CN112099462B

CN112099462B - Flexible manufacturing scheduling system and manufacturing system comprising same

Info

Publication number: CN112099462B
Application number: CN202011300596.9A
Authority: CN
Inventors: 张文慧; 弓瑜; 潘宏祥
Original assignee: Phoenix Nanjing Intelligent Manufacturing Technology Engineering Co ltd
Current assignee: Phoenix Nanjing Intelligent Manufacturing Technology Engineering Co ltd
Priority date: 2020-11-19
Filing date: 2020-11-19
Publication date: 2021-03-09
Anticipated expiration: 2040-11-19
Also published as: CN112099462A

Abstract

The invention provides a flexible manufacturing scheduling system and a manufacturing system comprising the same. The flexible manufacturing scheduling system may include a processor. The processor may be configured to: receiving order information; one or more of the at least one controller is controlled based on preprogrammed scheduling logic corresponding to the order information to cause the controller to control the action of the at least one implement to fulfill the order task. Scheduling logic is a set of instructions needed to fulfill the order task that can be identified and executed by the controller.

Description

Flexible manufacturing scheduling system and manufacturing system comprising same

Technical Field

The present disclosure relates to the field of automated manufacturing, and more particularly, to a lightweight flexible manufacturing scheduling system and a manufacturing system including the same.

Background

The traditional large-scale automatic production line needs a Manufacturing Execution System (MES) and a production line control system to cooperate with each other to carry out scheduling and control of production and manufacturing. The main function of the MES is scheduling, that is, issuing the order to the equipment. Devices can be divided into two categories: one type is a standardized production line, usually only one product or product with similar process parameters is produced, and the scheduling logic is relatively simple, so the scheduling logic is generally written in a control system such as a PLC (programmable logic controller); the other type is a hybrid production line, which is suitable for the production of multi-variety and small-batch products, the scheduling logic is relatively complex, and if the corresponding scheduling logic is written into the PLC, the scheduling logic is relatively complex and difficult to realize. However, if a conventional large MES is applied to the multi-variety and small-lot hybrid production line, cost efficiency cannot be achieved.

Therefore, a need exists for a lightweight flexible manufacturing scheduling system for small production lines.

Disclosure of Invention

One aspect of the present disclosure provides a flexible manufacturing scheduling system communicatively coupled with at least one controller, each controller for controlling at least one actuator. The flexible manufacturing scheduling system may include a processor. The processor may be configured to: receiving order information; one or more of the at least one controller is controlled based on preprogrammed scheduling logic corresponding to the order information to cause the controller to control the action of the at least one implement to fulfill the order task. Scheduling logic is a set of instructions needed to fulfill the order task that can be identified and executed by the controller.

In one example implementation, the scheduling logic may be a set of instructions needed to fulfill the order task that can be recognized and executed by the controller.

In one example implementation, the instruction set may include one or more scheduling instructions that are recognizable and executable by the controller.

In one example implementation, the scheduling instructions may indicate one or more control steps required to fulfill the order.

In one example implementation, the processor may be further configured to send one or more scheduling instructions to the corresponding controller.

In one example implementation, the controller may be configured to generate control instructions for controlling the action of the at least one actuator based on the scheduling instructions.

In one example implementation, the order information may be obtained from a manufacturing execution system MES.

In one example implementation, the flexible manufacturing scheduling system may communicate with the at least one controller via a first communication protocol and communicate with the MES via a second communication protocol different from the first communication protocol.

In one example implementation, the first communication protocol may be OPC UA.

In one example implementation, the flexible manufacturing scheduling system may further include an ordering system for receiving user input to generate order information and communicating the order information to the processor.

In one example implementation, the flexible manufacturing scheduling system may further include a local client. The local client may be configured to present statistical analysis information from the at least one controller indicative of operating state data of the at least one actuator, performance of the production task, and the production data.

In one example implementation, a local client may exchange data with a processor through a socket.

Another aspect of the present disclosure provides a manufacturing system, comprising: at least one actuator; at least one controller, each controller for controlling one or more of the at least one actuator; and a flexible manufacturing scheduling system communicatively coupled to at least one controller, each controller for controlling at least one actuator. The flexible manufacturing scheduling system may include a processor. The processor may be configured to: receiving order information; one or more of the at least one controller is controlled based on preprogrammed scheduling logic corresponding to the order information to cause the controller to control the action of the at least one implement to fulfill the order task. Scheduling logic is a set of instructions needed to fulfill the order task that can be identified and executed by the controller.

