CN111582537A - Digital workshop construction method for producing blades - Google Patents
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Abstract
The invention discloses a digital workshop construction method for producing blades, which relates to the field of digital workshops and comprises the following steps: (1) upgrading and transforming the equipment; (2) establishing a digital workshop process layout simulation model; (3) constructing a workshop site information perception system; (4) constructing an enterprise-level collaborative research and development platform; (5) developing a production process information comprehensive integrated management and control center facing a digital workshop; (6) implementing a computer aided design system; (7) constructing a machine tool Internet of things system; the aim of integrating and digitizing the turbofan blade production line is achieved, digitized production of the turbofan blade is developed from digitized finish machining starting of the gas turbine blade, intelligent scheduling, intelligent control and visualization of the whole production process are achieved, and scientification of production management is promoted.
Description
Technical Field
The invention relates to the field of digital workshops, in particular to a digital workshop construction method for producing blades.
Background
At present, the blade production of domestic turbofan still has certain lagging nature compared with abroad, for example: high-grade numerical control equipment is more, but due to unreasonable planning and scheduling, the utilization rate is relatively low, the equipment load capacity is not clear, the complexity degree of the blade process is high, the process is long in time consumption, and multi-constraint real-time dynamic task planning is extremely difficult in a manual mode; in addition, the requirement on the technological parameters of the blades is extremely high, so that the accuracy of the technological process parameter inspection result recorded by manual writing cannot be ensured.
The blade is used as the heart of the turbofan engine, the technology and the production level of the blade are directly related to the development of the turbofan engine, so that an intelligent factory/digital workshop for blade production is urgently needed to be established so as to carry out quick intelligent management and control on the manufacturing process. Through the integrated management and control platform which takes the production plan as a drive, takes the process control as a core, takes the visualization as a means and takes the integrated management as a core, the intelligent control on the production process of the blade is realized while the key technology of the blade is continuously broken through.
Disclosure of Invention
The technical problem to be solved by the invention is as follows: aiming at the defects of the prior art, the digital workshop construction method for producing the blades is provided, aims at the integration and digitization of a turbofan blade production line, starts from the digital finish machining of the gas turbine blades, develops the digital production of the turbofan blades, realizes the intelligent scheduling, intelligent control and visualization of the whole production process, and promotes the scientification of production management.
The invention provides a digital workshop construction method for producing blades, which comprises the following steps
(1) Upgrading and transforming the equipment; the equipment comprises production equipment and production auxiliary equipment; the production equipment comprises a numerical control seven-axis five-linkage machining center, a five-axis machining center, a horizontal machining center, a numerical control follow-up milling machine, a powerful mill and the like.
(2) Establishing a digital workshop process layout simulation model;
(3) constructing a workshop site information perception system;
(4) constructing an enterprise-level collaborative research and development platform; the information development tool comprises PLM, CAD, CAPP and the like.
(5) Developing a production process information comprehensive integrated management and control center facing a digital workshop;
(6) implementing a computer aided design system;
(7) and constructing a machine tool internet of things system.
Further, the step (2) specifically comprises,
performing preliminary early-stage planning on the product;
planning and designing a production process;
designing a characteristic value and a control strategy;
modeling a production line;
and (6) simulation optimization.
Furthermore, the simulation optimization specifically includes optimization by adjusting parameters of preliminary prophase planning, production process planning design, characteristic value design, control strategy design and production line modeling.
Further, the production line modeling comprises geometric modeling and logic modeling;
the geometric modeling is used for carrying out three-dimensional solid modeling on the equipment;
the logical modeling is used to describe decision-making behavior of different resource object interactions that occur at a particular time.
Furthermore, the workshop site information perception system in the step (3) comprises,
equipment information perception system, material monitoring system and quality monitoring system. The material monitoring combines the material and the station information flowing through the material by a process card with process bar code information.
Furthermore, the equipment information perception system comprises a data terminal, wherein the data terminal is in communication connection with the equipment, automatically detects the running state of the equipment, the product being processed and the progress, and carries out early warning and prompting on a delayed plan. The running state comprises the shutdown, startup debugging, startup processing and the like of the equipment. The data terminal comprises an intelligent sensor, an RFID identification device, a sensor, a laser scanner and the like.
