, the method for controlling the production quality of the steel structure product comprises the following specific steps of:
with the component of steel construction product, generate the part information for the prepare material table according to structural feature: the method comprises the steps of sequentially inputting part information into a database, inquiring the stock condition of raw materials in the database, calculating the required purchase quantity, generating a material preparation table and storing the material preparation table into the database, wherein the material preparation table comprises the part information and order information.
The production quality control method of the steel structure product is preferably characterized in that the compiling of the typesetting list comprises the following specific steps:
according to the blanking list, a material stock preparation table and the material stock storage condition stored in a database, a typesetting list is formulated according to the manufacturing process requirement and the product structure characteristics, and the typesetting list comprises: component name, component specification, type, specification and quantity of raw materials required.
The production quality control method of the steel structure product is preferably characterized by comprising the following specific steps of:
raw materials are taken according to a typesetting list, then blanking is carried out according to large pieces and small pieces, and the large pieces and the small pieces of the box type beam column are transferred to a main assembly process after grooves are polished; h type, the assembly operation is carried out after the unloading of cross beam column: roughly welding parts of the H-shaped and cross-shaped beams and columns according to requirements, and transferring to an assembly process after assembly; wherein the content of the first and second substances,
before the box beam column is transferred to the assembling procedure and before the H-shaped and cross beam columns are transferred to the assembling procedure, the following procedures are carried out:
generating a one-dimensional bar code of a component, printing the bar code on a sticker, pasting the one-dimensional bar code on the component and reporting for inspection, scanning the one-dimensional bar code to perform quality inspection and confirmation, and inputting confirmation information into a database by scanning the one-dimensional bar code after inspection; and scanning the one-dimensional bar code during transferring to generate transferring information, storing the transferring information into a database, and then transferring the material object component to an assembly process.
The production quality control method of the steel structure product is preferably as follows: the assembly process is carried out according to the following steps:
scanning a one-dimensional bar code for large and small pieces of the assembled component or box-type beam column, transmitting component information to a database, starting door welding for the component, reporting inspection after the completion, transferring information to be corrected to a correction process for correction and processing by scanning the one-dimensional bar code after the inspection, reporting inspection after the correction, and transmitting inspection information to the database by scanning the one-dimensional bar code after the inspection;
and (5) turning to the next welding procedure after the inspection is finished: reporting inspection after welding is finished, transmitting inspection information to a database by scanning a one-dimensional bar code after inspection, and then turning to a cleaning process;
and (4) cleaning and grinding the component, reporting inspection after the component is finished, scanning a one-dimensional code after the component is inspected to confirm quality, inputting confirmation information into a database, generating and printing the one-dimensional bar code of the component in the process after the quality inspection is finished, pasting the one-dimensional bar code on the component, and transferring to a surface treatment process.
The production quality control method of the steel structure product is preferably as follows: the surface treatment process comprises the following steps:
surface pretreatment: receiving component information sent by each previous process, checking the component information and a component real object according to the component information, receiving the component information after checking the component real object, sending the received information to a database in a bar code scanning mode, firstly carrying out shot blasting on the component after receiving the received information, then cleaning steel grit, cleaning the component again after cleaning, carrying out covering protection on a part which is not painted and pre-painting on a special part, and then transferring to a painting process;
painting: and (3) performing paint spraying on the component according to the requirement of a bill of materials, reporting quality inspection after the paint is dried, generating two-dimensional code information and one-dimensional code information, printing a corresponding finished product label containing the one-dimensional code and the two-dimensional code by a printer, after all processes of painting are completed, pasting a finished product label on a painted surface after the painted surface is dried, scanning the one-dimensional code on the finished product label after the finished product label is qualified by inspection, automatically generating warehousing information, storing the warehousing information in a database, and then entering a delivery process.
