CN111538308A - Method and system for constructing production queue of flexible conversion production line manufacturing execution system - Google Patents
Method and system for constructing production queue of flexible conversion production line manufacturing execution system Download PDFInfo
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Abstract
The invention provides a method and a system for constructing a production queue of a flexible production line manufacturing execution system, which comprises the following steps: step M1: when different production queues appear in the management and control system of the whole production line, carrying out production change preparation verification; step M2: when the check of the production change preparation is successful, obtaining the number of production queues of the production change prepared in advance based on a dynamically reconstructed flexible production change calculation algorithm; step M3: according to the number of production queues to be prepared in advance for production change, a management and control system sends a production change preparation instruction in advance, the production change instruction is called, and the construction of a flexible production line to be prepared is completed; compared with the common production changing mode, the method can save the invalid waiting time between beats and improve the production efficiency; the flexibility of the whole production line is improved, and the automation degree is high.
Description
Technical Field
The invention relates to a flexible production line replacing and manufacturing execution system, in particular to a method and a system for constructing a production queue of the flexible production line replacing and manufacturing execution system, and more particularly relates to a flexible production line replacing and manufacturing execution system in the automobile manufacturing industry.
Background
Flexible manufacturing technology (FMS), also known as Flexible integrated manufacturing technology, is a generic term for modern advanced manufacturing technologies. The flexible manufacturing technology integrates automation technology, information technology and manufacturing and processing technology, and forms an organic system covering the whole enterprise by the processes of engineering design, manufacturing, management and the like which are mutually isolated in the conventional factory enterprises under the support of a computer, software thereof and a database. The flexible manufacturing technology plays an important role in the automobile manufacturing industry, and particularly makes the multi-forming mixed line production possible; the manufacturing period is shortened; the development cost is reduced; the flexible device has excellent functions in expansion and the like.
From 2012 to this beginning, ford officials continuously published two segments of video, which introduced how they applied 3D printing technology to flexibly manufacture models and parts, and developing entity (sludge) models was the best practice in the development process, but this is also very time consuming and expensive. The advent of 3D printing technology has made this a difficult problem. Ford engineers can manufacture test parts by themselves, so that the operation rhythm of the automobile design process is more compact, and the time for the product to be put on the market is shorter.
Ford has tried to apply 3D printing techniques in large quantities, and known components to which this technique is applied include: rotors, damper housings and gearboxes in ford C-MAX and ford maser hybrid vehicles; the Ford wing tiger composite power vehicle uses an EcoBoost four-cylinder engine; brake pads of Ford 2011 explorers; exhaust duct in Ford F-150's 3.5LECOBoost engine.
With the progress of social technology, some advanced flexible technologies are also rapidly converted and applied to the automobile industry, for example, the current popular 3D printing technology is no exception, and 3D printing equipment is adopted for research and development links for almost all transnational automobile enterprises, so that the design of the automobile enterprises is more flexible and is more innovative. In the automobile manufacturing industry with a great deal of robots adopted today, with the combination of increasingly mature industrial vision technology, revolutionary changes will occur in many fields in the future, and the assembly of inner and outer decorations and the like of an automobile assembly line is replaced by the flexible assembly of a robot with eyes manually.
Patent document CN105676769A (application No. 201610003288.7) discloses a method for replacing products in a production line, wherein the process steps with communicated functions are regarded as a whole and divided into a same module, so that when a product is switched, a module controller can detect whether there is an old product in the whole module, and only when there is no old product in the whole module, the module controller can change a main PLC interlock command signal corresponding to the module into an off signal, and the device in the module can receive a new product from upstream, otherwise, even if some devices in the module have no old product, the device in the module can not receive the new product as long as there is an old product in other devices; therefore, on the premise of not influencing the product quality, the time and labor distribution required by product switching lines or material changing can be greatly reduced, the product quality can be monitored systematically, and Q-time overtime of a new product in the conveying process can be prevented.
However, in reality, the setup change preparation time is calculated in the production efficiency, and the setup change is performed in a manual manner or no setup change preparation is prepared in advance, so that the production efficiency is not high, and the flexible production mode cannot reach the expected value.
Disclosure of Invention
Aiming at the defects in the prior art, the invention aims to provide a method and a system for constructing a production queue of a flexible production line manufacturing execution system.