Further, the step (5) specifically comprises,
(51) carrying out visual modeling on the digital workshop based on the GIS; and carrying out two-dimensional dynamic modeling on enterprise production, and carrying out three-dimensional modeling on local key parts.
(52) Constructing a GIS map engine of a surface treatment workshop; the method comprises the steps of modeling the whole elements of the workshop and constructing a multi-resolution map engine.
(53) The space live-action view based on the DMI monitors the workshop in real time, and can monitor live-action images of key equipment and areas of the workshop;
(54) and constructing a digital workshop index evaluation system, and establishing a production index evaluation system aiming at the discrete manufacturing characteristics.
Further, the step (51) specifically comprises,
performing data processing on CAD data, observation data and attribute data of a workshop and establishing a workshop model;
and carrying out visual interactive design on the established workshop model.
Further, the step (53) specifically comprises,
obtaining the installation of map data through an original database;
map data access is obtained through an original database and a map data installation and editing database;
obtaining the retrieval of the map data through the map data access;
displaying a map by retrieving map data;
measuring a map, picking up map objects and printing the map on the displayed map;
and obtaining the operation of map object attributes and the editing of the map objects through the picking of the map objects.
Further, the computer-aided design system includes,
the system comprises an operation plan scheduling module and a multi-layer hierarchical distributed plan scheduling algorithm module.
By adopting the technical scheme, the invention has the beneficial effects that: by planning and scheduling factory-level and workshop-level, managing the equipment operation process, tracking production tasks and materials and monitoring and managing the production process, the planning, production, scheduling and resource allocation are more scientific and accurate, the coordination and command capability among all systems of each department is improved, the continuity and controllability of production are guaranteed, the production process is digitalized, intelligentized and transparent, the resource scheduling optimization and the tracking visibility of the whole production process are realized, the integration between the production equipment and upper management and the unified management, use and analysis of production data resources on production sites are realized, the intelligent scheduling, intelligent management and control and visibility of the whole production process are realized, and the scientification of the production management is promoted.
Drawings
The invention will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a schematic diagram of a digital plant process layout simulation model;
FIG. 2 is a schematic diagram of a plant site information sensing system;
FIG. 3 is a flow chart of visual modeling;
fig. 4 is a block diagram of real-time monitoring of a plant.
Detailed Description
Any feature disclosed in this specification may be replaced by alternative features serving equivalent or similar purposes, unless expressly stated otherwise. That is, unless expressly stated otherwise, each feature is only an example of a generic series of equivalent or similar features.
The digital workshop for producing the blades realizes the management of the operation process of equipment, the tracking of production tasks and materials and the monitoring and management of the production process, ensures that planning, production, scheduling and resource allocation are more scientific and accurate, improves the coordination and command capability among systems of all departments, ensures the continuity and controllability of production, ensures the digitization, the intellectualization and the transparence of the production process, realizes the optimization of resource scheduling and the tracking and visibility of the whole production process, realizes the integration between the production equipment and upper management and the unified management, the use and the analysis of production data resources on a production site, achieves the intelligent scheduling, the intelligent management and the visibility of the whole production process, promotes the scientization of the production management, and further improves the lean production and the intelligent manufacturing capability of the blade manufacturing industry.
The invention specifically comprises the following contents:
1) and upgrading and transforming the equipment to improve the equipment manufacturing capacity.
The equipment comprises production and production auxiliary equipment;
the production equipment comprises a numerical control seven-axis five-linkage machining center, a five-axis machining center, a horizontal machining center, a numerical control follow-up milling machine, a powerful mill and the like.
The production auxiliary equipment comprises software modules such as CAXA (DNC) software, CAPP software, MES software, ERP software, post-processing general platform software, production technology and the like.
2) Establishing a digital workshop process layout simulation model;
the technical framework of the digital workshop process layout simulation model is shown in figure 1 and comprises the steps of carrying out preliminary early-stage planning on a product; planning and designing a production process; designing a characteristic value and a control strategy; modeling a production line; and (6) simulation optimization.
The production process planning design mainly determines the production process flow, the scale, the composition and the layout of a production system, including the selection and the layout of the types and the number of processing equipment, the selection and the design of a logistics system, the determination of related auxiliary equipment and the like so as to reasonably configure the whole production system.