The production quality control method of the steel structure product preferably further comprises a raw material warehousing and ex-warehouse management process, wherein the process comprises the following steps:
(1) put in storage
After the plates are sent to a factory, a one-dimensional code random label is generated and printed out, then the one-dimensional code random label is attached to each plate at random, then the bar code of each plate is scanned, the related information of the plate is input, and the related information is uploaded to a database server;
(2) delivery from warehouse
When the materials are delivered from the warehouse, firstly, an electronic material receiving list is generated, one-dimensional code labels are scanned in the warehouse according to the material receiving list, then the materials are delivered from the warehouse, delivery information is transmitted to a database, and the quantity and the weight of related materials are automatically reduced in the database;
(3) exit warehouse
If the excess materials are not used up, returning the warehouse, re-pasting random one-dimensional codes for the warehouse-returning plates, scanning the labels of the one-dimensional codes, then inputting warehouse-returning information, transmitting the warehouse-returning information to a database, and automatically accumulating the quantity and weight of the related warehouse materials stored in the database by the database;
(4) query statement
Through the management of the ex-warehouse, the in-warehouse and the out-warehouse, an inventory list and an inventory summary list are automatically generated in the database, and the inventory quantity of the specified date and the query of the total inventory information are provided through the database.
In the method for controlling the production quality of a steel structure product, the delivery process preferably includes delivery of one or a combination of three of the following items:
(1) and (4) common component delivery: recording vehicle information, scanning the components, scanning one by one, generating delivery information after scanning, transmitting the delivery information to a database for storage, automatically generating a delivery bill according to the delivery information data, printing a 4-joint delivery bill, and transporting the delivery bill to a construction site along with goods;
(2) and (3) bulk delivery: firstly, electronic packaging is carried out, namely all component information is recorded into a bar code to generate a packaging code, the components are packaged and then pasted with the packaging code, the packaging code is scanned during delivery so as to completely extract the packaged delivery information and send the delivery information to a database for storage, and a 4-joint delivery bill is automatically generated according to the delivery information and is transported to a construction site along with the packaged delivery;
(3) shipping the container: firstly, performing virtual packaging, firstly generating a one-dimensional bar code and pasting the bar code to a container, then scanning and storing the one-dimensional bar code on the corresponding container one by one, simultaneously scanning the one-dimensional bar code on the corresponding container, loading the member into the container after scanning, scanning the one-dimensional bar code during delivery, calling all stored member information in the corresponding container according to the one-dimensional bar code information and forming delivery information data, finally storing the delivery information in a database, and automatically generating 4 distribution lists according to the delivery information and delivering the lists to a construction site along with the container.
Drawings
FIG. 1 is a schematic structural diagram of a production control system for steel-structured products according to the present invention;
FIG. 2 is a flow chart of the production control method of the steel structure product of the present invention.
Detailed Description
As shown in FIG. 1, the production control system for steel structure products comprises a PDA (preferably a handheld WINDOWS CE6.0PDA), wherein a built-in MYSQL database of the PDA can actively analyze data and upload the data to a server according to the analysis result; the bar code generating device is used for generating a one-dimensional bar code; the bar code printer is used for printing a bar code on the PET high-strength sticker; a client (preferably a PC entry platform); a JAVA query platform (preferably a Web server); a database server; a data processing server; a high capacity cloud server; the wireless access point AP. The system comprises a professional bar code generating device, a professional bar code printer, a client, a JAVA inquiry platform, a database server and a data processing server, wherein the professional bar code generating device, the professional bar code printer, the client, the JAVA inquiry platform, the database server and the data processing server are used as local equipment and are communicated with one another in a wired or wireless mode, and a local equipment PDA is communicated with other local equipment through a wireless access point AP; the database server and the client communicate with the cloud server through the Internet.
As shown in FIG. 2, the production control method of the steel structure product comprises the following steps:
making a list:
receiving a CAD (computer-aided design) design drawing of a steel structure product provided by a design department, sequentially inputting all parts of each component of the steel structure product in the drawing into a database server according to part information requirements such as name, thickness, width, length, quantity, material, weight and the like (the input mode is that a client logs in a web server and accesses the database server through the web server, information is input under an input interface provided by the web server, the input data is stored in the database, and the database information input through the client in other procedures is similar to the input), after the input is finished, the database automatically generates a steel structure product list with uniform format (comprising all the part information), calculates the weight of all the components, and further generates and stores a complete blanking list, a material list and a list of the delivery drawing. Wherein the blanking list comprises the following information: information such as part name, part size, plate required by the part, part cutting information and shearing information; the bill of materials includes the following information: the type, model, quantity and other information of raw materials required by the steel structure product; the invoice includes the following information: the finished product list of the steel structure product comprises information such as component type, name, specification (length, width and height), quantity, weight, area code (such as building number installed on a construction site) and the like. Wherein the steel structural product is composed of a plurality of members, each member being composed of a plurality of parts. And after the list is generated, the data processing server generates a unique identification code of each component according to the finished product list.