Yet another aspect of the present disclosure provides a manufacturing system, comprising: manufacturing execution system MES; at least one actuator; at least one controller, each controller for controlling one or more of the at least one actuator; and a flexible manufacturing scheduling system communicatively coupled to at least one controller and the MES, each controller for controlling at least one actuator. The flexible manufacturing scheduling system may include a processor. The processor may be configured to: receiving order information from the MES; one or more of the at least one controller is controlled based on preprogrammed scheduling logic corresponding to the order information to cause the controller to control the action of the at least one implement to fulfill the order task. Scheduling logic is a set of instructions needed to fulfill the order task that can be identified and executed by the controller.

Drawings

In order to more clearly illustrate the embodiments of the present invention, the drawings, which are needed to be used in the embodiments and are described below, will be briefly described.

FIG. 1 is a block diagram illustrating an example flexible manufacturing scheduling system 100, according to an embodiment.

FIG. 2 is a schematic diagram illustrating the cooperative relationship of units in an example flexible manufacturing scheduling system 100, according to an embodiment.

Detailed Description

The technical solutions of the present invention will be described more clearly and completely with reference to the accompanying drawings, and the described embodiments are only some embodiments, not all embodiments, of the present invention. All other embodiments, which can be obtained by a person skilled in the art without inventive step based on the embodiments of the present invention, will fall within the scope of the present invention.

In the following description, numerous specific details are set forth. However, it is understood that embodiments of the invention may be practiced without these specific details. In other instances, well-known circuits, structures and techniques have not been shown in detail in order not to obscure an understanding of this description.

References in the specification to "one embodiment," "an example embodiment," etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to affect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

For the purposes of this disclosure, the phrase "a and/or B" means (a), (B), or (a and B). For the purposes of this disclosure, the phrase "A, B, and/or C" means (a), (B), (C), (a and B), (a and C), (B and C), or (A, B and C).

For a small production line or a demonstration type production line, the cycle is short, the cost is low, the self-defining degree of flow logic is high, and the introduction of MES has no cost benefit. If the corresponding scheduling logic is written to the PLC, it is relatively complex and difficult to implement. Moreover, the PLCs of each manufacturing execution unit may be independent of each other and need to be modified separately. On the other hand, in the case of adding such a small production line to a large production line to which an MES is applied, the MES needs to be modified to accommodate the newly added production line. However, MES is large in size, making such modifications to small production lines is also not cost effective, and such modifications can result in the entire system being inoperable and often not being able to be made.

The flexible manufacturing scheduling system of the present disclosure can serve as an intermediate layer between the MES and the production line control equipment, and can also realize a part of functions of the MES to meet the automatic production needs when the production line does not reach the scale (such as a small-scale production line, a demonstration display line, etc.) of the MES to be docked. The flexible manufacturing scheduling system disclosed by the invention has the necessary functions of intelligent production, such as equipment data, order management, energy management, process data, production inspection, quality tracing and the like, and can be better suitable for a small-scale production line. Meanwhile, the flexible manufacturing scheduling system disclosed by the invention integrates the function of production line control, dynamically manages and constrains the material in and out of the warehouse, monitors and intelligently schedules the production process in real time, reduces the field management difficulty and realizes flexible production.

In addition, each application developer has its own communication system in the process of data exchange between the MES system and the field PLC. Some developers with strong technical strength own perfect communication systems and have communication standards of themselves. However, most developers do not form their own communication systems, and the development process of the communication module is performed simultaneously along with the development process of the application program. Due to the reasons, the MES may not be uniform with the communication standard between the equipment PLCs, the development of a communication module is complex, and the use and maintenance of an end user are not facilitated. The flexible manufacturing scheduling system of the present disclosure as an intermediate layer between the MES and the PLC can extend the communication interface of the PLC, enabling it to interface with MES of other communication types or other external systems, such as WMS (warehouse management system).

OPC UA (object oriented linking and embedding) unified architecture) described herein is a communication standard for secure transfer of data between different systems in important industrial networks and critical infrastructure networks, and is an improved version of OPC. In various embodiments, OPC UA may also be replaced with OPC or other communication standards without affecting the implementation of the present disclosure.

Socket (Socket) described herein is an abstraction of an endpoint for two-way communication between different application processes in a network, a technique for accomplishing data transfer between two applications.

FIG. 1 is a block diagram illustrating an example flexible manufacturing scheduling system 100, according to an embodiment. The system 100 includes a local server 3 for communicably connecting with an AGV dispatch system 4 on a production line and unit devices PLC 5 for controlling unit actuators and sensors 7 to perform the various functions described in this disclosure. The local server 3, as a carrier for the lightweight flexible manufacturing scheduling system of the present disclosure, can interface as an intermediate layer with a traditional MES. Of course, the local server 3 may also individually control the AGV dispatching system 4 and each unit device PLC 5 to implement intelligent dispatching.

