CN111798733A - Modular plant - Google Patents

Abstract

The invention relates to a module factory for producing a production line, wherein the module factory has a plurality of production modules and an electronic control unit which is provided for controlling at least one of the production modules, wherein the at least one production module has a first data interface which is provided for converting control instructions received from the electronic control unit into control signals, wherein the electronic control unit has a second data interface which is provided for converting control program code into control instructions, and wherein the electronic control unit has a third data interface which is provided for converting input data input by means of an input device into control program code.

Description

Modular plant

Technical Field

The invention relates to a module factory for producing a production line.

The modular factory is used to test different workflows, logistics flows and possible methods and techniques that should be applied and used in a production line and in this way identify and eliminate faults on a small scale and optimize the production line to be built. Furthermore, module factories are used to train engineers, for example, production or process technology, and provide them with different workflows, logistics flows or methods and techniques that can be used in generating a production line.

It is therefore important in such a module factory to provide as large a number of different production modules as possible, from which the user of the module factory can select and combine as freely as possible to achieve a flow of the production line that is as optimal as possible. This not only involves the sequencing and distribution of work steps and the arrangement of different workstations in space, for example to optimize the logistic process, but also the selection of viable production modules and technical support that can simplify the workflow, reduce the sources of failure and increase productivity. In order to be able to make use of such a module factory as good as possible and to achieve as high a learning effect as possible when training engineers in cultivation, it is advantageous or even necessary that the different production modules can be easily and intuitively operated and can be connected to one another quickly and simply in terms of structure. Only then can the new ideas for building the production line be converted, checked and, if necessary, discarded and replaced quickly and simply.

Background

From the prior art, therefore, module plants are known which have a plurality of workstations which can be equipped with different production modules and which are composed of these. This relates, for example, to work tables, shelving elements and logistics elements (e.g. roller plates) on which semi-finished products or manufactured products can be moved quickly and simply from one work station to the next. The different production modules are preferably mounted on rollers so that they can be quickly and easily brought into different positions and orientations relative to one another, for example, in order to be able to quickly and easily find a logistically optimized position of the different work stations relative to one another.

However, modern production lines also have computer-supported, computer-assisted and/or computer-controlled production modules in addition to the already described production modules. This relates, for example, to a tracking system with which semi-finished products, workpieces, components or raw materials can be tracked on their way through a production process, a production line and/or a workshop. This is necessary or at least very advantageous in particular for quality assurance and optimization of the logistic process. Disadvantageously, such production modules cannot be used in a module factory, since they cannot be easily, quickly and intuitively adjusted to the respective situation. In order to build, for example, a tracking system and to adapt it to the respective requirements, it is first necessary to specify which elements are to be tracked by which technology. Such an element can be provided, for example, with an RFID chip, the signals of which can be read by a corresponding sensor and processed in an electronic data processing device. However, in order to build the tracking system, not only must the elements be provided with a chip, but the electronic control unit must also be programmed to meet the desired requirements and be able to process the received signals as desired. For this purpose, it is often necessary to change the programming in a complicated manner and to adapt it to the individual case.

Disclosure of Invention

The object underlying the invention is therefore to further develop the module factory in such a way that production modules which can be controlled by means of an electronic control unit can also be used in the module factory and used for the production of a production line and the optimization thereof.

The invention solves the stated object by means of a module factory for producing a production line, wherein the module factory has a plurality of production modules and an electronic control unit which is provided for controlling at least one of the production modules, wherein the at least one production module has a first data interface which is provided for converting control commands received from the electronic control unit into control signals, wherein the electronic control unit has a second data interface which is provided for converting control program codes into the control commands, wherein the electronic control unit has a third data interface which is provided for converting input data input by means of an input device into the control program codes.

The production modules which can be controlled by the electronic control unit receive control commands from the electronic control unit, which are converted by the respective production module into control signals by means of the first data interface. These control signals operate, for example, actuators, thereby, for example, moving elements of the production module. Alternatively or in addition thereto, the control signal can also contain electronic instructions, which for example control the evaluation of sensor data (for example camera images). The control signal is thus adapted to directly cause an action of the corresponding production module.