Manufacturing a material preparation table:
the process is set up to improve production efficiency. After the CAD design drawing of the steel structure product is completed, the design department formulates a stock preparation form according to the drawing information so as to count in advance which raw materials need to be prepared for the production of the steel structure product. The components such as a large plate part, a bracket part, a small plate part and the like in the finished product list of the steel structure product, designing a system (such as a Tekla model) by referring to a steel structure detailed diagram according to the structural characteristics, according to different use positions, process requirements and production conditions, the purchasing period is processed in the data processing server to generate all the part information of the stock preparation list including serial number, project name, project part/monomer, part number, material, specification, blanking width, width of the fixed rolling plate, blanking length, length of the fixed rolling plate, number of sheets, weight of large plate, weight of small plate, excess material, loss rate, etc., and the data processing server calculates the required purchase amount, generates a material preparation table and stores the material preparation table into the database, wherein the table comprises the part information and order information (including information of which raw materials are required to be purchased and the purchase amount and the like).
Making a typesetting list:
the data processing server makes a typesetting list according to the blanking list, the material preparation table and the material warehousing condition stored in the database and according to the manufacturing process requirement, the structural characteristics and the like provided by a design department, wherein the typesetting list comprises: component name, component specification (length, width and height), type, specification and quantity of required raw materials.
Managing raw materials in and out of the warehouse:
(1) put in storage
After the plates are sent to a factory, a warehouse manager logs in a data processing server through a client to control a bar code generating device to generate a one-dimensional code random label and prints the one-dimensional code random label through a bar code printer, then the one-dimensional code random label is randomly attached to each plate, then the bar code of each plate is scanned through a handheld PDA, relevant information of the plate, such as the material, the manufacturer, the specification, the furnace batch number information and the like of the plate, is recorded through the PDA, and then the information is uploaded to a database server.
(2) Delivery from warehouse
When the materials are taken out of the warehouse, the workshop staff log in the web server through the client to access the database server, electronic material getting lists are filled in the database and sent to the account number of the plate warehouse manager, the warehouse manager scans the one-dimensional code label in the warehouse through the handheld PDA according to the material getting lists and then takes out of the warehouse, the information of the taken out warehouse is transmitted to the database server, and at the moment, the quantity and the weight of the related materials can be automatically reduced in the database.
(3) Exit warehouse
If the excess materials are not used up, the warehouse will be returned, the warehouse manager will re-paste the random one-dimensional code for the returned plate, scan the one-dimensional code label through the handheld PDA and then input the returned information (including the name, specification, quantity, etc. of the returned plate) in the PDA, the returned information is transmitted to the database server, and the database will automatically accumulate the quantity and weight of the related stock materials stored in the database.
(4) Query statement
Through the management of the warehouse-in, warehouse-out and warehouse-out, the inventory list is automatically generated in the database, and the inventory list comprises the specification, weight, quantity, material and the like of the current warehouse-in materials, and the inventory summary list comprises the current total tonnage of the inventory, the warehouse-out quantity and the like. The inventory of the specified date in the database and the total inventory information can be checked in real time by logging in a web server through the client. And is laid for later quality tracking.
Blanking:
and according to the typesetting list, the client opens an electronic material getting list through the data processing server, then opens a main material getting list to a storehouse for material supporting according to the electronic material getting list, and if the materials are not uniform, the main material getting list is reflected to the project management center in time so as to open a purchase instruction list in the data processing server. After the material is received, the makeup is arranged at the beginning of the makeup (that is, different parts are processed on a steel plate according to the information of size, quantity and the like, namely, the makeup), and then the material is discharged. Generally, a square plate with the thickness of less than 16mm and a part with a straight line edge are called small parts, blanking is carried out by using a plate shearing machine, a part with the thickness of more than 16mm is called large parts, the large parts and special-shaped parts are blanked by using a numerical control slitting machine, and the small parts with holes on the parts need to be transferred to a drilling machine for punching; the large and small pieces needing to be beveled (the groove with a certain geometric shape which is formed by processing and assembling the parts to be welded of the weldment) are turned to a beveling team to be beveled. All large and small pieces need to be polished, and the large and small pieces of the box type beam column are transferred to a main assembly workshop for assembly after finishing groove polishing; h type, cross beam column then needs to carry out the assemblage operation (also is thick welding) earlier: the assembly workshop carries out rough welding on parts of H-shaped and cross-shaped beams and columns according to requirements: and after the assembly is finished, transferring the assembly to a main assembly workshop for assembly.