According to the invention, the method for constructing the production queue of the flexible production line manufacturing execution system comprises the following steps:
step M1: when different production queues appear in the management and control system of the whole production line, carrying out production change preparation verification;
step M2: when the check of the production change preparation is successful, obtaining the number of production queues of the production change prepared in advance based on a dynamically reconstructed flexible production change calculation algorithm;
step M3: according to the number of production queues to be prepared in advance for production change, a management and control system sends a production change preparation instruction in advance, the production change instruction is called, and the construction of a flexible production line to be prepared is completed;
preferably, the management and control system of the whole production line in the step M1 includes a preset number of production sequences, and each production sequence includes different parts;
the setup change preparation verification comprises: when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is equal to a preset value, the production change preparation is successfully verified; and when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is larger than the preset value, the production change preparation fails to be checked, normal production operation is continued, the next node production task queue is carried out, the task state is updated, and circulation is continued.
Preferably, the calculation algorithm of the dynamically reconstructed flexible swap in step M2 includes:
preferably, the number of the production queues prepared in advance is between (n-1) A and nA, and the management and control system can issue a production change preparation instruction n production waiting sequences before ending the product A batch.
Preferably, the step M3 includes: and according to the number of production queues prepared in advance for production change, when the control system reaches a preset step number according to the previous station processing sequence, sending a production change preparation instruction, and calling a PLC (programmable logic controller) system and a WMS (wireless multimedia system) system by the control system to prepare for production change.
Preferably, the number of the production queues prepared in advance in the step M3 does not reach the preset value, and when the number of the production queues does not meet the actual value, the number of the production queues prepared in advance is increased to a fixed preset value, so as to ensure the feasibility of the method.
According to the invention, the system for constructing the production queue of the flexible production line production execution system comprises:
module M1: when different production queues appear in the management and control system of the whole production line, carrying out production change preparation verification;
module M2: when the check of the production change preparation is successful, obtaining the number of production queues of the production change prepared in advance based on a dynamically reconstructed flexible production change calculation algorithm;
module M3: according to the number of production queues to be prepared in advance for production change, a management and control system sends a production change preparation instruction in advance, the production change instruction is called, and the construction of a flexible production line to be prepared is completed;
preferably, the management and control system of the whole production line in the module M1 includes a preset number of production sequences, and each production sequence includes different parts;
the setup change preparation verification comprises: when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is equal to a preset value, the production change preparation is successfully verified; and when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is larger than the preset value, the production change preparation fails to be checked, normal production operation is continued, the next node production task queue is carried out, the task state is updated, and circulation is continued.
Preferably, the calculation algorithm of the dynamically reconstructed flexible yield in the module M2 includes:
preferably, the number of the production queues prepared in advance is between (n-1) A and nA, and the management and control system can issue a production change preparation instruction n production waiting sequences before ending the product A batch.
Preferably, said module M3 comprises: and according to the number of production queues prepared in advance for production change, when the control system reaches a preset step number according to the previous station processing sequence, sending a production change preparation instruction, and calling a PLC (programmable logic controller) system and a WMS (wireless multimedia system) system by the control system to prepare for production change.
Preferably, the number of the production queues prepared in advance in the module M3 does not reach the preset value, and when the number of the production queues does not meet the actual value, the number of the production queues prepared in advance is increased to a fixed preset value, so as to ensure the feasibility of the method.
Compared with the prior art, the invention has the following beneficial effects:
1. the dynamic construction of the production queue provided by the invention is a flexible production mode, highlights dynamic state and aims to generate an efficient processing queue in a control system;
2. compared with a common production changing mode, the method can save the invalid waiting time between beats, improve the production efficiency, improve the flexibility of the whole production line, improve the utilization rate of equipment and have very high automation degree;
3. the method of the invention can improve the efficiency by 40 percent under the existing conditions.
Drawings
Other features, objects and advantages of the invention will become more apparent upon reading of the detailed description of non-limiting embodiments with reference to the following drawings:
FIG. 1 is a flow chart of a process route modeling method;
FIG. 2 is a flow chart of a second step of establishing business logic within a node in a process route modeling method;
FIG. 3 is a flowchart of a method for performing integrated debugging of a manufacturing system and a production line;
FIG. 4 is a flowchart of a debug virtual PLC program in a method of manufacturing an execution system;
FIG. 5 is a flow chart of an example of a setup preparation;
FIG. 6 is a flow chart of the system framework for an overall process setup change;
FIG. 7 is a digital twin schematic of a production line.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the invention, but are not intended to limit the invention in any way. It should be noted that it would be obvious to those skilled in the art that various changes and modifications can be made without departing from the spirit of the invention. All falling within the scope of the present invention.