The control instructions are generated in an electronic control unit. To this end, the control program code is converted into control instructions. The control program code can be, for example, the source text of a computer program, which is therefore written in a programming language. The second data interface of the electronic control unit converts the control program code from the programming language into the machine language in which the control instructions are written in this embodiment. The person using the electronic control unit in the actual production line of the production company to use the respective production module as desired can directly edit the control program code and in this way match the functional manner and task of the respective production module to the desired requirements. Users of a module factory who are in training often do not have the pre-training required for this. For this purpose, according to the invention, the electronic control unit has a third data interface. The third data interface is used for converting input data input by the input device into the control program code.

Preferably, the electronic control unit is an electronic data processing device, in particular a computer or at least a part thereof. Particularly preferably, the electronic control unit has an input device by means of which the input data can be input by a user of the module factory. These input data are, for example, the initial and/or end position of the actuator, rules and regulations regarding how the electrical and/or electronic signals determined jointly, for example by the RFID chip, should be processed, or output regulations, for example, relating the display of images (in particular photographs) to a determined work result.

The device according to the invention thus eliminates the conversion of the corresponding commands, logic requirements and control programs, which are conventionally required by the user of the corresponding production module, from the desired operations which the corresponding production module is to perform, into the control program code. In this way, it is possible for almost any user of the module factory, in particular for an engineer in training, to incorporate complex electronic production modules into the optimization of the production line, to practice their use, to learn advantages and disadvantages and to match the production modules to the desired task and to integrate them into the production line, with only short instructions.

Preferably, the at least one production module which can be controlled by means of the electronic control unit is a robot module, a digital worker guidance module (Werkerf ü hrungsmodule), an RFID tracking module, a 3D printing module, a computer-aided (CAx) module and/or a "light pick-up (pick-by-light)" module, in particular in the form of an "active roof light".

The robot modules used in the preferred configuration of the module factory are for example provided for performing different functions, such as gripping, transporting, loosening and/or tightening. Preferably, different functions can be performed sequentially, resulting in complex actions. In addition or alternatively thereto, the robot module can have a bolt transmitter which separates the bolts or other small parts required for production and which is preferably provided in a specific orientation so that it can be gripped by a robot module which can be part of the same or a further robot module. Preferably, the robot module can be used in almost any location of the module factory. It is easily fixed on shelves, work tables and other elements of the module factory and has an interface by means of which a data connection to the electronic control unit can be established, preferably anywhere within the module factory.

The third data interface is provided for easy and fast conversion of parameters entered by a user of the modular plant into control program code, for example in the form of a Graphical User Interface (GUI). Different sequences corresponding to the individual movements or actions of the robot module can be programmed by means of input data entered via the input device, and a sequence order which can be composed of a plurality of sequences can also be realized in the module factory. This can be achieved easily and with little pre-training and in particular without programming knowledge by means of the third data interface.

Advantageously, the robot module has one or more cameras by means of which the environment of the robot module is detected. The semifinished product produced during the production process, which is suitable for optimization by means of a modular factory, can preferably be stored in the form of an image, in particular a photograph, and be recognized by an image recognition program in the image detected by the at least one camera. The third interface is preferably provided in this case to enable storage of images representing individually manufactured and different production phases, for example by pulling them into the desired position in a "drag and drop" method. In this way, not only the sequence or sequence order to be executed by the robot module respectively can be programmed, but also the point in time at which the robot module is to be involved in the production process (optimized in the module factory) can be adjusted and personalized individually and almost without prior training of the programming technique.

Advantageously, a region of the semifinished product to be gripped, handled and/or manipulated can be predefined, for example, wherein the accuracy of the designation of the region is variable. It is thus possible to specify a precise position and/or orientation of the semifinished product or, for example, to identify a region on the table in which the robot module finds the semifinished product to be handled. By means of the images taken by the at least one camera, which are compared with the stored images, the robot module with the electronic control unit is able to autonomously detect the exact position and orientation of the semi-finished product and control the robot module such that the desired sequence can be performed.

At least one production module which can be controlled by means of an electronic control unit advantageously has a lamp which is known, for example, from the exhibition technology (veranstattenblack) as a "moving roof" lamp. It can be rotated over a wide angular range and preferably emits a clearly delimited light beam which, when it falls on a surface several meters away, produces a spot of, for example, 0.5m, 0.25m or 1cm in diameter. The lamp is preferably arranged in the space where the module factory is located. It is advantageous here that as many modules of the module factory as possible can be illuminated by the illumination lamp. In combination with switches, for example in the form of push-buttons, which can be actuated by the user of the module factory, in this way a simple yet effective logistics system can be implemented into the module factory.