Before the box beam column is transferred to a main assembly workshop and an H-shaped beam column, before the cross beam column is transferred to the main assembly workshop, the following procedures need to be carried out in a blanking workshop or an assembly workshop:
generating a one-dimensional bar code (including an identification code, a process and engineering number information and the like of the component) of the component by a data processing server through a bar code generating device, printing the bar code on a PET high-strength sticker through a bar code printer, attaching the one-dimensional bar code on the component and performing inspection, scanning the one-dimensional bar code by an inspector through a handheld PDA to perform quality inspection confirmation, and inputting the confirmation information into a database through the PDA; and then the workshop executive scans the one-dimensional code through the handheld PDA to generate handover information, the handover information is stored in the database and is sent to the main assembly workshop PDA to complete handover, and then the material object component is transferred to the main assembly workshop for assembly.
Assembling main components (such as building steel components like beams and columns):
after the main assembly shop executive receives the handover information through the PDA, the large and small pieces of the component assembled and completed in the assembly shop or the box beam column processed in the blanking shop are received by scanning one-dimensional codes through the handheld PDA and transmitting the component information to the database through the PDA, and then the component in the workshop is welded, and the inspection is reported after the completion, and the inspector scans the component through the PDA after the inspection, and transfers the information to be corrected to the correction process: i.e. straightening out the component with insufficient straightness. The correction large team leader scans the one-dimensional code through the PDA and transmits information of the component to be corrected to the database through the PDA, so that the component to be corrected is received and corrected, the inspection is reported after the correction is finished, and an inspector scans the one-dimensional code through the PDA and transmits inspection information to the database. After the inspection is finished, the next welding process is carried out, the assembly chief staff uses the PDA to scan the one-dimensional code and transmits the component information to the database through the PDA, then the fine assembly of small components is started after the component information is received, the quality inspector inspects the component information, the inspector scans the one-dimensional code through the PDA and transmits the inspection information to the database, then the next welding process is carried out, the welding chief staff receives the component information (the component information is transmitted to the database through the PDA after the one-dimensional code is scanned by the PDA), then the welding (the connecting piece and the like are welded on the large components such as the beam, the column and the like) is started, the welding is carried out after the welding is finished, the inspection information is transmitted to the database through the PDA scanning inspection after the inspector inspects the component information, then the cleaning process is carried out, the cleaning process is carried out after the cleaning and the long chief staff scans the one-dimensional code through the PDA and transmits the component information to the database, inputting the confirmation information into a database, after the quality inspection is confirmed, generating a one-dimensional bar code of the process member by a data processing server through a bar code generating device, printing the bar code on the PET high-strength sticker through a bar code printer, attaching the one-dimensional bar code on the member, and transferring to a surface treatment process.
The secondary member (which is a member of a staircase, railing, etc. that is not connected to the primary member) is assembled:
the unloading workshop receives the secondary components from a chief executive in the secondary assembly workshop after the unloading of the secondary components is finished, the quality inspectors are matched with corresponding assembly teams after the inspection is finished (the receiving and inspecting processes are similar to those of the main component assembly process), and meanwhile, transfer lists (including component numbers, names, specifications, numbers and the like) are created in a data processing server through a client and are input into a database; after receiving the components, the assembly team firstly checks, confirms that no problem exists and starts assembly (performs rough welding), performs self-checking after assembly, reports to a quality inspector to inspect after self-checking confirms that no error exists, performs next procedure welding (fine welding) after inspection of the quality inspector is completed, and simultaneously opens a transfer bill to perform database entry. And the welding team receives the component, firstly confirms the full penetration part of flaw detection and the size of a welding leg, detects the component by a quality inspector after welding, performs next procedure cleaning and grinding after detection, and simultaneously opens a transfer bill for database entry. Cleaning the welding bead splash of the component by a cleaning and grinding team, performing final inspection by a quality inspector after cleaning, and performing surface treatment by switching to the next procedure after the error is confirmed by a large team leader.