The local server 3 includes a local database 32, a local server-side program 34, a local client program 36, and an OPC UA server 38.

The local server side program 34 serves as a processing unit for scheduling, data exchange, etc. of the production units. The local server side program 34 performs Socket communication with the Socket client 362 of the local client program 36 through the Socket server 342. The local server side program 34 also communicates OPC UA with the OPC UA server 38 via the OPC UA client 344. The OPC UA server 38 exchanges data with each unit device PLC 5 through OPC UA communication. Or the local server program 34 can exchange data with each unit device PLC 5 through a database mode. The AGV dispatching system 4 communicates with the AGV6 through a Socket protocol.

The local client program 36 may be used to present the operating status data of the current production equipment, the performance of production tasks, and statistical analysis of the production data. Specifically, the data from each unit device PLC 5 is received by the local server-side program 34 via the OPC UA server 38 and the local database 32. Local server-side program 34 may communicate the processed data to local client-side program 36 via Socket communications for display on an output device such as a display.

The local database 32 has stored therein, but is not limited to, order information, executive component status data, sensor data, inspection data, etc. to implement various intelligent production functions.

As mentioned above, the MES is primarily responsible for scheduling. In the production and manufacturing of enterprises, production plans are made for a certain period of time based on materials, personnel, production equipment and other factors. Then, the production is carried out according to the prior production plan by utilizing the factors of the existing materials, personnel, production equipment and the like. The MES can determine production planning data for the goods over the predetermined time period. The production plan data carries the quantity of goods expected to be produced in the predetermined time period. However, the production plan data does not directly realize the control of each unit execution part and the sensor 7.

For example, a humidification plan using a humidifier involves various links such as the state of the humidifier, the transportation of materials, the start-up of the humidifier, and the state monitoring. These control scheduling logic are difficult to program into the devices PLC 5 of the various execution blocks. In the case of small production lines, modifying an MES to implement scheduling logic is not cost effective, even some small production lines may not have an MES originally.

The local server 3 of the present embodiment stores in advance scheduling logic corresponding to order information in the local database 32. Taking a humidification order as an example, example scheduling logic may include:

step 1) judging whether the PLC 5 is in an idle state. If yes, entering the step 2), otherwise, executing the step 1) again;

and 2) judging whether a sensor at the inlet of the humidifying system detects the material tank. If yes, entering the step 3), otherwise, executing the step 2) again;

and 3) judging whether the humidifier has an idle humidifying position. If yes, entering the step 4), otherwise, executing the step 3) again;

and step 4) sending an instruction to the PLC 5 to grab the humidifying box from the waiting area to the box reversing mechanism. Then entering step 5);

and step 5) judging whether the result message from the PLC 5 indicates that the task is successfully executed. If yes, entering step 6), otherwise, entering an exception handling process;

and step 6) sending an instruction to the PLC 5 to scan codes of the humidifying boxes on the box reversing mechanism. Then step 7) is carried out;

and 7) judging whether the result message from the PLC 5 indicates that the task is successfully executed and contains bar code information. If yes, entering step 8), otherwise, entering an exception handling process;

and 8) judging whether the bar code information is consistent with the system record. If yes, entering step 9), otherwise, entering an exception handling process;

and step 9) sending an instruction to the PLC 5 to enable the motor of the box pouring mechanism to rotate. Then entering step 10);

step 10) determines whether the result message from the PLC 5 indicates that the task was successfully performed. If yes, entering step 11), otherwise, entering an exception handling process;

and step 11) sending an instruction to the PLC 5 to grab the material tank from the inlet of the humidifying system to the tank dumping mechanism. Then step 12) is entered;

step 12) determines whether the result message from the PLC 5 indicates that the task was successfully performed. If yes, entering step 13), otherwise, entering an exception handling process;

and step 13) sending an instruction to the PLC 5 to scan codes of the material boxes on the box reversing mechanism. Then step 14) is entered;

step 14) determines whether the result message from the PLC 5 indicates that the task was successfully performed. If yes, entering step 15), otherwise, entering an exception handling process;

step 15) communicating with a WMS (warehouse management system) system to obtain material information, a humidifying program number and the like according to the bar code information of the material box; recording and binding bar code information of the humidifying box and the material box on the box reversing mechanism; and sending a command to the PLC 5 to rotate the motor of the box pouring mechanism. Then step 16) is entered;

step 16) determines whether the result message from the PLC 5 indicates that the task was successfully performed. If yes, entering step 17), otherwise, entering an exception handling process;