If, for example, raw materials, components, semi-finished products or tools are required at the workstations of the module factory, the personnel can actuate the respective keys at the respective workstations. In a particularly simple embodiment, the illumination lamp illuminates a specific workstation in this case, so that the logistics personnel can know where the need is. Furthermore, if an input element is arranged on the workstation, by means of which it is possible to input which component is required, for example, this can be transmitted by color coding of the light beam emitted by the lamp. It is of course also possible, for example, for the illumination lamp to first illuminate an area in a warehouse or a rack, which is preferably likewise part of the module factory, in which area the desired components, semi-finished products or tools can be found, and to illuminate the target location only after the logistics personnel have indicated, for example by means of a handling element, that the desired element has been received.

Possible parameters in the form of input data that can be input are, for example, the position to be illuminated, the color used here, the geometry of the emitted light cone and the determined sequential order. Alternatively or additionally, this can be of the type that is attached to individual or all production modules or additional input devices, for example in the form of operating elements.

The input device is designed, for example, as a touch screen or a computer keyboard, by means of which the input data can be input. It is also conceivable to arrange a microphone as long as the electronic control unit is arranged to be controlled, for example, by human speech.

Preferably, the at least one production module controllable by means of the electronic control unit comprises at least one module for digital quality assurance. This preferably comprises at least one camera, the image of which is supplied to an electronic data processing device, which is preferably an electronic control unit or at least a part thereof. In addition to or instead of using the images to control the robot module, the data processing device can also use the images generated in this way to guarantee quality, to certify quality and to track workpieces, tools or semi-finished products. The images recorded by the at least one camera are compared as actual images with reference images stored in the electronic data processing device, so that, for example, the screw connections, the mounted components and/or their position and orientation can be checked, rejected if necessary (branded), and recorded.

The module factory preferably allows at least one camera to be arranged at virtually any position and in virtually any orientation on other modules, in particular on production modules, work tables, shelf elements and/or transport elements. The at least one camera preferably has a device with which a data connection to the electronic control unit can be established wirelessly.

Preferably, at least one production module which can be controlled by means of an electronic control unit has a module for digital plant planning. In this way, for example, the spatial arrangement of the different modules, components and elements of the module plant can be planned electronically and virtually and, for example, 2-dimensional or three-dimensional images can be displayed on a screen. For this purpose, the CAD data of a plurality of, preferably all, production modules are preferably stored in an electronic data processing device, preferably in an electronic control unit. They are preferably able to be moved across the touch screen by "drag and drop" and positioned as desired. If necessary, there is also an interface to the virtual world (e.g. in the form of VR glasses) to make the planning more realistic and complete.

The digital plant planning preferably also includes the possibility of establishing, checking and, if necessary, discarding and changing the transport relationships between the different production modules. Particularly preferably, for the different production modules, the respective requirements for raw materials, components, semi-finished products and/or tools and the respective production results of the respective production modules are stored, so that logistic chains and logistic flows can be generated easily and almost without prior training of programming techniques.

Preferably, at least one of the production modules also has a sensor by means of which components, raw materials, semi-finished products and/or tools can be detected and tracked. This can be, for example, an RFID sensor, by means of which the position of the respective component is determined. Other sensor forms, such as a camera, are of course also conceivable. Particularly preferably, at least one of the sensors is adapted to recognize the position of the person in space, so that, for example, a movement sequence carried out by the respective person when using the modular plant can be detected, digitally stored and recalled. In this way, the production process can be optimized and the movement process can be reduced.

Preferably, at least one production module allows the generation of a digital projection or a digital map. Furthermore, the work results achieved when using the modular plant can be stored and deposited by digital plant planning, so that further improvements and optimizations can be carried out at a later point in time. This is particularly advantageous when the module factory is used by a plurality of participants before the respective preceding participant has finished its work and optimization.

