CN114042649A

CN114042649A - Steel plate part sorting and disc combining method based on limited cache

Info

Publication number: CN114042649A
Application number: CN202111363165.1A
Authority: CN
Inventors: 常梦辉; 吴瑞芳; 赵俊丽; 高岩; 赵珂
Original assignee: Zhengzhou Coal Machinery Shuyun Intelligent Technology Co ltd
Current assignee: Zhengzhou Coal Machinery Shuyun Intelligent Technology Co ltd
Priority date: 2021-11-17
Filing date: 2021-11-17
Publication date: 2022-02-15
Anticipated expiration: 2041-11-17
Also published as: CN114042649B

Abstract

The invention discloses a steel plate part sorting and disc combining method based on limited cache, belongs to the technical field of hydraulic support structural part production, and solves the problems of untimely sorting line edge tray conversion and AGV transfer and difficult control of subsequent cache materials. The sorting workshop comprises a sorting blanking position, a sorting line, a tray-closing turnover area, a tray for placing parts and an AGV (automatic guided vehicle) for transferring the tray; the method comprises the following steps: firstly, sorting according to the judging sequence of line side trays, tray closing turnover area trays and empty trays, after a part is sorted, transferring the tray which reaches the full-load transferring condition to a later process, and when the part does not reach the transferring condition, determining whether the line side trays need to be transferred to the tray closing turnover area according to the material, the plate thickness and the part type of a subsequent steel plate to be sorted; and taking T as a time period, and carrying out primary disc closing operation on the trays storing the same parts in the disc closing turnover area.

Description

Steel plate part sorting and disc combining method based on limited cache

Technical Field

The invention belongs to the technical field of production of hydraulic support structural members, and particularly relates to a steel plate part sorting and disc combining method based on limited cache.

Background

The cutting and sorting of the steel plate are widely applied to the industries of mechanical equipment manufacturing, marine engineering of ships and the like, but the phenomena of low automation degree, high labor intensity, low production efficiency and the like generally exist in the existing steel plate cutting and sorting, the improvement of productivity is seriously influenced, the waste of production resources is caused, meanwhile, the improvement of product quality is not facilitated, and the requirement of lean production cannot be met.

The existing steel plate cutting workshop replaces part of manual operation with the help of automatic equipment such as a laser cutting machine, an automatic sorting truss, a vision system and an AGV, and the automation and the intelligent degree of steel plate cutting and sorting are improved. However, due to the compact layout of the plant and the constraints of buffer space, the number of AGVs and the number of trays that can be accommodated by the side of the sorting line, the following problems are caused: due to the limited buffer space, the processed workpieces cannot enter the buffer area, so that trays beside the sorting line cannot be timely transferred to a later process, and production blockage is caused; secondly, due to the fact that the number of the AGVs is limited, the workload of the AGVs is too large due to frequent tray transportation tasks, and production stagnation can be caused due to untimely transportation; thirdly, because the diversity of steel sheet cutting part and the limited restriction of tray quantity can be held on the side of letter sorting line, lead to the part to sort the in-process and need frequent switching tray, increased AGV's work load to a certain extent, the tray transports the management and control degree of difficulty that discordance of batch has increased follow-up buffer memory material moreover, needs a large amount of tray quantity simultaneously.

Disclosure of Invention

The invention aims to solve the defects of the background technology, and provides a steel plate part sorting and disc combining method based on limited cache.