The invention mainly provides a construction method aiming at beat gap time loss caused by unreasonable production change in the flexible production line industry. In the traditional production changing process, the cutter is changed purely manually, and the cutter is manually disassembled, so that the useless work of insufficient manpower, redundant personnel and time waste exists, and the method is neither economical nor efficient. Aiming at the pain point, the invention provides a method for dynamically reconstructing a production queue of a flexible production changing system, corresponding production changing preparation is made in advance for the whole production changing process according to time sequence, and production changing is directly executed on the basis of a workpiece after the processing is finished, so that unnecessary waiting idle time is greatly shortened. The production change is to determine whether a production change task and production change preparation are generated. And the complete set of inspection is to inquire whether the production type is matched with the current process formula according to the current node task queue. The processing ready check is carried out when a workpiece enters a station, the automatic system sends an entering signal and a material number to the management and control system, and the management and control system carries out processing ready check. The setup change preparation verification is a trigger condition of setup change preparation, which is the key point of the invention. The setup preparation triggering condition is that the setup required time/beat of each workstation = the number of production queues prepared in advance, and the number of production queues is the setup time. Through experimental tests, the method can greatly improve the production efficiency and reduce the human investment.
In the invention, the problems of measurement and calculation of time efficiency, connection between each step sequence, positioning precision of the production changing trolley and the like are the most complicated in the process of the invention. The measurement of time efficiency is the most tedious because we need to know the time of each beat and the whole period of the whole production line and the time of the AGV walking alone; the second solution is about how to optimize the sequential beats, and if there are different sequences between beats, there will be different total times, so that the beat needs to be optimized, and the simulation is performed by using the PLANT software of the product under Siemens, so as to obtain the optimal solution of the beats; the last problem is the positioning accuracy problem of the AGV, and if the accuracy is wrong, the production change progress is affected, so that the operation of the whole production line is affected, and manual inspection is necessary.
Example 1
In the integrated virtual debugging of the manufacturing execution system and the production line, a virtual PLC program is written according to the design requirements of a real production line, as shown in FIG. 7; debugging the virtual PLC program in a virtual debugging mode; the manufacturing execution system issues an instruction to control the virtual PLC program; controlling a virtual model of a factory production line by using a virtual PLC program; judging whether the operation result of the virtual model of the factory production line needs to debug and modify the manufacturing execution system or not according to the designed real production line until the operation result of the virtual model of the factory production line is consistent with the designed real production line;
judging whether the control effect of the virtual PLC program is the same as that of the real PLC program, and rectifying and debugging the virtual PLC program;
and debugging the virtual PLC program in a virtual debugging mode according to the fact whether the virtual production line of the virtual model of the factory production line is the same as the designed real production line information or not and when the virtual production line is different from the designed real production line information.
The modifying and debugging the virtual PLC program comprises gradually modifying the virtual PLC program according to different points by using a virtual debugging method.
The step-by-step modification of the virtual PLC program according to different points means that each station controlled by the virtual PLC is tested from a virtual production line starting station to a production line ending station, the testing is compared with the information such as the capacity, the beat and the like of the point of a designed production line, if the difference exists, the virtual PLC program of the station is modified according to the difference, and if the difference does not exist, the next point is debugged.
The virtual PLC program controls the operation of each virtual production line device in the virtual model of the factory production line according to the instructions of the manufacturing execution system.
The virtual model of the factory production line is established in virtual test software, the actions of each device of the factory production line including the device and the signal characteristics of the device are defined correctly, and the established virtual model of the factory production line is controlled by a virtual PLC program;
the virtual test software is connected with the manufacturing execution system, judges whether the information of a virtual production line of a virtual model of a factory production line is the same as the information of a designed real production line, and when the information of the virtual production line is different from the information of the designed production line, the manufacturing execution system is rectified, modified and debugged until the information of the virtual production line is the same as the information of the designed production line.
Specifically, the process line information consistent with the design includes: the production line information to be designed includes beat information, capacity information and process information.
A method of modeling a process route for manufacturing an execution system, comprising:
step N1: mapping each device in the production line into a node, determining the production range and production parameters of each node, and ensuring that the production device is used in the determined parameter range;
step N2: establishing service logic in the node, and finishing logic judgment of a task flow in the node and circulation in the node;
step N3: and selecting a corresponding node combination according to the characteristics and requirements of the processed product, and constructing a corresponding process route according to the production range and production parameters of each node and the service logic in the node.
The node combination means that different workpieces have different processing processes; for example: the process route of element 1 includes node 123, the process route of workpiece 2 includes node 134;
specifically, the production parameters of the node in the step N1 include: the operation parameters of the equipment, the acquisition parameters of the equipment and the control parameters of the equipment.
