CN113031551B - Intelligent arrangement method and system for automatic production line of workshop - Google Patents
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Abstract
The invention discloses an intelligent arrangement method and system for a workshop automatic production line, wherein the production line comprises a main line, a split line and a cache region, and the intelligent arrangement method is characterized by comprising the following steps of: acquiring a production sequence and production comprehensive data of a real-time main line; optimizing the production sequence of the split lines and the inventory updating of the cache region according to the production sequence and the production comprehensive data of the main line; and determining that the production sequence of the main line is synchronously matched with the production sequence of the split lines. The system comprises an acquisition module, a processing module and a control module, wherein the acquisition module is used for acquiring a production sequence; the database is used for storing data and algorithms; the PAS system module is used for receiving the acquired information and calling an algorithm model to calculate a splicing line and a supplementary plan of a cache region; and the PLC module is used for receiving the production plan information to control the main line and the split line. The invention provides a steady production scheduling strategy for the part of the split line matched with the cache buffer. The most efficient production of a random continuous sequence of product types can be accomplished without breaking at a smaller buffer size.
Description
Technical Field
The invention relates to the technical field of intelligent arrangement of production lines, in particular to an intelligent arrangement method and system for an automatic production line of a workshop.
Background
With the development of full automation of production lines in manufacturing industry, unmanned operation of the production lines becomes more and more extensive. The full-automatic production line is introduced, so that the manpower resource cost of manufacturers can be saved, and the production efficiency of the production line can be improved due to the fact that manual operation errors can be reduced. However, there are often multiple line operations in a production line, for example, a main line for part assembly and a sub-assembly line for part production. Different types of products are often available on the main line, and the products need different parts to be assembled on the main line. If the automatic production assembly of the main line meets the condition of insufficient part inventory in the production of the split assembly line, the whole production line is stopped and restarted, and huge manpower and material resource loss is brought to a production workshop.
The defects of the prior art are that the traditional production line cannot automatically switch when the product types are changed for multi-type production, and unpredictable disturbances such as machine faults, insertion of sharp parts and the like are often generated in the production process, so that the production sequence of the main line is not coordinated with the production sequence of the sub-assembly line, the risk of main line production halt is generated, and huge loss is caused.
Disclosure of Invention
The invention aims to overcome the defects in the prior art, and in order to realize the aim, an intelligent arrangement method of a workshop automatic production line is adopted to solve the problems in the background technology.
An intelligent arrangement method for an automatic production line of a workshop, wherein the production line comprises a main line, a split line and a cache region, and comprises the following steps:
acquiring a production sequence and production comprehensive data of a real-time main line;
optimizing the production sequence of the split lines and the inventory updating of the cache region according to the production sequence and the production comprehensive data of the main line;
and determining that the production sequence of the split lines is synchronously matched with the production sequence of the main line.
As a further aspect of the invention: the specific steps for acquiring the production sequence and the production comprehensive data of the real-time mainline are as follows:
reading the RFID information of the vehicle body through a butt joint production line system to obtain a real-time production sequence;
and meanwhile, reading the production comprehensive data of the database, wherein the production comprehensive data comprises supply chain data, production plan data, equipment running state data and product tracking ID data.
As a further aspect of the invention: the specific steps of optimizing the production sequence of the split lines and updating the inventory of the cache region according to the production sequence and the production comprehensive data information of the main line are as follows:
establishing an optimization model, and automatically generating a production sequence corresponding to the split lines according to the production sequence of the main line;
judging whether the detected production sequence of the real-time mainline is the same as the plan or not;
if the main line sequence is different from the current main line sequence, the corresponding production sequence of the sub-assembly line is automatically generated according to the current latest main line sequence, and the material supplementing requirement of the cache bank at the side of the sub-assembly line is recalculated.
As a further aspect of the invention: the specific steps for establishing the optimization model are as follows:
obtaining the maximum time M of continuous production of a production line;
carrying out production time constraint, following the batch production in sequence and ending the production within the longest time M;
respectively carrying out the updating of the cache between the beginning production of one batch and the end of the production and the updating from the end to the production of the next batch;
maintaining the main line demand between the end of one batch production and the next batch production within the M time;
maintaining the main line demand between the beginning of production and the end of production of a batch in M time;
and in the M time, caching the buffer memory to be less than the maximum buffer memory amount.