In order to solve the technical problems, the invention adopts the following technical scheme:

designing a steel plate part sorting and disc combining method based on limited cache, wherein a sorting workshop comprises a sorting blanking position, a sorting line, a disc combining turnover area, a tray for placing parts and an AGV (automatic guided vehicle) for transferring the tray; a pallet turnover shelf is arranged in the pallet combination turnover area;

the tray combination sorting method comprises the following steps:

s1, the steel plate after being cut in the laser cutting workshop enters a sorting and blanking position, and the types, the number and the weight of all parts on the steel plate are obtained according to the nesting scheme;

s2, checking the part information stored in the line edge tray, judging whether the parts on the steel plate are the same as the parts in the line edge tray, if the same parts exist in the line edge tray, preferentially sorting the parts, and sorting the parts into the tray; if the same parts do not exist in the line edge tray, sorting the parts one by one according to the set part sorting priority;

s3, when a part on the steel plate is sorted, judging whether a line edge tray for placing the part reaches a full-load transferring condition, if so, calling the AGV to execute a full-tray transferring task, transferring the tray to the next procedure, and supplementing an empty tray at the position of the original tray; if the full-load transferring condition is not met, judging whether the current steel plate is completely sorted or not, and whether the material and the plate thickness of the subsequent steel plate to be sorted are the same as those of the current steel plate or not; if the material and the plate thickness of the steel plate to be sorted subsequently are the same as those of the current steel plate, executing step S4, and if the material and the plate thickness of the steel plate to be sorted subsequently are different from those of the current steel plate, executing step S5;

s4, judging whether the type of the parts on the subsequent steel plate to be sorted is the same as the parts in the line edge tray or not, if the same parts exist in the line edge tray, keeping the tray for storing the same parts in the line edge in-situ, waiting for the sorting of the same parts of the next steel plate, and simultaneously transferring the tray which is not full and is loaded with other different types of parts while the line edge to a disc-closing turnover area for temporary storage; if the same parts do not exist on the edge of the line, all the trays with the edge less than the full edge of the line are transferred to a disc closing turnover area for temporary storage, and meanwhile, the step S6 is executed;

s5, if the material and the plate thickness of the steel plate parts to be sorted subsequently are different from those of the current steel plate, all the edge trays are transferred to a disc closing turnover area for temporary storage after the current steel plate parts are sorted, and meanwhile, the step S6 is executed;

s6, searching whether a part same as the steel plate part to be sorted exists in the disc-closing turnover area, if so, transferring a tray storing the part in the disc-closing turnover area to the line edge for position supplementing, and waiting for sorting of the next steel plate part; if the same parts do not exist in the disc-closing turnover area, selecting a corresponding number of empty trays to be transferred to the line edge for position supplementing;

and S7, checking whether two or more trays store the same type of parts in the disc closing turnover area every other period by taking the time T as a period, and closing different trays storing the same type of parts.

Preferably, the sorting lines are two, the two sorting lines are respectively provided with a first-stage sorting station and a second-stage sorting station, the first-stage sorting station is used for sorting parts more than 1.8 meters, the second-stage sorting station is used for sorting parts less than 1.8 meters, after the steel plates to be sorted enter the sorting line, the large parts are sorted through the first-stage sorting station, and then the small parts are sorted through the second-stage sorting station.

Preferably, in the sorting process, the same tray can only store one type of parts at the same time, and in the sorting process, the sorted parts are stored in the line side trays beside the corresponding sorting lines, and are not allowed to be stored in the line side trays of other sorting lines.

Preferably, when sorting the parts one by one according to the principle that large parts are preferred and the same parts are preferred in step S2, for the part a, it is determined whether a tray with the same parts exists in the closing tray turnaround area, and if a tray with the same parts exists, the tray is shifted to the side of the sorting line to sort the part a; and if the pallet combination turnover area does not have the pallets with the same parts, selecting an empty pallet to sort the parts A.

Preferably, in the current steel plate part sorting process, if the part types are larger than the number of trays capable of being accommodated by the line edge, a tray which is not full is selected to be transferred to the disc closing turnover area on line edge, the tray storing the same parts in the disc closing turnover area is transferred to the line edge, and if the same parts do not exist in the disc closing turnover area, an empty tray is supplemented to the line edge.

Preferably, in step S3, determining a tray capacity C according to the size and weight of each part, determining a tray transfer lot B according to the part demand per day, setting the number of parts P planned to be produced per day as X racks, and the number of parts a required for each part P as Y, and then taking the minimum value of the tray transfer lot B and the tray capacity C as a criterion for determining whether the full load transfer is achieved; full transfer is performed when the number of parts in the pallet reaches the minimum of the pallet transfer lot B and the pallet capacity C.