The production line modeling is an abstract description of the actual production system and can reflect the essential attributes of the actual production system. The accuracy of the simulation model establishment directly affects the final result of the simulation, and is the key of the production line simulation. The project production line simulation modeling comprises geometric modeling and logic modeling. Geometric modeling refers to three-dimensional solid modeling of all equipment (processing equipment, logistics equipment, inspection auxiliary equipment) on a production line. Logical modeling refers to the decision-making activities that occur for each manufacturing resource in an actual production system. The logic control realizes the selection of production resources, and the decision behavior of the interaction of different resource objects occurring at a specific time is described in an abstract way by using a logic control class.
The simulation optimization refers to finding out and improving the bottleneck of the production line on the basis of simulation result analysis, such as the utilization rate of equipment, the product quantity of an equipment cache region, the process processing capacity and the like. The simulation optimization method comprises an accurate algorithm, a heuristic algorithm, a working research method and the like. The heuristic algorithm is an algorithm constructed based on intuition or experience, and for the complexity of modern production logistics systems, the heuristic algorithm is usually adopted for production line optimization, and modern heuristic algorithms (such as tabu search algorithm and genetic algorithm) are mainly adopted at present.
3) Constructing a workshop site information intelligent sensing system based on a digital manufacturing technology and an Internet of things technology;
the method is characterized in that a sensing network is formed by using various sensing technologies, such as various devices and technologies of intelligent sensors, RFID identification devices, various sensors, laser scanners and the like, any object or process needing monitoring, connection and interaction in the blade manufacturing and production process is collected in real time, and various required state data, such as various production factors of man-machine materials, water, electricity, gas, production progress, process parameters, quality, environment and the like, are collected. The intelligent sensing system realizes intelligent identification, positioning, tracking, monitoring and management and realizes management automation. The overall structure of the information perception model of the invention is shown in fig. 2:
the main perception objects of the intelligent information perception system comprise equipment, materials, personnel, quality, a cutter die and the like. An information intelligent sensing system is established based on a digital manufacturing technology and an internet of things technology, and is connected with production equipment through a data terminal, so that various operation states of the equipment, such as shutdown, startup debugging, startup processing and the like, can be automatically detected, products and progress of the equipment in processing can be obtained in detail, and early warning prompt is carried out on a delayed plan. And supports displaying the equipment state of each area on various display media (data terminal, computer, electronic billboard, mobile phone, etc.).
The material monitoring system uses a process card with process bar code information and the circulation of products in process, the transfer-in/transfer-out between processes is realized by scanning the process card on a data terminal, and materials and station information flowing through are combined to realize material tracking, product quality tracing analysis, material abnormity alarm and the like.
Inputting a test result through a quality monitoring system to perform online statistics on the number of qualified products, the number of defective products, the number of industrial wastes, the number of material wastes and others on a work order; moreover, the defect number, type, occurrence time, operators and the like of the work order can be traced and inquired on the defect overview interface.
In addition, the monitoring of the authority, the state, the performance statistics and the like of personnel and the use monitoring of the cutter die can be realized.
4) Implementing information research and development tools such as PLM (product lifecycle system), CAD, CAPP and the like, and constructing an enterprise-level collaborative research and development platform; the method and the system realize the parallel development of the products, manage the engineering change and control the progress of the product development project, thereby ensuring the effective implementation of the product development process and improving the development quality and efficiency.
5) And developing a production process information comprehensive integrated management and control center oriented to a digital workshop.
Carrying out visual modeling on the digital workshop based on the GIS;
the digital workshop three-dimensional modeling research based on the GIS organically combines the GIS and the digital workshop to construct a unified network graphic platform, performs two-dimensional dynamic modeling on enterprise production on the basis of the GIS, performs three-dimensional modeling on local key parts, adopts an enterprise field bus control system, presents the information in a visual mode and reveals the spatial and temporal relationship among the information, so that production personnel can accurately know various information in blade production in real time to realize visual management, and the process diagram of visual modeling is shown in figure 3.
And constructing a GIS map engine of the surface treatment workshop.
The storage and processing efficiency of mass data is improved by researching algorithms in the aspect of software, such as various high-efficiency data model designs, parallel processing algorithms, wavelet compression algorithms, direct analysis processing in a compression state and the like aiming at different conditions;
and (3) modeling all elements of the workshop, comprehensively considering the actual geographic environment and the operation management condition of the workshop, taking the actual scene of the workshop as a prototype, combining a CAD drawing of the workshop, simulating the distribution of all elements of the workshop in a two-dimensional and three-dimensional modeling mode according to the actual condition, and tightly combining the spatial data with the attribute data.