Specifically, the intra-node task flow in step N2 includes:
step N2.1: the current node is ready, and a next node task is confirmed according to the rule relation between the current task and the current node;
the rule of the nodes is to determine a process route and a node circulation sequence corresponding to the task type according to the task type in the nodes, and then determine equipment corresponding to a next node of the process route;
step N2.2: after confirming the next node task, matching the current production task with the elements in the previous production process formula to complete the production change inspection;
the elements in the production process formula comprise a program corresponding to the production process, equipment parameters such as pressure, temperature, torque, rotating speed, acceleration and the like, a tool, a clamp, a cutter, materials and auxiliary materials;
step N2.3: after the production change inspection is carried out, matching the production type with the current node process formula to complete the complete set inspection;
step N2.4: after the complete inspection is passed, dispatching conveying equipment to convey workpieces, and simultaneously issuing a production task to an automatic system by a control system;
the parameters of the complete inspection comprise: tool matching, tool life, NC program matching and tool matching;
step N2.5: after the production task is issued, the automatic system finishes sending the incoming signal and the material number to the management and control system; the management and control system carries out processing ready check and checks whether the materials are matched or not;
step N2.6: after the processing ready check is successful, performing production line change preparation check according to the production line task list, completing the production line change preparation check, and simultaneously starting operation by the automatic system for the control system;
step N2.7: after the operation is finished, acquiring the information of the next node;
step N2, 8: determining next node information, and scheduling logistics to be delivered to a cache region when the next node has the cache region; when the next node does not have a cache area, waiting for the next node to schedule the logistics equipment to pull the material; conveying the workpiece to different places according to the information of the next node to finish the work-piece outbound;
step N2.9: and after the workpiece is out of the station, updating the task state and confirming the next node.
Specifically, the logical decision of the setup preparation includes: and according to time sequencing, preferentially acquiring the data with the same material number of the previous production task, and if the data with the same material number does not exist in the list, returning the first piece of data (the query task rule is undetermined).
Matching the current production task with the production change element in the process formula of the previous production task, generating the production change task when the current production task is not matched with the production change element in the process formula of the previous production task, executing the production change task, simultaneously inquiring whether the corresponding production change preparation is generated and is already executed, and simultaneously updating the node state; when matching, a production change task does not need to be generated, and complete set inspection is executed;
the logical decision of the nesting check comprises: inquiring according to the current node task queue, and judging whether the production type is matched with the current node process formula; when the equipment is not matched, waiting for equipment to be ready or carrying out manual intervention, and then carrying out complete set inspection; when matched, the complete set inspection is completed.
Specifically, the logical decision of the setup change preparation check includes: when a node executes a current task, whether a product change needs to be executed or not is judged according to a production line task list, a next task with a material number different from that of the currently executed task in the production line list is obtained for judgment, whether the currently executed task node is in a process route of the next task or not is judged, if yes, the current task node is matched with a product change element in a process formula configured by the next task node, and when the product change element is not matched, the product change is needed;
when the production needs to be changed, a dynamic rule is configured to trigger the production change preparation according to the production change preparation time and the production beat time of the current node; production change preparation time/production beat time = number of tasks in advance; acquiring a task number corresponding to the number of the tasks in advance and matching the task number with the current task number, and starting production change preparation when the task number is consistent with the current task number; when the node information is inconsistent with the node information, completing the operation and acquiring the next node information;
the logic for obtaining next node information comprises: judging whether the current production task is a sampling inspection piece, and if the current production task belongs to the sampling inspection piece, belonging to a sampling inspection flow; and when the current production task does not belong to the sampling inspection piece, acquiring a next node according to a preset process model, and simultaneously inserting a piece of data into a production queue of the next node.
The process model is formed by formulating a process route and selecting required equipment, tools, clamps, cutters and material auxiliary materials according to the task type of the manufactured workpiece under the condition of meeting process requirements such as tempo and quality;
according to the invention, the method for constructing the production queue of the flexible production line manufacturing execution system comprises the following steps: based on a calculation algorithm of dynamically reconstructed flexible production change, the whole production processing flow and judgment conditions of production change preparation, and the number of production queues of the production change preparation in advance;
step M1: when different production queues appear in the management and control system of the whole production line, carrying out production change preparation verification;
step M2: when the check of the production change preparation is successful, the number of production queues prepared in advance for production change is obtained based on a dynamically reconstructed flexible production change calculation algorithm, so that the waiting time between beats can be avoided;
step M3: according to the number of production queues to be prepared in advance for production change, a management and control system sends out a production change preparation instruction in advance, and the production change instruction is called, for example: when the current station processing sequence reaches the specified number of steps, calling an AGV trolley to carry clamps and the like in corresponding process parameters in advance, and completing the construction of a flexible production line;
the number of the production queues prepared in advance is the advanced departure time of the production change preparation.