The sorting and disc combining method can realize the following functions:

(1) the temporary storage of the trays which do not reach the part transferring batch is convenient to realize when the parts are switched;

(2) the tray combination operation can be performed according to the required batch quantity under the condition that the same part is stored in a plurality of trays;

(3) for sorting of small parts, trays different from a follow-up workshop are adopted as sorting trays, so that more trays can be placed at the line edge of a sorting line at the same time, and the trays are changed uniformly after disc combination in a disc combination area;

(4) the flexibility and the flexibility of the sorting line can be improved by adding the disc combining process, and the influence of uncertainty of nesting and blanking sequences on the sorting line is solved;

(5) materials can be released to a subsequent link according to the state of a subsequent station, so that the production balance adjustment of the subsequent production link is realized;

(6) the materials are released in batches according to the planned requirements, and the difficulty of material control in the subsequent production links is reduced.

A three-dimensional model is established for a cutting workshop by using Plant Simulation software, and Simulation operation is performed on a cutting process, a sorting and transferring process, and a Simulation result shows that the sorting and disc combining method improves the equipment utilization rate to a certain extent and reduces the station blocking time. The method is characterized in the following three aspects:

(1) due to the addition of the disc combining area, the situation that due to the fact that the types of parts are more, the trays on the side of the sorting line cannot be replaced timely, the sorting line is blocked, and further the cutting machine cannot timely discharge materials, cutting output is influenced, and production resources are wasted is relieved;

(2) the tray combination method improves the flexibility and the flexibility of the sorting station. The tray quantity that letter sorting line limit can hold is limited, because the change of letter sorting part will bring more tray switching adjustment demand around, the frequent transform of tray has increased the number of times that the commodity circulation was transported to can cause the influence to the efficiency of part letter sorting. In addition, the same parts are likely to finish sorting operation on different sorting lines, so that the situation that two trays store different quantities of the same parts may occur finally, and the use amount of the trays and the material flow transportation amount are increased. Meanwhile, due to the fact that the number of the logistics transfer batches is reduced and the number of the trays is increased, certain pressure is caused on the logistics and the number of the trays.

(3) The disk combination is beneficial to strengthening the management and control of the line edge cache in a subsequent workshop. Due to the fact that the complete set of materials in time and the limitation of the capacity of a part of large material trays need to be considered, a strategy of transferring the sorted parts to a subsequent workshop according to a certain batch needs to be considered, otherwise, the situation that the materials are not complete or the quantity of the complete sets of the parts is not consistent, and the line-side inventory management of the subsequent workshop is disordered is caused. If the same parts are stored in different sorting trays, the problem of material line edge alignment and sleeve control (such as the problems of material shortage in alignment and material reaching the line edge too early) is inevitably caused.

Drawings

FIG. 1 is a flow chart of a limited-cache-based method for sorting and assembling steel plate parts according to the present invention;

FIG. 2 is a layout view of a cutting shop;

FIG. 3 a sort station layout;

fig. 4 is a turnaround area utilization statistical chart.

Reference numbers in the figures: 1 is the laser cutting workshop, 2 is laser cutting machine, and 3 are the letter sorting workshop, and 4 are the letter sorting line, and 5 are one-level letter sorting station, and 6 are second grade letter sorting station, and 7 are the tray, and 8 are material level, 9 are tray turnover goods shelves under the letter sorting.

Detailed Description

The following examples are given to illustrate specific embodiments of the present invention, but are not intended to limit the scope of the present invention in any way. The elements of the apparatus referred to in the following examples are conventional elements of the apparatus unless otherwise specified.