A multi-resolution map engine is constructed, design, simulation, analysis and optimization are carried out on various links of production, namely different levels, different granularities, small equipment, large production units and production lines, and parallel engineering, namely logistics processes, various equipment, factory layout, production scheduling and the like, is supported.
And monitoring the workshop in real time based on a space live-action view of a DMI (measurable live-action image).
The production process information comprehensive integration system based on the GIS is fused with the DMI technology, and real-time image monitoring can be carried out on key equipment and areas of a workshop to display real-time manufacturing information; meanwhile, on-site abnormalities, such as delayed delivery, equipment failure, material shortage and the like, can be responded in time, and as shown in fig. 4, the method is a frame diagram for monitoring a workshop in real time.
And constructing a digital workshop index evaluation system.
Aiming at the discrete manufacturing characteristics, a production index evaluation system is established. The statistical analysis processing is carried out on the production data from different subjects, different dimensions and different granularities, and comprises the following steps: counting the operation data of product yield, equipment parameters, storage materials, tool fixtures and the like; key indexes such as production efficiency, equipment utilization rate, quantity of products being processed, delivery timeliness rate and the like. The online real-time statistical analysis and the post statistical analysis can be carried out, the long-term accumulated production process data form an industrial big database, and the data mining analysis processing facing the industrial big data can be carried out.
6) Further implementing a computer aided design system (CAPP);
by using CAPP, on the basis of the production resource and capability constraint of a workshop, a set of optimal schemes is selected from a huge number of feasible schemes through an advanced optimization algorithm, and a scientific detailed production plan is generated, so that the workshop is helped to carry out comprehensive planning, execution, analysis, optimization and decision management on production tasks.
Job plan scheduling module
The blade workshop operation scheduling problem mainly focuses on planning and scheduling aspects of workshops, and an effective scheduling method and an effective optimization technology are the basis and the key for improving production efficiency. At present, an operation scheduling system is not established in most blade workshops, actual production depends on much personnel experience, man-made interference is obvious, and intelligent scheduling is difficult to achieve.
Aiming at the characteristics of complexity, dynamic randomness, multiple targets and the like of blade workshop operation scheduling, the input-output relation and the target function are analyzed, constraint conditions such as equipment capacity, product reloading, product in-process inventory and the like are comprehensively considered, an operation scheduling optimization model is established by using a mathematical linear programming and constraint theory method, the operation scheduling optimization model has the capability of accurately describing production scheduling problems, contains rich scheduling logic, can effectively guarantee the matching requirement of workshop tasks in the scheduling process, and provides a reasonable scheduling result with instructive significance for enterprises. The job scheduling problem based on the model can achieve the effect of time-cost double optimization, and the model lays a foundation for constructing a distributed plan scheduling system.
Multi-layer hierarchical distributed planning and scheduling module
The shop floor job scheduling problem is typically an NP-complete problem, one of the most difficult problems in the optimization and composition problem, so it is natural to find a fast algorithm that can produce acceptable scheduling in the right time. In a blade manufacturing network, plans among layers have a hierarchical relation, and plans of nodes have an association relation among nodes on the same layer. The algorithm is a plan scheduling algorithm based on anthropomorphic ideas by taking the reference of strategies adopted by people in actual scheduling work, contains abundant scheduling logics, can rapidly make various and multi-process production plans, and obtains a fine operation plan and an integral multi-granularity network plan which take minutes as the shortest time partially.
7) Machine tool thing system (DNC + MES)
All equipment is networked, remotely communicated and centrally managed and controlled, and complete networked management of the numerical control machine tool is realized; establishing a numerical control program library to realize the unified management of numerical control programs, and selectively downloading the corresponding numerical control programs to numerical control equipment by a DNC system according to a production order; the DNC system collects production progress data, equipment running state data and the like of a production field in real time; and information integration is carried out with an MES system and a PLM system, so that the integration of enterprise information flow is realized.