Specifically, the management and control system of the whole production line in the step M1 includes a preset number of production sequences, and the production sequences include different parts;
the setup change preparation verification comprises: when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is equal to a preset value, the production change preparation is successfully verified; and when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is larger than the preset value, the production change preparation fails to be checked, normal production operation is continued, the next node production task queue is carried out, the task state is updated, and circulation is continued.
Specifically, the calculation algorithm of the dynamically reconstructed flexible swap in step M2 includes:
the number of the production queues prepared in advance is the time of preparation in advance, and in the production queue of the management and control system, a production change preparation instruction is sent out in advance at the number correspondingly calculated in the previous workpiece production queue;
the number of the production queues prepared in advance for production change can be used for depicting the time of preparation in advance through the number of the production queues, and if the time of preparation in advance is solidified only by using production experience, the flexible production is not met;
specifically, the number of the production queues prepared in advance is (n-1) between A and nA, and the management and control system can send a production change preparation instruction by n production waiting sequence numbers before finishing the batch of the product A;
when the number of production queues prepared in advance is very small (as small as not to be in compliance with reality), it can be considered to add it to a certain fixed value to ensure compliance with the practical feasibility.
Specifically, the step M3 includes: and according to the number of production queues prepared in advance for production change, when the control system reaches a preset step number according to the previous station processing sequence, sending a production change preparation instruction, and calling a PLC (programmable logic controller) system and a WMS (wireless multimedia system) system by the control system to prepare for production change.
Our management and control system is the control center of the whole production line, however, the two systems of our PLC system and WMS system (for managing AGVs) are independent, but both communicate with the management and control system, and specific operation instructions are not sent out in the management and control system, but generally tell some requirements to the PLC or WMS, and then the two systems perform detailed operations, as shown in fig. 6.
A process route modeling system for manufacturing an execution system, comprising: as shown in figure 1 of the drawings, in which,
module N1: mapping each device in the production line into a node, determining the production range and production parameters of each node, and ensuring that the production device is used in the determined parameter range;
module N2: establishing service logic in the node, and finishing logic judgment of a task flow in the node and circulation in the node;
module N3: and selecting a corresponding node combination according to the characteristics and requirements of the processed product, and constructing a corresponding process route according to the production range and production parameters of each node and the service logic in the node.
The node combination means that different workpieces have different processing processes; for example: the process route of element 1 includes node 123, the process route of workpiece 2 is 134;
specifically, the production parameters of the nodes in the module N1 include: the operation parameters of the equipment, the acquisition parameters of the equipment and the control parameters of the equipment.
Specifically, the intra-node task flow in the module N2 includes: as shown in figure 2 of the drawings, in which,
module N2.1: the current node is ready, and a next node task is confirmed according to the rule relation between the current task and the current node;
the rule of the nodes is to determine a process route and a node circulation sequence corresponding to the task type according to the task type in the nodes, and then determine equipment corresponding to a next node of the process route;
module N2.2: after confirming the next node task, matching the current production task with the elements in the previous production process formula to complete the production change inspection;
the elements in the production process formula comprise a program corresponding to the production process, equipment parameters such as pressure, temperature, torque, rotating speed, acceleration and the like, a tool, a clamp, a cutter, materials and auxiliary materials;
module N2.3: after the production change inspection is carried out, matching the production type with the current node process formula to complete the complete set inspection;
module N2.4: after the complete inspection is passed, dispatching conveying equipment to convey workpieces, and simultaneously issuing a production task to an automatic system by a control system;
the parameters of the complete inspection comprise: tool matching, tool life, NC program matching and tool matching;
module N2.5: after the production task is issued, the automatic system finishes sending the incoming signal and the material number to the management and control system; the management and control system carries out processing ready check and checks whether the materials are matched or not;
module N2.6: after the processing ready check is successful, performing production line change preparation check according to the production line task list, completing the production line change preparation check, and simultaneously starting operation by the automatic system for the control system;
module N2.7: after the operation is finished, acquiring the information of the next node;
module N2, 8: determining next node information, and scheduling logistics to be delivered to a cache region when the next node has the cache region; when the next node does not have a cache area, waiting for the next node to schedule the logistics equipment to pull the material; conveying the workpiece to different places according to the information of the next node to finish the work-piece outbound;
module N2.9: and after the workpiece is out of the station, updating the task state and confirming the next node.