Example 1

In the embodiment, a disc combination mode is not adopted, the two sorting lines are respectively provided with a first-stage sorting station and a second-stage sorting station, the first-stage sorting station is used for sorting parts more than 1.8 meters, the second-stage sorting station is used for sorting parts less than 1.8 meters, and two trays with different sizes are used according to different sorting stations; the transport principle is as follows: calling an AGV to execute a full tray transferring task when the line edge tray reaches the minimum value of transferring batch and tray capacity; when the material and the plate thickness of the sorting steel plates before and after the sorting station are changed, all the trays with less full edges are transferred to the subsequent process; the number of the trays capable of being accommodated by the line edge is limited, when 5 small trays on the line edge are all occupied and the next part to be sorted and the line edge have no same part, one part is selected from the trays on the line edge to be transferred to a post-process, and meanwhile, an empty tray is supplemented. The specific implementation steps are as follows:

(1) and establishing a cutting workshop simulation model. And establishing a three-dimensional model for the cutting workshop by using Plant Simulation software according to the workshop site resource allocation condition, the steel plate and part information, the process equipment data and the logistics transfer equipment data.

(2) When the cut steel plate enters a sorting and discharging position, the types and the number of parts on the steel plate are obtained according to a nesting scheme, and the following table 1 shows the types and the number of the parts.

Table 1 steel plate parts information table in example 1

(3) The tray type that sees this steel sheet part to correspond is all for little tray by the jacking scheme, consequently, directly goes to second grade letter sorting station and sorts.

(4) Calling an AGV (automatic guided vehicle) to transfer to a subsequent process for the trays reaching the minimum value of transfer batch and tray capacity in the sorting process; when the material and the thickness of the steel plate are changed, emptying the tray at the line edge, namely completely turning the tray at the line edge; when the type of the steel plate parts is larger than the number of the trays contained on the line side and the trays on the line side are all occupied, in order to reduce the dead time of the sorting station, one tray is randomly selected to turn to the post-process.

(5) The simulation running time is set to be 10 days, and the equipment utilization rates of the cutting machine and the sorting station are obtained according to the simulation result and are shown in the table 2.

Table 2 equipment utilization in example 1

	Laser cutting machine	Sorting station
			Average working time	64.75％	48.56％
Average waiting time	18.75％	43.31％
			Mean time to block	14.5％	8.13％

Example 2

The method for sorting and assembling the steel plate parts based on the limited cache is adopted, and the method is verified by combining Plant Simulation software. The workshop model and the sorting station are respectively shown in fig. 2 and 3. The sorting workshop 3 comprises a sorting blanking position 8, a sorting line 4, a tray-closing turnover area, a tray 7 for placing parts and an AGV (automatic guided vehicle) for transferring the tray 7; a pallet turnover shelf 9 is arranged in the pallet combination turnover area; the sorting line 4 is two, and two sorting lines are equipped with one-level letter sorting station 5 and second grade letter sorting station 6 respectively, and one-level letter sorting station 5 is used for the part more than the letter sorting 1.8 meters, and second grade letter sorting station 6 is used for the part below the letter sorting 1.8 meters, treats that the letter sorting steel sheet gets into the letter sorting line and passes through one-level letter sorting station 5 letter sorting major possession part earlier, then gets into second grade letter sorting station 6 letter sorting minor part. In the sorting process, the same tray can only store one type of parts, and in the sorting process, the sorted parts are stored in the line edge trays beside the corresponding sorting lines, and the line edge trays of other sorting lines are not allowed to be stored.

S1, the steel plate after being cut in the laser cutting workshop 1 enters a sorting blanking position 8, and the types, the number and the weight of all parts on the steel plate are obtained according to a nesting scheme, as shown in the following table 3.

Table 3 steel plate parts information table in example 2

S2, checking the part information stored in the line edge tray, judging whether the parts on the steel plate are the same as the parts in the line edge tray, if the same parts exist in the line edge tray, preferentially sorting the parts, and sorting the parts into the tray; if the same parts do not exist in the tray at the line edge, when sorting the parts one by one according to the principle that large parts are preferred and the same parts are preferred, judging whether trays with the same parts exist in a closing tray turnover area or not for the parts A, if so, transferring the trays to the sorting line edge to sort the parts A; and if the pallet combination turnover area does not have the pallets with the same parts, selecting an empty pallet to sort the parts A.

