CN114065441A - Simulation optimization method of hydraulic support part machining complete production line based on digital factory - Google Patents

Abstract

The invention discloses a simulation optimization method of a hydraulic support part machining nesting production line based on a digital factory, which is characterized in that three-dimensional simulation modeling is carried out by utilizing digital factory simulation software according to the initialized production line layout of a hydraulic support part production workshop, then a simulation model is subjected to iterative optimization, so that the utilization rate of each equipment resource is improved, balanced and stable, the material flow blocking rate is reduced, the nesting of parts is guaranteed, and the number of produced products per day reaches a preset value. The invention can adjust and optimize iteration according to different product types through the multi-series operation strategies, so that the workshop productivity reaches the target fixed number of frames produced every day, the delivery period of products is ensured, and meanwhile, under the condition of reasonable material transfer batch of parts, the equipment load, the AGV utilization rate and the buffer capacity are balanced, the energy consumption of a workshop is reduced, the cost is reduced, and the benefit is increased.

Description

Simulation optimization method of hydraulic support part machining complete production line based on digital factory

Technical Field

The invention relates to the technical field of large heavy industrial part machining nesting production line design, in particular to a simulation method of a hydraulic support part machining nesting production line based on a digital factory.

Background

The plant simulation technology is actually a discrete event simulation technology of a production system, and essentially is a process of establishing a system model for an actual real object and performing experimental research on the actual system by using the established model. The production planning link can perform pre-planning on production line layout, equipment configuration, production manufacturing process paths, logistics and the like of a factory by utilizing a virtual simulation technology, and performs analysis, evaluation and verification on the basis of 'preview' of a simulation model, so that problems and parts to be improved in system operation are quickly found, adjustment and optimization are performed in time, the change and rework times of a subsequent production execution link on an entity system are reduced, and therefore cost is effectively reduced, construction period is shortened, and efficiency is improved.

As a typical discrete production enterprise in the traditional coal mine machinery manufacturing industry, due to the factors of change of market operation environment, adoption of new materials, technology and production process and the like, the industry pattern is oscillating, the product manufacturing period must be continuously shortened, the production flexibility is improved, and the personalized requirements of users are met.

The virtual simulation is used as an important means for workshop production line process planning and production line balance, a typical discrete system simulation model is constructed, the layout and logistics scheme of the hydraulic support part processing production line are analyzed, the equipment bottleneck and the AGV strategy are analyzed, the workshop capacity is optimized, and the virtual simulation method has important significance for stable production operation of enterprises and reduction of planning iteration cost.

Disclosure of Invention

The invention aims to provide a simulation modeling method based on digitization and solve the problem of the complete set of part processing types in order to solve the guidance of an intelligent factory on aspects of product productivity evaluation, site planning evaluation, equipment bottleneck evaluation and the like in the design planning stage.

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

a simulation optimization method of a hydraulic support part machining complete set production line based on a digital factory is designed, and comprises the following steps:

s1, acquiring production equipment, function partitions and production resource configuration data in the production line according to the initialized production line layout of the hydraulic support part production workshop;

s2, carrying out three-dimensional Simulation modeling on a hydraulic support part processing production line by using digital Plant Simulation software, and building a processing production line suitable for different types of hydraulic support parts through Simulation, wherein the production line comprises a preorder incoming material cache region, a cutting slope region, a straightening region, a profiling region, a boring hole drilling region, an edge milling region, a splicing point pre-embedding region, a part finishing cache region, a disc matching region and logistics transfer equipment; the logistics transfer equipment comprises a crown block, an intelligent AGV material transport vehicle and a half gantry crane;

s3, acquiring the production time of each part in each machining process on the hydraulic support part machining production line in the step S2;

s4, optimizing the processing and production scheduling time of various parts according to the principle of preferential processing of long line parts;

s5, dividing the production workshop into different task areas, planning the AGV route, and making an AGV transfer strategy;