Specifically, the logical decision of the setup preparation includes: and according to time sequencing, preferentially acquiring the data with the same material number of the previous production task, and if the data with the same material number does not exist in the list, returning the first piece of data (the query task rule is undetermined).
Matching the current production task with the production change element in the process formula of the previous production task, generating the production change task when the current production task is not matched with the production change element in the process formula of the previous production task, executing the production change task, simultaneously inquiring whether the corresponding production change preparation is generated and is already executed, and simultaneously updating the node state; when matching, a production change task does not need to be generated, and complete set inspection is executed;
the logical decision of the nesting check comprises: inquiring according to the current node task queue, and judging whether the production type is matched with the current node process formula; when the equipment is not matched, waiting for equipment to be ready or carrying out manual intervention, and then carrying out complete set inspection; when matched, the complete set inspection is completed.
Specifically, the logical decision of the setup change preparation check includes: when a node executes a current task, whether a product change needs to be executed or not is judged according to a production line task list, a next task with a material number different from that of the currently executed task in the production line list is obtained for judgment, whether the currently executed task node is in a process route of the next task or not is judged, if yes, the current task node is matched with a product change element in a process formula configured by the next task node, and when the product change element is not matched, the product change is needed;
when the production needs to be changed, a dynamic rule is configured to trigger the production change preparation according to the production change preparation time and the production beat time of the current node; production change preparation time/production beat time = number of tasks in advance; acquiring a task number corresponding to the number of the tasks in advance and matching the task number with the current task number, and starting production change preparation when the task number is consistent with the current task number; when the node information is inconsistent with the node information, completing the operation and acquiring the next node information;
the logic for obtaining next node information comprises: judging whether the current production task is a sampling inspection piece, and if the current production task belongs to the sampling inspection piece, belonging to a sampling inspection flow; and when the current production task does not belong to the sampling inspection piece, acquiring a next node according to a preset process model, and simultaneously inserting a piece of data into a production queue of the next node.
The process model is formed by formulating a process route and selecting required equipment, tools, clamps, cutters and material auxiliary materials according to the task type of the manufactured workpiece under the condition of meeting process requirements such as tempo and quality;
according to the invention, the system for constructing the production queue of the flexible production line production execution system comprises: based on a calculation algorithm of dynamically reconstructed flexible production change, the whole production processing flow and judgment conditions of production change preparation, and the number of production queues of the production change preparation in advance;
module M1: when different production queues appear in the management and control system of the whole production line, carrying out production change preparation verification;
module M2: when the check of the production change preparation is successful, the number of production queues prepared in advance for production change is obtained based on a dynamically reconstructed flexible production change calculation algorithm, so that the waiting time between beats can be avoided;
module M3: according to the number of production queues to be prepared in advance for production change, a management and control system sends out a production change preparation instruction in advance, and the production change instruction is called, for example: when the current station processing sequence reaches the specified number of steps, calling an AGV trolley to carry clamps and the like in corresponding process parameters in advance, and completing the construction of a flexible production line;
the number of the production queues prepared in advance is the advanced departure time of the production change preparation.
Specifically, the management and control system of the whole production line in the module M1 includes a preset number of production sequences, and each production sequence includes different parts;
the setup change preparation verification comprises: when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is equal to a preset value, the production change preparation is successfully verified; and when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is larger than the preset value, the production change preparation fails to be checked, normal production operation is continued, the next node production task queue is carried out, the task state is updated, and circulation is continued.
Specifically, the calculation algorithm of the dynamically reconstructed flexible swap in the module M2 includes:
the number of the production queues prepared in advance is the time of preparation in advance, and in the production queue of the management and control system, a production change preparation instruction is sent out in advance at the number correspondingly calculated in the previous workpiece production queue;
the number of the production queues prepared in advance for production change can be used for depicting the time of preparation in advance through the number of the production queues, and if the time of preparation in advance is solidified only by using production experience, the flexible production is not met;
specifically, the number of the production queues prepared in advance is (n-1) between A and nA, and the management and control system can send a production change preparation instruction by n production waiting sequence numbers before finishing the batch of the product A;
when the number of production queues prepared in advance is very small (as small as not to be in compliance with reality), it can be considered to add it to a certain fixed value to ensure compliance with the practical feasibility.