In the current steel plate part sorting process, if the part types are larger than the number of trays capable of being accommodated by the line edge, firstly selecting a tray which is not full and has no same part in a steel plate on line edge to transfer to a disc closing turnover area, converting the tray which stores the same part in the disc closing turnover area to the line edge, and if the disc closing turnover area has no same part, supplementing an empty tray to the line edge.

In the present embodiment, the part information stored in the line edge tray is shown in the following table. At this time, the sorting station 2 has 5 small tray positions, 3 tray positions are occupied, and 2 tray positions are in an idle state. There are 5 kinds of parts in total on the current steel sheet, and there is one kind same part in line limit tray, still has 2 empty trays, consequently, needs the additional 2 trays of replenishment.

Table 4 edge tray part information in example 2

The part information temporarily stored in the closing transfer area is checked as shown in table 5 below. The same parts as those on the steel plate do not exist in the current turnover area, so that the trays with 2 different parts on the line edge are firstly transferred to the tray-closing turnover area, and then two empty trays are supplemented to the line edge from the empty tray area.

Table 5 pallet turnaround temporary storage pallet part information in example 2

S3, when a part on the steel plate is sorted, judging whether a line edge tray for placing the part reaches a full-load transferring condition, if so, calling the AGV to execute a full-tray transferring task, transferring the tray to the next procedure, and supplementing an empty tray at the position of the original tray; if the full-load transferring condition is not met, whether the current steel plate is sorted or not and whether the material and the plate thickness of the subsequent steel plate to be sorted are the same or not are judged.

Determining tray capacity C according to the size and weight of each part, determining tray transfer batches B according to the part demand of each day, setting the number of planned production parts P per day as X frames, setting the number of parts A required by each part P as Y, setting the tray transfer batches as X X Y, and taking the minimum value of the tray transfer batches B and the tray capacity C as a standard for judging whether the full-load transfer is achieved; and calling the AGV to execute a full tray transferring task when the number of the parts in the tray reaches the minimum value in the tray transferring batch B and the tray capacity C, and replenishing an empty tray at the original tray position.

If the material and the plate thickness of the steel plate to be sorted subsequently are the same as those of the current steel plate, executing step S4, and if the material and the plate thickness of the steel plate to be sorted subsequently are different from those of the current steel plate, executing step S5;

s7, assuming that 6 hours is a time period, a tray closing operation is performed on the tray storing the same parts in the tray closing transfer area, and the information of the tray in the tray closing transfer area is shown in table 6 below. Parts Y552-0101-50 in Table 6 are present in trays 21358 and 21432, respectively, at which time the parts in both trays are combined.

Table 6 pallet turnaround area temporary storage pallet part information in example 2

The simulation operation time is set to be 10 days, the statistical results of the number of the turnover and closing trays of the sorting line trays and the utilization rate of cutting and sorting equipment are respectively obtained from the simulation operation results, and the utilization condition of the turnover area is shown in tables 7 and 8. As can be seen from the table 7, 149 trays in the cutting workshop need to enter the turnover area for temporary storage on average every day, and after all the steel plates are processed every day, the final states of 62 trays and 9 trays in the turnover area and the edge of the sorting line are not in one tray, so that tray combination operation is needed.