Preferably, the different production modules can be used independently of one another and in different combinations with one another, wherein preferably only an electronic control unit is necessary. In particular, the entire logistic chain of the module plant can be used and optimized separately and independently from the rest of the module plant. The production modules of the logistics, which can be controlled electronically, are for example unmanned aerial vehicles or self-propelled transport systems. The parameters of these modules are, for example, the starting and/or end points of the movement, the respective path which should be traversed between the starting and end points and/or the type, size, shape and/or weight of the object to be transported. These parameters can also be entered in the form of input data via an input device and converted into control program code by the electronic control unit. Of course, these modules can also be combined with other modules, for example robot modules. The robot modules are preferably configured such that they are configured for human-robot communication and, for example, identify a human being located in the area of, for example, a robot arm or close to a hazardous area caused by the robot modules.

The production module which can be controlled by means of the electronic control unit is preferably a computer-aided module. For example, a construction module (e.g., a CAD module) or a computer-aided manufacturing module (CAM module) can be considered. Computer-supported quality assurance modules (e.g., CAQ modules) can also be used. All these computer-assisted modules are configured in such a way that the parameters required by the control module can be input via the input device in the form of input data, which are subsequently converted into control program code via the third data interface. This can be achieved, for example, by means of a graphical user interface and/or a web-based input device, such as a browser window, as with all of the modules described herein.

Additionally or alternatively, the production module can also be a 3D scanner and/or a 3D printer.

Preferably, the electronic control unit is arranged for controlling a plurality of production modules. The construction of the module factory is thereby simpler in construction, since there is no need to use a separate electronic control unit for each production module to be electronically controlled. In this case, it is particularly preferred that the third data interface is provided for assigning the input data entered into the unique input mask of the input device to different production modules and converting it into a corresponding control program code for each production module to be controlled. The control program code can be converted into control commands for the respective production module via the second data interface and transmitted to the production module, where these control commands are converted into control signals in the first data interface and control the production module.

Preferably, the modular factory has a plurality of work stations and/or a plurality of shelving elements and/or a plurality of transport elements, which preferably can be freely combined with each other and connected to each other. In this case, for example, the table can have different heights, different widths and/or different lengths and/or can be adjusted to at least one, preferably all, of these dimensions. As the different work stations can be used with each other, it is also possible to create the following stations, which are defined by: a defined process or work step of the production line is carried out on one of the work stations. In this case, different workstations can have different work stations, if required by different work steps of the production line.

The same applies to the shelf elements. These shelf elements can also be designed as shelves, receiving elements for preferably removable boxes and boxes or drawers. They can have different heights, widths and/or depths and can be adjusted to one of these dimensions, but preferably all dimensions. In this way, the shelf elements optimized for the respective workstation can be combined and connected to one another in such a way that they are adapted on the one hand to the process to be carried out at the respective workstation and on the other hand to the individualized physical condition, for example the height of a person. For example, the drawers, boxes or cassettes can be positioned so that their dimensions match the elements and components they contain, and their positions selected so that they can be comfortably and ergonomically used by a person using the workstation.

The transport elements comprise, for example, roller plates, conveyor belts or other elements with which the elements, semi-finished products, workpieces and/or raw materials can be transported along the work table or from one work station to an adjacent work station. These elements can also preferably be freely combined and connected to one another, so that a combination and configuration that is optimized for the respective task is achieved.

Preferably, the work platform and/or the shelf element and/or the transport element have at least one connection interface, which can be connected to at least one correspondingly configured connection interface of the electronic control unit, so that a data connection is produced. This can be achieved, for example, by a plug connection, wherein one part of the plug connection forms one connection interface and another part of the plug connection forms the other connection interface. If, for example, electronic components (for example sensors, cameras, keys or operating elements) are used for the electronically controllable production modules, these electronic components can be easily fixed to the respective work table, shelf element or transport element and connected to the connection interface, so that in this way a data connection to the electronic control unit can be established particularly easily, in a structurally simple manner and also easily adapted.

Preferably, this plug connection not only makes possible a data connection to the electronic control unit, but also simultaneously a mechanical connection of the different production modules.

In a preferred embodiment, the data connection is a wireless data connection, which is preferably established via WLAN and/or bluetooth. The work table, the shelf element and/or the transport element have a transmission/reception device, by means of which corresponding data can be transmitted and received. In this way, elaborate wiring is superfluous, so that the different components and modules as well as the work tables, shelf elements and/or transport elements can also be connected to one another in a simpler manner and in a more diversified manner.