As a further aspect of the invention: the specific steps of synchronously matching the production sequence of the main line and the production sequence of the split lines comprise:
current product type X according to main linetNumber g (X) remaining before type conversiont) And the number of cached products BF (X)t) Performing conversion judgment on the types of the main products;
firstly, judging whether the number of parts to be produced in a cache is less than the number of the parts left before type conversion;
then judging whether mb-g (X) existst)<BF(Yt) If the number of the split lines is less than the preset value, switching is not carried out, wherein mb is the number of the split line batches;
secondly, judging whether the number of the types of the parts with the least number in the cache is smaller than a preset threshold value, and determining whether the parts are supplemented;
and finally, judging whether the number of the current types of the residual continuous production is larger than a preset threshold value or not, and determining whether the cache is excessive or not.
The system comprising the intelligent arrangement method for the automatic production line of the workshop, which is described in any one of the above items, comprises the following steps:
the acquisition module is used for acquiring a real-time main line production sequence of the detection production line;
the database is used for storing production line data and a production line optimization algorithm;
the PAS system module is used for receiving the acquired production line data information and calling an algorithm model to calculate a splicing line and a supplementary plan of a cache region;
and the PLC module is used for receiving the production plan information to control the main line and the split line.
As a further aspect of the invention: the PAS system module is provided with a wireless communication module.
As a further aspect of the invention: and the signal output end of the wireless communication module is connected with the signal input end of the PLC module.
Compared with the prior art, the invention has the following technical effects:
by adopting the technical scheme, the RFID information is read by using the production line system to obtain the production sequence of the main line and the sub-assembly line, meanwhile, whether the main line production sequence changes or not is judged by taking the daily production plan data of a workshop as a reference, the material preparation in a cache region is realized, the part types of the sub-assembly line are changed in real time, the self-organization logistics distribution is carried out as required, the manual operation is not needed, and the synchronous matching of the production logistics of the main line and the sub-assembly line is ensured. Therefore, the problems that automatic conversion cannot be achieved when the product types are changed, main line products are assembled, and production line stop is caused due to the fact that sub-assembly line accessories cannot be accurately matched and produced are solved.
Drawings
The following detailed description of embodiments of the invention refers to the accompanying drawings in which:
fig. 1 is a schematic flow chart of a method for intelligently arranging a plant automation line according to some embodiments disclosed herein;
fig. 2 is a block flow diagram of a balancing algorithm of some embodiments disclosed herein.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, in an embodiment of the present invention, an intelligent layout method for an automatic production line of a workshop includes the specific steps of: .
S1, acquiring the production sequence and the production comprehensive data of the real-time main line, and the method comprises the following specific steps:
reading the RFID information of the vehicle body through a butt-joint production line system to obtain a real-time production sequence, and obtaining required information from equipment on a production line, such as extracting information from a sensor and the RFID;
and meanwhile, reading the production comprehensive data of the database, wherein the production comprehensive data comprises supply chain data, production plan data, equipment running state data and product tracking ID data.
S2, optimizing the production sequence of the split lines and the inventory update of the cache region according to the production sequence and the production comprehensive data of the main line, and the specific steps are as follows:
establishing an optimization model, and automatically generating a production sequence corresponding to the split lines according to the production sequence of the main line;
judging whether the detected production sequence of the real-time mainline is the same as the plan or not;
if the product spot check occurs and the conditions of external part production planning and the like cause different conditions, a production sequence corresponding to the composition is automatically generated according to the current latest main line sequence, and the material supplementing requirement of the cache bank at the side of the composition line is recalculated.
S3, determining that the production sequence of the main line is synchronously matched with the production sequence of the split line.
In some specific embodiments, the specific steps of establishing the optimization model are:
obtaining the maximum time M of continuous production of a production line;
carrying out production time constraint, following the batch production in sequence and ending the production within the longest time M;
respectively carrying out the updating of the cache between the beginning production of one batch and the end of the production and the updating from the end to the production of the next batch;
maintaining the main line demand between the end of one batch production and the next batch production within the M time;
maintaining the main line demand between the beginning of production and the end of production of a batch in M time;
and in the M time, caching the buffer memory to be less than the maximum buffer memory amount.
In some specific embodiments, the step of synchronously matching the production sequence of the main line with the production sequence of the split line includes:
current product type X according to main linetNumber g (X) remaining before type conversiont) And the number of cached products BF (X)t) Performing conversion judgment on the types of the main products;
a first layer: firstly, judging whether the number of parts to be produced in a cache is less than the number of the parts left before type conversion;
a second layer: then judging whether mb-g (X) existst)<BF(Yt) If the number of the split lines is less than the preset value, switching is not carried out, wherein mb is the number of the split line batches;
and a third layer: secondly, judging whether the number of the types of the parts with the least number in the cache is smaller than a preset threshold value, and determining whether the parts are supplemented;
a fourth layer: and finally, judging whether the number of the current types of the residual continuous production is larger than a preset threshold value or not, and determining whether the cache is excessive or not.