Surface treatment:
1. surface pretreatment: firstly, a large office in a paint shop receives component information sent from each shop by using a PDA (personal digital assistant), checks the component information and a component real object according to the component information, receives the component information after checking the component real object, and sends the received information to a database in a mode of scanning bar codes by the PDA and the like. Performing shot blasting on the component after receiving: the method comprises the steps of polishing a component according to shot blasting grade, cleaning steel grit, namely cleaning the component by using an air pipe, putting the component on a frame, cleaning the component by using the air pipe, checking whether the component has special places which do not need to be painted, protecting the component by using paper if the component has special places which do not need to be painted, and pre-painting the parts which are not well painted.
2. Painting: the method comprises the steps of performing paint spraying on a component according to the requirement of a bill of materials, performing PDA (personal digital assistant) quality inspection after the paint is dried, controlling a professional bar code generating device through a data processing server to generate two-dimensional code information and one-dimensional code information for delivery, and printing a corresponding finished product label containing the one-dimensional code and the two-dimensional code through a printer, wherein the two-dimensional code content comprises information such as component name, length, weight, plate material information, furnace lot number information, producer information, general packet unit, supervision unit, producing unit and the like, the two-dimensional code information is used for inquiring product information for customers, and the one-dimensional code is used for inter-delivery and delivery. And after all the processes of painting are finished, a finished product label is attached to the painted surface after the painted surface is dried, a quality inspector scans one-dimensional codes on the finished product label through a PDA after the finished product label is qualified, automatically generates warehousing information and stores the warehousing information in a database, and the real object is transferred to a delivery workshop and electronically signed by the delivery workshop. And (4) taking the finished product out of the warehouse:
and the delivery workshop transports the finished product components to a corresponding site of the delivery workshop for storage. And arranging the personnel to be transported to the corresponding production workshop by using the components needing to be changed. And then:
receiving a delivery notice issued by the project management center;
and informing the engineering delivery responsible person to go to a delivery site for finding the component according to the component steel number, and simultaneously informing a transportation team to determine that the delivery product uses the vehicle. For different types of components, the tonnage statistics of the sent components is carried out respectively according to the following three modes:
1. and (4) common component delivery: a chief manager in the delivery shop records vehicle information by using the handheld PDA and scans the components at the same time, scans the components one by one, generates delivery information after scanning is completed and transmits the delivery information to the database for storage, and meanwhile, an office in the delivery shop automatically generates a delivery bill after receiving the delivery information data through a client, prints out 4 delivery bills and transports the delivery bills along with goods to a construction site.
2. And (3) transporting the parts: because the delivery can not be realized by single scanning in hundreds of scattered product components, the electronic packaging is carried out firstly, namely, the components with the same specification are packaged and then are pasted with codes: the delivery workshop logs in a data processing server through a client, all component information is recorded into a bar code through the data processing server to generate a packaging code, the components are packaged and then pasted with the packaging code, the packaging code is scanned during delivery, all package data (delivery information) are extracted to a PDA and sent to a database for storage, and a delivery office receives the delivery information through the client and then automatically generates a 4-joint delivery bill, and the 4-joint delivery bill is transported to a construction site along with packaged goods.
3. Shipping the container: since the container packing needs to be carried out in advance in overseas transportation, single scanning cannot be carried out after all products are packed. And then, the delivery workshop carries out virtual packaging in a handheld PDA, firstly, a data processing server generates one-dimensional bar codes through a bar code printer and pastes the one-dimensional bar codes to a container, then, one piece of the component is scanned to a database in the handheld PDA for storage, meanwhile, the one-dimensional bar codes on the corresponding container are scanned, the scanned data are directly stored in MYSQL in the PDA, the component is loaded into the container, the one-dimensional bar codes are scanned during delivery, the PDA calls all component information in the corresponding container in the PDA database according to the one-dimensional bar codes to form delivery information data, finally, the delivery information is stored in the database and sent to a delivery office, and the delivery office automatically generates a 4-link delivery order after receiving the delivery information through a client and transports the delivery order to a construction site along with the container.
In the above steps, if data in the database server is updated, such as data input and data storage, the database server uploads the data in the database to the cloud server in real time for backup, and the cloud server also provides a service for data access.