Table 7 statistics of sorting line tray turnaround and closing count in example 2

Table 8 equipment utilization in example 2

	Laser cutting machine	Sorting station
			Average working time	75.85％	53.50％
Average waiting time	15.69％	45.29％
			Mean time to block	8.45％	1.22％

From the results of the two simulation simulations, it can be seen that after the disk-closing turnover area is increased and the disk-closing sorting method is adopted, the equipment utilization rate of the cutting machine is improved to 75.85% from 64.75%, and the average blocking time is reduced to 8.45% from 14.5%. The results show that: the disk combination method improves the utilization rate of equipment and reduces the station blocking time. The method is characterized in the following three aspects:

(1) due to the addition of the disc combination area, the situation that due to the fact that the types of parts are more, trays at the edges of the sorting lines are not replaced timely, the sorting lines are jammed, and therefore the cutting machine cannot timely discharge materials, cutting output is affected, and waste of production resources is caused is relieved;

(3) The disk combination is beneficial to strengthening the management and control of the line edge cache in a subsequent workshop. Due to the fact that the nesting performance of materials in time and the limitation of the capacity of a part of large material trays need to be considered, a strategy of transferring the sorted parts to a subsequent workshop according to a certain batch needs to be considered, otherwise, the situation that the line-side inventory management of the subsequent workshop is disordered due to the fact that the materials are not nested or the quantity of the parts is not consistent is caused. If the same parts are stored in different sorting trays, the problem of material line edge alignment and sleeve control (such as the problems of material shortage in alignment and material reaching the line edge too early) is inevitably caused.

While the present invention has been described in detail with reference to the embodiments, those skilled in the art will appreciate that various changes can be made in the specific parameters of the embodiments without departing from the spirit of the present invention, and that various specific embodiments can be made, which are common variations of the present invention and will not be described in detail herein.

Claims

1. A steel plate part sorting and disc combining method based on limited cache is characterized in that a sorting workshop comprises a sorting blanking position, a sorting line, a disc combining turnover area, a tray for placing parts and an AGV (automated guided vehicle) for transferring the tray; a pallet turnover shelf is arranged in the pallet combination turnover area;

the tray combination sorting method comprises the following steps:

2. The method for sorting and stacking steel plate parts based on the limited cache as claimed in claim 1, wherein the sorting lines are two, the two sorting lines are respectively provided with a first-stage sorting station and a second-stage sorting station, the first-stage sorting station is used for sorting parts with a size of more than 1.8 m, the second-stage sorting station is used for sorting parts with a size of less than 1.8 m, and after entering the sorting lines, the steel plates to be sorted firstly pass through the first-stage sorting station to sort large parts and then enter the second-stage sorting station to sort small parts.

3. The method for sorting and stacking steel plate parts based on limited buffer memory of claim 1, wherein during the sorting process, only one type of parts can be stored in the same tray, and during the sorting process, the sorted parts are stored in the line-side trays beside the corresponding sorting line, and are not allowed to be stored in the line-side trays of other sorting lines.

4. The method for sorting and stacking steel plate parts based on the limited cache of claim 1, wherein when the principle of large part priority and same part priority is adopted for sorting one by one in step S2, for part a, it is determined whether a pallet with the same part exists in the pallet-stacking turnaround area, and if a pallet with the same part exists, the pallet is shifted to the side of the sorting line to sort the part a; and if the pallet combination turnover area does not have the pallets with the same parts, selecting an empty pallet to sort the parts A.

5. The method for sorting and stacking steel plate parts based on limited buffer memory of claim 1, wherein in the current steel plate part sorting process, if the part type is larger than the number of trays capable of being accommodated by the line edge, an unfilled tray is selected on the line edge and transferred to the tray-combining turnover area, trays storing the same parts in the tray-combining turnover area are transferred to the line edge, and if the tray-combining turnover area does not have the same parts, an empty tray is supplemented to the line edge.

6. The method for sorting and stacking steel plate parts based on limited buffer memory according to claim 1, wherein in step S3, tray capacity C is determined according to the size and weight of each part, and tray transfer batch B is determined according to the part demand per day, the number of planned production parts P per day is X, the number of parts a required for each part P is Y, the transfer batch of trays is B = X Y, and the minimum value of the tray transfer batch B and the tray capacity C is taken as the criterion for judging whether full load transfer is achieved; full transfer is performed when the number of parts in the pallet reaches the minimum of the pallet transfer lot B and the pallet capacity C.