When some kind of parts in the cache buffer are reduced to a small number but are not supplemented in time, the production of the main line is seriously affected, namely the possibility of increasing the line stop is increased. Therefore, the first and third layer judgment conditions can provide certain guarantee for the part inventory of each type in the buffer. When the number of the remaining products of a certain type continuously produced is too small, the buffer is used for maintaining the production assembly of the product of the type on the main line, and the next to-be-produced type is produced, so that the product inventory pressure of the next to-be-produced type in the buffer is reduced. The conditions can ensure the buffer capacity of the stock in the buffer, and can flexibly adjust the production according to the type pattern of the product, thereby ensuring the matching of the main line and the sub line and the safe production.
In some embodiments, the plant automation line may be divided into three sections. The method comprises the following specific steps:
main line:
the sequence is transmitted from a remote end, for example, AAABBBCCC, on a main line, which is responsible for assembling parts, and the line speed is 51s per product. During 51 seconds, the assembly of one product is completed. t represents time, XtE S represents the product type being assembled by the production line at the time t, wherein S is { A, B, C, D, E, F, … } which is a product type set.
Splitting lines:
the split line can produce parts required by different types of products, and Y is usedtE s to represent the part type on the part line. Line speed was 49s per product. During 49 seconds, the production of one part is completed. Also, the line must produce a fixed number of parts at a time, and we use b to represent the number produced per batch. Specifically, b is 10. During each production, if the production type is changed, the change time is required to be 20s, for example, after 10A's are produced, if the production strategy is production B, the split line is required to be stopped for 20 s.
Buffer of the buffer:
the Buffer is used to store the surplus parts. That is, when a part is produced in the splitting line and the part does not match the part on the main line, the part is stored in the buffer. Meanwhile, the presence of the buffer can also ensure that the split wires cannot follow up the production without stopping the production under the condition that the type of the main wire product needs to be changed. Y at time ttThe amount BF (Y) in buffert)。
The product line may be shut down due to insufficient inventory of product parts assembled from the main line.
When t is 49b · k and k is 0,1,2,3, …, it is necessary to determine the type of part to be produced in the next batch of the part line. The long-time non-stop production of the automatic workshop is realized by formulating a split line production strategy based on the type of the main line product and the inventory state of parts in the buffer.
In this embodiment, an optimization model is established by using an operation research maximum error distance balance algorithm, and the specific steps are as follows:
and establishing a mathematical model, and setting mathematical parameters and constants.
{A:1,B:2,C:3,D:4,E:5,F:6}；
Constants are:
z is the maximum value of the buffer, Bj(0) Is a cache initial value;
decision variables:
Dj[0,t]the number of type j cars in the main line sequence from 0 to t, j being 1,2,3,.4,5, 6;
Bj(t) the number of type j buffers at time t;
Tiproduction type of the ith sub-line batch;
tiproduction time for sub-line batch i;
m is the longest time that the production line can be smooth and easy.
The model is represented as follows:
max M
(1):
(1.1):
(2):
(3):
(4):
(5):
(6):
(7):
(1): and (3) restricting the production time: the (i + 1) th batch can be produced after the (i) th batch is produced;
(1.1): we consider that these production batches end before M;
(2): buffering updates that begin production and end production in a batch;
(3): caching updates between the beginning of production and the end of production of a batch;
(4): caching updates between the end of one batch production and the next batch production;
(5): between the end of one batch production to the next, we can meet the mainline demand (in M time);
(6): between the beginning of a batch and the end of production, we can meet the mainline demand (within M time);
(7): the buffer memory can not be larger than the maximum buffer memory amount in the M time.
In some embodiments, as shown in FIG. 2, the triggering time is a multiple of 49, i.e., each time a batch of sub-line parts production is completed, the type of parts produced by the next batch of sub-lines is determined. To track the production of the sub-line and the main line, we define a new variable g (X)t) That is, the current product type X at the moment ttThe number remaining before the type is transformed. For example, the production sequence is AAAAABBBBBBBCCCCCCC, XtA, then g (X)t) I.e. the number of a left before conversion to B. In addition, we will also convert YtDefined as the next part type to be converted, in this example, YtB. Will depend on the amount of inventory in the buffer and g (X)t) And carrying out policy conversion under different states.
The system comprising the intelligent arrangement method for the automatic production line of the workshop, which is described in any one of the above items, comprises the following steps:
the acquisition module is used for acquiring a real-time main line production sequence of the detection production line;
the database is used for storing production line data and a production line optimization algorithm;
the PAS system module is used for receiving the acquired production line data information and calling an algorithm model to calculate a splicing line and a supplementary plan of a cache region; and issuing a production task to a factory production line in real time and adjusting a production plan automatically under the conditions of product defect repair, unplanned production and the like. The PAS system module is provided with a wireless communication module.