According to the invention, refined control is realized on all links and the whole process of warehousing the steel structure products from raw materials, designing the products, producing, transporting, inspecting the quality and the like, which is beneficial to improving the production efficiency and improving the product quality.
Claims (1)
1. A production control method of a steel structure product is characterized by comprising the following steps:
(1) making a list: receiving a CAD (computer-aided design) design drawing of a steel structure product, inputting all part information of each component of the steel structure product in the drawing into a database, generating a list of the steel structure product, further forming a complete blanking list, a material list and a delivery list of the drawing, and generating a unique identification code of each component according to the delivery list; wherein the blanking list comprises the following information: part name, part size, plate required by the part, part cutting and shearing information; the bill of materials includes the following information: the type, model and quantity of raw materials required by the steel structure product; the delivery list comprises a finished product list of steel structure products, and the finished product list comprises component types, names, specifications, quantities, weights and area codes of the components;
(2) generating a material preparation table: according to the delivery list, inquiring the stock condition of the raw materials in the database, calculating the required purchase amount of the raw materials, and generating a material preparation table, wherein the concrete steps of generating the material preparation table are as follows: with the component of steel construction product, generate the part information for the prepare material table according to structural feature: the method comprises the steps of sequentially inputting part information into a database, inquiring the stock condition of raw materials in the database, calculating the required purchase quantity, generating a material preparation table and storing the material preparation table into the database, wherein the material preparation table comprises order information besides the part information;
(3) compiling a typesetting list: combining material preparation table and raw material according to blanking list
The inventory condition makes a typesetting list, and the concrete steps of compiling the typesetting list are as follows: according to the blanking list, a material stock preparation table and the material stock storage condition stored in a database, a typesetting list is formulated according to the manufacturing process requirement and the product structure characteristics, and the typesetting list comprises: the name of the component, the specification of the component, the type, the specification and the quantity of the required raw materials;
(4) blanking: getting raw materials according to the typesetting list, and carrying out processing on each component after the materials are picked up
Blanking, wherein the blanking comprises the following specific steps: raw materials are taken according to a typesetting list, then blanking is carried out according to large pieces and small pieces, and the large pieces and the small pieces of the box type beam column are transferred to a main assembly process after grooves are polished; h type, the assembly operation is carried out after the unloading of cross beam column: roughly welding parts of the H-shaped and cross-shaped beams and columns according to requirements, and transferring to an assembly process after assembly; after the blanking of the parts of the box-type beam column is finished, transferring the parts to a main assembly process; assembling H-shaped and cross-shaped beams and columns, and transferring to a main assembly process after the assembling is finished;
the following steps are completed before transferring to the main assembly process: generating one dimension of a component to be transferred
The bar code is printed on the sticker, the one-dimensional bar code is pasted on the component to be transferred and is checked, after the check, the confirmation information is input into the database by scanning the one-dimensional bar code, when the transfer is carried out, the transfer information is input into the database after the one-dimensional bar code is scanned, and finally the component to be transferred is transferred to the assembling process;
(5) scanning the received one-dimensional code of the component and inputting the received information into a database, then performing door welding on the component, reporting and checking after the door welding is completed, and inputting the checking information into the database by scanning the one-dimensional bar code after the door welding is completed, and assembling; before assembly, scanning a one-dimensional bar code to complete receiving, then assembling a component, reporting and checking after the assembly is completed, inputting inspection information into a database by scanning the one-dimensional bar code after the inspection information is inspected, then turning to next step of welding, welding a connecting piece on the component after the one-dimensional bar code is scanned before the welding is completed, reporting and checking after the inspection is completed, inputting the inspection information into the database by scanning the one-dimensional bar code after the inspection information is inspected, turning to cleaning and grinding, starting cleaning and grinding after the one-dimensional bar code is scanned before cleaning and grinding is received, reporting and checking after the inspection is completed, performing quality inspection confirmation by scanning the one-dimensional bar code, inputting confirmation information into the database, generating the one-dimensional bar code of the component of the process, printing the one-dimensional bar code, pasting the one-dimensional bar code;
(6) surface treatment;
the assembly process is carried out according to the following steps:
scanning one-dimensional bar codes for large and small pieces of assembled components or box-type beam columns, transmitting component information to a database, starting door welding for the components, reporting inspection after the components are assembled, transferring information to be corrected to a correction procedure for correction and processing by scanning the one-dimensional bar codes after the components are inspected, reporting inspection after the components are corrected, and transmitting inspection information to the database by scanning the one-dimensional bar codes after the components are inspected;
and (5) turning to the next welding procedure after the inspection is finished: reporting inspection after welding is finished, transmitting inspection information to a database by scanning a one-dimensional bar code after inspection, and then turning to a cleaning and grinding process;
cleaning and grinding the component, reporting inspection after the component is finished, scanning a one-dimensional bar code for quality inspection confirmation after the inspection, inputting confirmation information into a database, generating and printing the one-dimensional bar code of the component in the process after the quality inspection is finished, pasting the one-dimensional bar code on the component, and turning to a surface treatment process;
the surface treatment process comprises the following steps:
surface pretreatment: receiving component information sent by each previous process, checking the component information and a component real object according to the component information, receiving the component information after checking the component real object, sending the received information to a database in a mode of scanning a one-dimensional bar code, performing shot blasting on the component after receiving the received information, cleaning steel grit, cleaning the component again after cleaning, performing covering protection on a part which is not painted, performing pre-painting on a special part, and then transferring to a painting process;
painting: painting the component according to the requirement of a bill of materials, reporting quality inspection after the paint is dried, generating two-dimensional code information and one-dimensional code information, printing a corresponding finished product label containing the one-dimensional code and the two-dimensional code by a printer, pasting the finished product label after the painted surface is dried after all procedures of painting are finished, scanning the one-dimensional code on the finished product label after the finished product label is qualified by inspection, automatically generating warehousing information, storing the warehousing information in a database, and then entering a delivery procedure;
the production quality control method of the steel structure product further comprises a raw material warehousing and ex-warehouse management process, and the process comprises the following steps:
(1) put in storage
After the plates are sent to a factory, a one-dimensional code random label is generated and printed out, then the one-dimensional code random label is attached to each plate at random, then the one-dimensional code label of each plate is scanned, the related information of the plate is input, and the related information is uploaded to a database server;
(2) delivery from warehouse
When the materials are delivered from the warehouse, firstly, an electronic material receiving list is generated, one-dimensional code labels are scanned in the warehouse according to the material receiving list, then the materials are delivered from the warehouse, delivery information is transmitted to a database, and the quantity and the weight of related materials are automatically reduced in the database;
(3) exit warehouse
If the excess materials are not used up, returning the warehouse, re-pasting random one-dimensional codes for the warehouse-returning plates, scanning the labels of the one-dimensional codes, then inputting warehouse-returning information, transmitting the warehouse-returning information to a database, and automatically accumulating the quantity and weight of the related warehouse materials stored in the database by the database;
(4) query statement
Through the management of the ex-warehouse, the in-warehouse and the out-warehouse, an inventory detail table and an inventory summary table are automatically generated in the database, and the inventory on the appointed date and the query of the total inventory information are provided through the database;
the delivery process comprises delivery of one or a combination of three or more of the following:
(1) and (4) common component delivery: recording vehicle information while scanning the component, one by one,
after scanning, generating delivery information, transmitting the delivery information to a database for storage, automatically generating a delivery bill according to the delivery information data, and printing out a 4-joint delivery bill to be transported to a construction site along with goods;
(2) and (3) bulk delivery: firstly, electronic packaging is carried out, namely, all component information is recorded
Inputting a bar code to generate a packaging code, packaging the components and then pasting the packaging code, scanning the packaging code during delivery to completely extract and send the packaged delivery information to a database for storage, automatically generating a 4-joint delivery bill according to the delivery information, and delivering the packaged delivery to a construction site along with the packaged delivery;
(3) shipping the container: firstly, performing virtual packaging, firstly generating a one-dimensional bar code and pasting the bar code to a container, then scanning and storing the one-dimensional bar code on the corresponding container one by one, simultaneously scanning the one-dimensional bar code on the corresponding container, loading the member into the container after scanning, scanning the one-dimensional bar code during delivery, calling all stored member information in the corresponding container according to the one-dimensional bar code information and forming delivery information data, finally storing the delivery information in a database, and automatically generating 4 distribution lists according to the delivery information and delivering the lists to a construction site along with the container.
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| CN108646677B (en) | 2020-02-07 |
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