step 17) sending an instruction to the PLC 5 to grab the humidifying box containing the material to a humidifying position (meanwhile, sending a humidifying program number to the PLC 5). Then step 18) is entered;

step 18) determines whether the result message from the PLC 5 indicates that the task was successfully performed. If yes, entering step 19), otherwise, entering an exception handling process;

step 19), the PLC 5 sends the humidification program number to the humidifier and informs the humidifier to start the humidification program;

and sending a command to the PLC 5 to rotate the motor of the box pouring mechanism. Then step 20) is entered;

step 20) determines whether the result message from the PLC 5 indicates that the task was successfully performed. If yes, entering step 21), otherwise, entering an exception handling process;

step 21) sends an instruction to the PLC 5 to grab the empty bin to the waiting area.

An example scheduling logic is described above to facilitate an understanding of the present disclosure, and the scheduling logic may be designed arbitrarily.

Each PLC 5 controls one or more execution units and/or sensors connected to the PLC 5 to execute operations in accordance with a scheduling command from the local server 3. It should be noted that the scheduling logic is essentially a set of instructions that can be recognized and executed by the PLC 5 that are needed to fulfill the order task, including one or more scheduling instructions for the PLC 5, as shown by the above example scheduling logic. The scheduling instructions may indicate one or more control steps required to fulfill the order, such as the code scanning step, the grabbing step, etc., described above. The scheduling logic may also include one or more scheduling control instructions that are not executed by the PLC 5, such as the decision steps described above. The scheduling instructions typically cannot directly control the execution units and the sensors 7. The PLC 5 can analyze the scheduling command and generate a control command to control the corresponding one or more actuators and/or sensors to operate. For example, during the motion of a robotic arm, the cooperation of multiple mechanical structures and/or electrical components (such as cylinders, motors) is required. The PLC 5 converts a scheduling command indicating the operation of the robot arm into a control command for a mechanical structure or an electrical component involved in the operation. Specific operating parameters (e.g., six-axis coordinates corresponding to the corresponding actions performed by the robot arm) may be pre-stored in the execution component (e.g., the robot arm) to facilitate retrieval by the PLC 5. It should be understood that the scheduling instructions and scheduling control instructions may take into account information such as the results of execution or status data from the PLC 5.

In an implementation not as an intermediate layer between the PLC 5 and the MES, the system 100 may include an ordering client 1 and a cloud server 2 to form an ordering system, so as to implement the order obtaining and managing functions. The user may place an order through the ordering interface 12. The order information is transmitted to the local server 3 via the cloud server 2. In some embodiments, the ordering system may be provided with a face recognition function to realize user identity authentication.

During the production process, the local server 3 may send information related to the real-time production status to the cloud server 2, and present the information to the user through the ordering client 1. When the order is completed, the order placing client 1 can prompt the user, and the goods taking can be completed through face recognition verification again. This applies in particular to demonstration production lines.

In order to implement order management, the local server 3 may obtain the issued order from the cloud server 2. The local server program 34 splits the order into device tasks according to the scheduling logic corresponding to the order information, and issues the device tasks to each unit device PLC 5 through the local database 32 or the OPC UA server 38 to control the unit execution component (e.g., robot) to fulfill the order. Local server side program 34 also issues dispatch logic to AGV dispatch system 4 to dispatch AGV6 to perform the transport tasks. Each unit device PLC 5 transmits the feedback result of each task to the local database 32 of the local server 3 or the OPC UA server 38. The local server 3 feeds back the received feedback result to the cloud server 2 so as to push the order progress to the ordering client 1 in real time. Order information is also stored in the local database 32 to facilitate statistical analysis of the data.

The data interaction mode between the local server 3 and each unit device PLC 5 may be OPC UA, or other communication standards. The data of the interaction may include: equipment state, alarm information, sensor state, energy consumption information, task progress and the like, so as to realize the functions of equipment data, energy management and process data. In some embodiments, the local server 3 may interface with the MES or other external system (e.g., WMS) to enable extension of the PLC 5's communication interface, with a communication standard different from that of the PLC 5.

Some of the execution units may be equipped with a machine vision system such as a camera. The product can now be photographed and inspected using machine vision techniques. The device PLC 5 can feed back the inspection data to the local server 3 along with the task execution progress information, and store the data in the local database 32, so as to perform statistical analysis on the data and implement quality tracing.

In order to dynamically manage and restrict the material in and out of the warehouse, the local server program 34 may obtain the position status of the material from the device PLC 5, issue a task of transporting the material to the AGV6 after analysis to the device PLC 5 and/or via the AGV dispatching system 4, or prompt a worker to perform material replenishment on an interface of the local client program 36, so as to implement the material in and out of the warehouse.