In particular, the table, the shelf element and/or the conveying element are preferably mounted movably, for example on rollers. In this way, different stations can be quickly established, which can be produced by different combinations of work tables, shelf elements and/or transport elements, and can be changed in position and orientation relative to one another.

Preferably, different work stations, shelf elements or transport elements have separate power supply devices, for example batteries or accumulators. Alternatively or additionally thereto, the power supply device is arranged on top of the space where the module factory is located, so that the cables can be laid from a position on the ceiling to a desired position, preferably at any position of the space. This further increases the modularity of the module factory and further increases the variation in the composition of the different modules and thus further increases the flexibility of the module factory.

Furthermore, with such a module factory, it is also possible to give lessons to users in the subject areas of lean management methods such as the continuous improvement process (KVP), KATA or PDCH method (Plan Do Check Act), and employee or human resource management, team competence, and human resource development, while optimizing the production line and giving feedback and feedback. Preferably, when the production line is generated within the module factory, the user of the module factory is photographed, for example, at least temporarily, in order to be able to provide feedback, improvement recommendations and feedback by means of the recorded operations. Group dynamic experiences, such as the autonomous organization (KVP) of a group of people without formal guidance, can also experience, record, and be used for lectures and training themselves, such as feedback dialogues, individual development sessions, and delegation and distribution of tasks and responsibilities.

Drawings

Embodiments of the invention are explained in detail below with the aid of the figures. It shows that:

figure 1 is a schematic view of a module factory according to a first embodiment of the invention,

figures 2 to 5 shelf elements of different filling degrees and sizes,

FIG. 6 additional shelf member, and

fig. 7 a combination of elements.

Detailed Description

Fig. 1 shows a schematic structure of a module factory. It has a plurality of production modules 2, all of which can be controlled by an electronic control unit 4 in the embodiment shown. The production module 2 can be configured in various embodiments and can in particular be or at least have a robot module.

A user who wants to use the production module 2 and integrate it into the production line that he wants to build must first program it and match it to the desired task and personalization requirements. For this purpose, the electronic control unit 4 is connected to an input device 6. The input device can be, for example, a touch screen, a keyboard or a microphone, wherein in the last case the electronic control unit 4 is provided for reacting to voice commands. Data are input via the input device 6, which are transmitted via the first data line 8 to the electronic control unit 4. It can be seen that a first data line 8 is introduced into the control unit 4, wherein the first data line 8 can be designed with a wired or wireless connection. The input data transmitted from the input device 6 via the first data line 8 to the electronic control unit 4 now arrive at the third data interface 10 and are converted there into control program code.

The control program code is transmitted via a second data line 12 to a second data interface 14, which converts the control program code into control commands. The second data interface 14 and the third data interface 10 can be part of a single electronic data processing device together with the second data line 12 or can be designed as separate data processing devices and data transmission devices. In particular, both the second data interface 14 and the third data interface 10 and the second data line 12 can be a computer program product, in particular software.

After conversion of the control program code into control commands in the second data interface 14, the control commands are transmitted via the third data line 16 to the respective production module 2, which in each case has a first data interface, not shown, in which the received control commands are converted into control signals, which are converted into the desired activity by the respective production module 2.

Furthermore, the module factory schematically illustrated in fig. 1 has various sensors, for example a camera 18 and an RFID sensor system 20, which represent, by way of example, various sensors by means of which measured variables of the environment of the module factory can be sensed. The measurement data of these sensors are transmitted via further data lines to the electronic control unit 4 or to further electronic data processing devices, processed in the respective processing module 22 and then supplied to the respective production modules 2, which require said data, in particular, for carrying out the desired sequence or sequence order. In the embodiment shown, this is only the case in the production module 2 shown at the bottom.

Furthermore, the module factory schematically illustrated in fig. 1 has a lamp 24 which, in the framework of logistic applications, for example illuminates the location, workstation or production module to be operated on. The operation can, for example, comprise providing a raw material, a component, a semi-finished product or a tool.