Specifically, the module M3 includes: and according to the number of production queues prepared in advance for production change, when the control system reaches a preset step number according to the previous station processing sequence, sending a production change preparation instruction, and calling a PLC (programmable logic controller) system and a WMS (wireless multimedia system) system by the control system to prepare for production change.
Our management and control system is the control center of the whole production line, however, the two systems of our PLC system and WMS system (for managing AGVs) are independent, but both communicate with the management and control system, and specific operation instructions are not sent out in the management and control system, but generally tell some needs of PLC or WMS, and then the two systems perform detailed operations.
Example 2
Example 2 is a modification of example 1
And aiming at the production queue of the flexible production line manufacturing execution system, the production sequence is constructed in the form of dynamic reconstruction, so that the production efficiency is improved. As shown in figure 5 of the drawings,
further, the basic approach is that there are several production sequences in the management and control system of the whole production line, and there are different parts A, B and so on in these production sequences.
Further, when the machining process A is finished, the machining process B is processed, the production process formula needs to be replaced in a small range, if manual replacement is conducted, heavy fixtures cannot be reached by manpower, and an AGV is needed to carry the fixtures and the like for preparation of replacement.
Further, if the product A is just waited for being processed, a production change preparation instruction is sent out in the control system, invalid waiting time is increased between two beats, and production efficiency is reduced.
Further, the invention is to eliminate the dead time between the beats, and the specific formula is:
number of advanced production sequences = setup time for change/tact time for production of current product
Furthermore, in the management and control system, a production change preparation instruction is sent out in advance when the production sequence number is advanced, and an AGV production change instruction is called. Further, when the advanced production sequence number is between (n-1) A and nA, the management and control system can send out a production change preparation instruction for n production waiting sequence numbers before ending the product A batch.
Further, when the last production sequence of the production A batch is produced, a production change preparation instruction needs to be sent, the time t of the production change preparation needs to be known in advance, and then the management and control system sends an instruction to start the production change preparation at the time t before the production processing A is finished, so that the process is just right, the time between beats cannot be dissipated, the invalid waiting of the AGV in the production change preparation is not occupied, and the utilization rate of the AGV is improved.
Example 3
Example 3 is a modification of example 1
Embodiment 3 discloses a manufacturing execution system and production line integrated virtual debugging method, which is shown in fig. 3 and includes:
step S01, judging whether the control result of the virtual PLC program is the same as the control result of the real PLC program, and referring to FIG. 4;
step S02, controlling the operation of the virtual production line by using the compiled virtual PLC program, and if the information of the capacity, the beat, the process and the like of the virtual production line is the same as that of the designed production line, indicating that the control result of the virtual PLC program is the same as that of the real PLC program;
step S03, if the information of the virtual production line under the control of the manufacturing execution system, such as the capacity, the beat, the process and the like, is different from the designed production line, the virtual PLC program is gradually modified according to different points, and the step N02 is switched to step N04 after the virtual PLC program is finished, until the control result of the virtual PLC program is the same as the control result of the real PLC program;
as can be seen, in this embodiment, the virtual plant production line created on the premise of debugging the virtual PLC program must be consistent with all the characteristics of the designed production line.
Step S04, debugging the manufacturing execution system by the debugged virtual PLC program;
referring to fig. 3, the step N04 in the previous embodiment may specifically include the following steps N05 to N09, which are specifically as follows:
SO4, connecting the manufacture execution system to be debugged and the virtual debugging software by using the defined interface in the virtual debugging software;
step S05, the manufacturing execution system to be debugged issues a processing instruction to the virtual PLC program;
step S06, the virtual PLC program controls the virtual production line model to run after receiving the processing instruction;
step S07, judging whether the virtual production line and the designed production line have the same information of capacity, beat, process and the like;
step S08, if the virtual production line and the designed production line have the same information of capacity, beat, process and the like, the intelligent manufacturing system to be debugged meets the requirement of production management and can be used for controlling and managing the actual production line;
and S09, if the information of the virtual production line and the designed production line is different, modifying the manufacturing execution system, and turning to the step N08 after the modification is finished until the information of the virtual production line and the designed production line is the same.
Those skilled in the art will appreciate that, in addition to implementing the systems, apparatus, and various modules thereof provided by the present invention in purely computer readable program code, the same procedures can be implemented entirely by logically programming method steps such that the systems, apparatus, and various modules thereof are provided in the form of logic gates, switches, application specific integrated circuits, programmable logic controllers, embedded microcontrollers and the like. Therefore, the system, the device and the modules thereof provided by the present invention can be considered as a hardware component, and the modules included in the system, the device and the modules thereof for implementing various programs can also be considered as structures in the hardware component; modules for performing various functions may also be considered to be both software programs for performing the methods and structures within hardware components.