The invention aims to effectively allocate materials, personnel, production and the like among all manufacturing units and warehouses in an enterprise, improve the delivery cycle of orders and more flexibly realize the manufacturing agility of the whole enterprise; and the manufacturing process of an enterprise is better monitored and controlled through the information perception and control of 'time, space, volume and state' of the multi-scale manufacturing process. The visualization of the whole production process is realized by applying the modern information technologies such as GIS, LBS, RFID, mobile interconnection and the like to the blade manufacturing process and by the logistics space view, the time progress view, the process index view and the field view of the production process.
The information interaction capacity inside and outside the enterprise manufacturing unit is improved, and a collaborative information system is constructed; the production plan scheduling time is shortened, and the manual scheduling efficiency is improved by 20-40%; the logistics cost and the inventory cost in the manufacturing process are effectively reduced, the inventory turnover rate is improved by 5-10%, the product manufacturing period is greatly shortened, and the product delivery period is improved according to the time rate; the capacity utilization rate of each manufacturing unit is improved by 5-20%.
While the foregoing description shows and describes a preferred embodiment of the invention, it is to be understood, as noted above, that the invention is not limited to the form disclosed herein, but is not intended to be exhaustive or to exclude other embodiments and may be used in various other combinations, modifications, and environments and may be modified within the scope of the inventive concept described herein by the above teachings or the skill or knowledge of the relevant art. And that modifications and variations may be effected by those skilled in the art without departing from the spirit and scope of the invention as defined by the appended claims.
Claims (10)
1. A digital workshop construction method for producing blades is characterized by comprising the following steps: comprises that
(1) Upgrading and transforming the equipment;
(2) establishing a digital workshop process layout simulation model;
(3) constructing a workshop site information perception system;
(4) constructing an enterprise-level collaborative research and development platform;
(5) developing a production process information comprehensive integrated management and control center facing a digital workshop;
(6) implementing a computer aided design system;
(7) and constructing a machine tool internet of things system.
2. The digital workshop construction method for producing blades according to claim 1, characterized in that: the step (2) specifically comprises the following steps,
performing preliminary early-stage planning on the product;
planning and designing a production process;
designing a characteristic value and a control strategy;
modeling a production line;
and (6) simulation optimization.
3. The digital workshop construction method for producing blades according to claim 2, characterized in that: the simulation optimization specifically comprises the step of optimizing by adjusting parameters of preliminary prophase planning, production process planning design, characteristic value design, control strategy design and production line modeling.
4. The digital workshop construction method for producing blades according to claim 2, characterized in that: the production line modeling comprises geometric modeling and logic modeling;
the geometric modeling is used for carrying out three-dimensional solid modeling on the equipment;
the logical modeling is used to describe decision-making behavior of different resource object interactions that occur at a particular time.
5. The digital workshop construction method for producing blades according to claim 1, characterized in that: the workshop site information perception system in the step (3) comprises,
equipment information perception system, material monitoring system and quality monitoring system.
6. The digital workshop construction method for producing blades according to claim 5, wherein: the equipment information perception system comprises a data terminal, wherein the data terminal is in communication connection with equipment, automatically detects the running state of the equipment, the product being processed and the progress, and carries out early warning prompt on a delayed plan.
7. The digital workshop construction method for producing blades according to claim 1, characterized in that: the step (5) specifically comprises the following steps,
(51) carrying out visual modeling on the digital workshop based on the GIS;
(52) constructing a GIS map engine of a surface treatment workshop;
(53) monitoring the workshop in real time based on the space live-action view of the DMI;
(54) and constructing a digital workshop index evaluation system.
8. The digital workshop construction method for producing blades according to claim 7, characterized in that: the step (51) specifically comprises that,
performing data processing on CAD data, observation data and attribute data of a workshop and establishing a workshop model;
and carrying out visual interactive design on the established workshop model.
9. The digital workshop construction method for producing blades according to claim 7, characterized in that: the step (53) specifically comprises the steps of,
obtaining the installation of map data through an original database;
map data access is obtained through an original database and a map data installation and editing database;
obtaining the retrieval of the map data through the map data access;
displaying a map by retrieving map data;
measuring a map, picking up map objects and printing the map on the displayed map;
and obtaining the operation of map object attributes and the editing of the map objects through the picking of the map objects.
10. The digital workshop construction method for producing blades according to claim 1, characterized in that: the computer-aided design system includes a computer-aided design system,
the system comprises an operation plan scheduling module and a multi-layer hierarchical distributed plan scheduling algorithm module.
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