And the PLC module is used for receiving the production plan information to control the main line and the split line. And the signal output end of the wireless communication module is connected with the signal input end of the PLC module.
Although embodiments of the present invention have been shown and described, it will be appreciated by those skilled in the art that changes, modifications, substitutions and alterations can be made in these embodiments without departing from the principles and spirit of the invention, the scope of which is defined in the appended claims and their equivalents, which should be construed as being within the scope of the invention.
Claims (5)
1. An intelligent arrangement method for an automatic production line of a workshop is disclosed, wherein the production line comprises a main line, a split line and a cache region, and is characterized by comprising the following steps:
acquiring a production sequence and production comprehensive data of a real-time main line;
optimizing the production sequence of the split lines and the inventory updating of the cache area according to the production sequence and the production comprehensive data of the main line, and specifically comprising the following steps:
establishing an optimization model, and automatically generating a production sequence corresponding to the split lines according to the production sequence of the main line;
judging whether the detected production sequence of the real-time mainline is the same as the plan or not;
if the main line sequences are different, automatically generating a production sequence corresponding to the sub-assembly according to the current latest main line sequence, and recalculating the material supplementing requirement of the cache bank at the side of the sub-assembly line;
the specific steps for acquiring the production sequence and the production comprehensive data of the real-time mainline are as follows:
reading the RFID information of the vehicle body through a butt joint production line system to obtain a real-time production sequence;
meanwhile, reading production comprehensive data of a database, wherein the production comprehensive data comprises supply chain data, production plan data, equipment running state data and product tracking ID data;
the specific steps for establishing the optimization model are as follows:
obtaining the maximum time M of continuous production of a production line;
carrying out production time constraint, following the batch production in sequence and ending the production within the longest time M;
respectively carrying out the updating of the cache between the beginning production of one batch and the end of the production and the updating from the end to the production of the next batch;
maintaining the main line demand between the end of one batch production and the next batch production within the M time;
maintaining the main line demand between the beginning of production and the end of production of a batch in M time;
in M time, caching the buffer memory to be less than the maximum buffer memory amount;
and determining that the production sequence of the main line is synchronously matched with the production sequence of the split lines.
2. The intelligent arrangement method of the automatic production line of the workshop according to claim 1, wherein the specific steps of synchronously matching the production sequence of the main line with the production sequence of the split line comprise:
current product type X according to main linetNumber g (X) remaining before type conversiont) And the number of cached products BF (X)t) Performing conversion judgment on the types of the main products;
firstly, judging whether the number of parts to be produced in a cache is less than the number of the parts left before type conversion;
then judging whether mb-g (X) existst)<BF(Yt) If the number of the split lines is less than the preset value, switching is not carried out, wherein mb is the number of the split line batches;
secondly, judging whether the number of the types of the parts with the least number in the cache is smaller than a preset threshold value, and determining whether the parts are supplemented;
and finally, judging whether the number of the current types of the residual continuous production is larger than a preset threshold value or not, and determining whether the cache is excessive or not.
3. A system comprising the intelligent arrangement method of the workshop automation line according to any one of claims 1 to 2, comprising:
the acquisition module is used for acquiring a real-time main line production sequence of the detection production line;
the database is used for storing production line data and a production line optimization algorithm;
the PAS system module is used for receiving the acquired production line data information and calling an algorithm model to calculate a splicing line and a supplementary plan of a cache region;
and the PLC module is used for receiving the production plan information to control the main line and the split line.
4. The system for the intelligent layout method of the automatic production line of the workshop according to claim 3, wherein the PAS system module is provided with a wireless communication module.
5. The system for the intelligent arrangement method of the automatic production line of the workshop as claimed in claim 4, wherein the signal output end of the wireless communication module is connected to the signal input end of the PLC module.
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| CN114119268B (en) * | 2022-01-24 | 2022-04-12 | 科大智能物联技术股份有限公司 | Collaborative manufacturing system for printing and packaging production line |
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| CN114881366A (en) * | 2022-06-13 | 2022-08-09 | 科大智能物联技术股份有限公司 | Multi-production-line collaborative scheduling method and system based on interaction of PAS and OPCS |
| CN116827883B (en) * | 2023-08-25 | 2023-11-17 | 明度智云(浙江)科技有限公司 | SCADA system offline data caching method, device and storage medium |
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| CN103870883A (en) * | 2012-12-11 | 2014-06-18 | 富泰华工业（深圳）有限公司 | Production line scheduling control system and method |
| CN105390734A (en) * | 2015-11-25 | 2016-03-09 | 昆山恩福赛印刷电子有限公司 | Printed battery production line |
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