Fig. 2 shows a shelf element 26 with four shelves 28 in each of which a plurality of boxes 30 are arranged, which boxes can contain, for example, components, raw materials or tools required in the stations of a modular factory. The frame of the shelf element 26 shown in fig. 2 is composed of a plurality of tube elements and can be supplemented, i.e. in particular expanded or lengthened, on the basis of this simple modular construction, in order to be able to accommodate further or additional boxes 30.

Fig. 3 shows the shelf element 26 of fig. 2 without the box 30. Roller guides 32, on which the box 30 shown in fig. 2 is arranged, can be seen. Due to the inclination of the roller guides 32, the boxes 30 arranged as shown in fig. 2 always roll forward in fig. 2 and 3, so that they are positioned in the operating area of the respective station, a part of which is the shelf element 26.

The roller guides 32 are also modules which form the shelf element 26, as are the different tube elements which form the frame of the shelf element 26. As a result, they can be arranged at any desired distance on the respective cross tube, which is preferably effected detachably, in particular by means of a clamping connection. Fig. 4 and 5 show a shelf element 26, which differs from the shelf element 26 in fig. 2 and 3 only in that the roller guides 32 are arranged at a small distance from one another on the respective transverse tubes of the frame of the shelf element 26. Thus, the tank 30 shown in fig. 4 is smaller than the tank 30 shown in fig. 2. Of course, boxes 30 of different sizes can also be combined in a single shelf element 26, for example, by arranging roller guides 32 at corresponding distances.

Fig. 6 shows a table 34 on which a further transport element 36 in the form of a roller guide is arranged. The table 34 is supported on rollers and can therefore easily be brought into further positions. The table 34 is also constructed modularly and can be assembled and used in different positions, sizes and orientations. The table has pipe elements 38, which correspond to those in fig. 2 to 5 and on which roller guides, in this case transport elements 36, are arranged. Additionally or alternatively, a robot module or other production module can also be arranged on the tube element 38.

FIG. 7 illustrates a workstation of a module factory according to one embodiment of the invention. The workstation has a work table 34 on which transport elements 36 in the form of roller guides are arranged. The work table 34 is connected to shelving members 26 containing bins 30 of different sizes. Furthermore, the lighting device 40 and the hook element 42 are located in the upper region, on which, for example, unnecessary tools or cables can be suspended or guided along. On the roller guide, a transport plate 44 is shown, on which the object to be produced is arranged.

List of reference numerals

2 production module

4 electronic control unit

6 input device

8 first data line

10 third data interface

12 second data line

14 second data interface

16 third data line

18 vidicon

20 RFID sensor system

22 processing module

24 lamp

26 shelf element

28 shelf

30 boxes

32 roller guide device

34 working table

36 transport element

38 pipe element

40 Lighting device

42 hook element

44 transport plates.

Claims (7)

1. A module factory for generating a production line, wherein the module factory has:

-a plurality of production modules, and

-an electronic control unit for controlling the operation of the electronic control unit,

the electronic control unit is arranged for controlling at least one of the production modules, wherein,

-the at least one production module has a first data interface arranged for converting control instructions received from the electronic control unit into control signals,

-the electronic control unit has a second data interface arranged for converting control program code into the control instructions, and

-the electronic control unit has a third data interface arranged for converting input data input through an input device into the control program code.

2. The module factory according to claim 1, wherein the at least one production module controllable by means of the electronic control unit is a robot module, a digital worker guidance module, an RFID tracking module, a 3D printing module, a computer aided (CAx) module and/or a light picking module, in particular in the form of an "active head light".

3. A modular plant according to claim 1 or 2, characterised in that the electronic control unit is arranged for controlling a plurality of production modules.

4. The modular factory according to any of the preceding claims, wherein the modular factory has a plurality of work tables and/or a plurality of shelving elements and/or a plurality of transport elements which preferably can be freely combined and interconnected with each other.

5. The modular factory according to claim 4, wherein the work tables and/or shelving elements and/or transport elements are interconnectable such that the at least one production module controllable by means of the electronic control unit is usable on all interconnected work tables and/or shelving elements and/or transport elements.

6. The modular factory according to claim 5, wherein the worktables and/or the shelving elements and/or the transport elements have at least one connection interface which can be connected with a correspondingly configured connection interface of the electronic control unit in such a way that a data connection is formed.

7. A modular factory according to claim 6, wherein the data connection is a wireless data connection, preferably WLAN and/or Bluetooth.

Images