The foregoing description of specific embodiments of the present invention has been presented. It is to be understood that the present invention is not limited to the specific embodiments described above, and that various changes or modifications may be made by one skilled in the art within the scope of the appended claims without departing from the spirit of the invention. The embodiments and features of the embodiments of the present application may be combined with each other arbitrarily without conflict.
Claims (10)
1. A method for constructing a production queue of a flexible production line manufacturing execution system is characterized by comprising the following steps:
step M1: when different production queues appear in the management and control system of the whole production line, carrying out production change preparation verification;
step M2: when the check of the production change preparation is successful, obtaining the number of production queues of the production change prepared in advance based on a dynamically reconstructed flexible production change calculation algorithm;
step M3: according to the number of production queues to be prepared in advance for production change, a management and control system sends a production change preparation instruction in advance, the production change instruction is called, and the construction of a flexible production line to be prepared is completed;
the management and control system of the whole production line in the step M1 comprises a preset number of production sequences, and the production sequences comprise different parts;
the setup change preparation verification comprises: when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is equal to a preset value, the production change preparation is successfully verified; when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is larger than a preset value, the production change preparation fails to be checked, normal production operation is continued, the next node production task queue is carried out, the task state is updated, and circulation is continued;
the calculation algorithm of the dynamically reconstructed flexible swap in the step M2 includes:
2. the method as claimed in claim 1, wherein the number of the production queues prepared in advance is between (n-1) a and nA, and the management and control system issues the preparation command for flexible production line manufacturing execution system n production wait sequences before ending the product a batch.
3. The method according to claim 1, wherein the step M3 includes: and according to the number of production queues prepared in advance for production change, when the control system reaches a preset step number according to the previous station processing sequence, sending a production change preparation instruction, and calling a PLC (programmable logic controller) system and a WMS (wireless multimedia system) system by the control system to prepare for production change.
4. The method for establishing the production queue of the flexible production line manufacturing execution system according to claim 3, wherein the management and control system calls a PLC system and a WMS system to manage the AGV trolley to carry corresponding process parameters in advance, including the clamp, so as to complete the establishment of the flexible production line.
5. The method as claimed in claim 1, wherein the number of the production queues prepared in advance in step M3 does not reach a predetermined value, and when the number of the production queues does not match the actual value, the number of the production queues prepared in advance is increased to a predetermined value, thereby ensuring feasibility.
6. A production queue building system for a flexible production line manufacturing execution system is characterized by comprising:
module M1: when different production queues appear in the management and control system of the whole production line, carrying out production change preparation verification;
module M2: when the check of the production change preparation is successful, obtaining the number of production queues of the production change prepared in advance based on a dynamically reconstructed flexible production change calculation algorithm;
module M3: according to the number of production queues to be prepared in advance for production change, a management and control system sends a production change preparation instruction in advance, the production change instruction is called, and the construction of a flexible production line to be prepared is completed;
the management and control system of the whole production line in the module M1 comprises a preset number of production sequences, wherein the production sequences comprise different parts;
the setup change preparation verification comprises: when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is equal to a preset value, the production change preparation is successfully verified; when the distance number between the pointer address of the part in the current production queue and the head address of the next production queue is larger than a preset value, the production change preparation fails to be checked, normal production operation is continued, the next node production task queue is carried out, the task state is updated, and circulation is continued;
the calculation algorithm of the dynamically reconstructed flexible swap in the module M2 includes:
7. the system according to claim 6, wherein the number of the production queues prepared in advance is between (n-1) a and nA, and the management and control system issues the preparation command for flexible production line manufacturing execution system n production wait sequences before ending the product a batch.
8. The system of claim 6, wherein the module M3 comprises: and according to the number of production queues prepared in advance for production change, when the control system reaches a preset step number according to the previous station processing sequence, sending a production change preparation instruction, and calling a PLC (programmable logic controller) system and a WMS (wireless multimedia system) system by the control system to prepare for production change.
9. The system of claim 8, wherein the management and control system invokes the PLC system and the WMS system to manage the AGV in advance to carry corresponding process parameters including the clamp, so as to complete the flexible production line construction.
10. The system according to claim 6, wherein the number of the production queues prepared in advance in the module M3 does not reach a predetermined value, and when the number of the production queues does not match the actual value, the number of the production queues prepared in advance is increased to a fixed predetermined value to ensure the feasibility of the method.
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