The manufacturing scheduling system 100 of the present disclosure integrates the production line control function, and can acquire order information from an ordering system, monitor the operation state of each unit in real time using a pre-programmed scheduling logic corresponding to the order information, intelligently schedule the production process, and issue unit tasks.

In addition, the manufacturing scheduling system 100 of the present disclosure can be deployed on a common industrial personal computer, thereby achieving light weight and saving hardware cost. As an intermediate layer between the equipment PLC 5 and the MES, the manufacturing scheduling system 100 of the present disclosure receives data from the equipment PLC 5 through the OPC UA and the database, and can perform data interaction with the MES in a protocol supported by the MES, and functions as an extended interface to the PLC.

Embodiments of the mechanisms disclosed herein may be implemented in hardware, software, firmware, or a combination of such implementations. Embodiments of the invention, such as the local server side program 34 and the scheduling logic, may be implemented as computer programs or program code executing on a programmable system including at least one processor.

One or more aspects of at least one embodiment may be implemented by representative instructions stored on a machine-readable medium which represent various logic in a processor, which when read by a machine causes the machine to fabricate logic to perform the techniques described herein.

The preferred embodiments of the present invention have been described above in detail. It will be appreciated that various embodiments and modifications may be made thereto without departing from the broader spirit and scope of the invention. Many modifications and variations will be apparent to those of ordinary skill in the art in light of the above teachings without undue experimentation. Therefore, the technical solutions available to those skilled in the art through logic analysis, reasoning and limited experiments based on the prior art according to the concept of the present invention should fall within the scope of protection defined by the claims of the present invention.

Claims

1. A flexible manufacturing scheduling system communicatively coupled to at least one controller, each controller for controlling at least one actuator, the flexible manufacturing scheduling system comprising:

a processor configured to:

receiving order information;

controlling one or more of the at least one controller based on preprogrammed scheduling logic corresponding to the order information to cause the controller to control the actions of the at least one implement to fulfill the order task,

wherein the scheduling logic is a set of instructions required to fulfill the order task that are recognizable and executable by the controller,

the instruction set includes one or more scheduling instructions recognizable and executable by the controller,

the scheduling instructions do not directly control the actions of the at least one implement, but rather indicate one or more control steps required to fulfill the order,

the controller is configured to interpret the scheduling instructions to generate control instructions to control the action of the at least one actuator,

the at least one actuator is configured to perform a corresponding action based on the control instruction and an operating parameter stored in the at least one actuator.

2. The flexible manufacturing scheduling system of claim 1, wherein the processor is further configured to send the one or more scheduling instructions to a corresponding controller.

3. The flexible manufacturing scheduling system of claim 1, wherein the controller is configured to generate control instructions for controlling the action of the at least one actuator based on the scheduling instructions.

4. The flexible manufacturing scheduling system of claim 1 wherein said order information is obtained from a Manufacturing Execution System (MES).

5. The flexible manufacturing scheduling system of claim 4, wherein the flexible manufacturing scheduling system communicates with the at least one controller via a first communication protocol and communicates with the MES via a second communication protocol that is different from the first communication protocol.

6. The flexible manufacturing scheduling system of claim 5,

the first communication protocol is OPC UA.

7. The flexible manufacturing scheduling system of claim 1 further comprising an ordering system for receiving user input to generate the order information and communicating the order information to the processor.

8. The flexible manufacturing scheduling system of claim 1, further comprising a local client configured to present statistical analysis information from the at least one controller indicative of operational status data, production task performance, and production data of the at least one actuator.

9. The flexible manufacturing scheduling system of claim 8 wherein the local client exchanges data with the processor through a socket.

10. A manufacturing system, comprising:

at least one actuator;

at least one controller, each said controller for controlling one or more of said at least one actuator; and

a flexible manufacturing scheduling system communicatively coupled to the at least one controller, each controller for controlling at least one actuator, the flexible manufacturing scheduling system comprising:

a processor configured to:

receiving order information;

the instruction set includes one or more scheduling instructions recognizable and executable by the at least one controller,

the at least one controller is configured to interpret the scheduling instructions to generate control instructions to control the action of the at least one actuator,

11. A manufacturing system, comprising:

manufacturing execution system MES;

at least one actuator;

a flexible manufacturing scheduling system communicatively coupled to the at least one controller and the MES, each controller for controlling at least one actuator, the flexible manufacturing scheduling system comprising:

a processor configured to:

receiving order information from the MES;