s6, checking complete set of time nodes of finished parts of the hydraulic support in a distribution area;

s7, acquiring complete set of simulation data of production equipment, logistics equipment and finished parts;

s8, performing iterative optimization on the simulation model according to the equipment work utilization rate, and adjusting production equipment and AGV equipment resources;

s9, carrying out iterative optimization on the simulation model according to the equipment logistics blocking rate, adjusting the material transportation strategy to improve the utilization rate of each equipment resource and balance and stabilize the equipment resource, ensuring the integrity of parts when the logistics blocking rate is low, ensuring that the number of produced products reaches a preset value every day, and proving that the model optimization is successful; otherwise, repeating the steps S3-S9, and performing further iterative optimization of the model.

Preferably, the part production time data in step S3 is the time required for machining a single part and the number of parts required for producing a single hydraulic mount.

Preferably, the principle of prioritizing the machining of the parts in step S4 is as follows: the main ribs, the top and bottom plate, the reinforcing plate, the flitch, the gap bridge, the top and side plate, the ribs, the ear plates, the cover plates and the arc plates.

Preferably, the step S5 specifically includes:

and (3) dividing tasks according to a region principle: dividing a production workshop into different task areas, wherein a cutting groove area is an area A, namely a first span, a profiling and splicing point area is an area B, namely a second span and a third span, and a disc matching area is an area C, namely a fourth span; the transfer tasks in each zone are performed by 5 ton AGVs and/or 10 ton AGVs on a time-sequenced priority basis.

Preferably, the scheduling execution strategy of the AGV transferring task comprises the following steps:

the method comprises the following steps that firstly, global AGV polling is performed, state information of the global AGV is obtained, polling is performed according to fixed frequency, and a scheduling program is triggered;

acquiring currently available AGV based on AGV state data;

inquiring a task queue of a region corresponding to the current transfer task;

fourthly, corresponding task queues are subjected to round inspection, and sorting is carried out according to the transfer priority;

fifthly, selecting an executable task and locking a target station according to the equipment state of the station in turn;

sixthly, selecting the best matching AGV according to the shortest distance principle;

and executing the tasks according to the defined AGV transferring task sequence.

Preferably, the triggering condition for the AGV to transfer the task includes:

leveling machine: loading the full tray, and unloading the full tray;

groove cutting station: loading the full tray, and unloading the full tray;

and (3) immediately adding a center: loading the full tray, and unloading the full tray;

1000 ton bending machine: loading the full tray, and unloading the full tray;

public interaction bit: the manually operated tray is transferred to the public interaction site.

Preferably, in step S6, the hydraulic support machining part complete set time node check includes:

and taking the time of the white shift and the night shift as time nodes, acquiring the time and the quantity data of each part in the simulation model when reaching the distribution cache region, and judging the type and the quantity of the missing complete parts by taking the preset number of the complete parts required for producing the X-piece hydraulic support every day as the limit according to the type and the quantity of each part when reaching the distribution cache region at the time nodes every day.

Preferably, the simulation model optimization iteration and the adjustment of the device resources in step S8 specifically include:

adjusting the processing and production scheduling time of the parts according to the types of the missing parts, and scheduling and processing in advance to ensure that the quantity of the parts which are arranged in a complete set every day meets the preset production quantity of the hydraulic support;

secondly, the quantity of the AGV equipment is adjusted according to the production equipment in the production line and the AGV utilization rate, the blocking rate and the waiting rate, so that the overload problem is solved, and the smooth transfer of the AGV is ensured;

regulating the resource allocation principle of the bottleneck equipment, judging the bottleneck resource according to the blocking rate of the equipment in the simulation data, and performing balanced allocation of the resource according to the work utilization rate of the equipment to realize sharing of the resource;

and fourthly, reducing the batch of the loaded parts in the tray: the feeding batch of unprocessed parts in 24 hours is reduced, and the number of times of model changing of equipment is increased; under the premise that the number of cache storage positions in a distribution area is limited, a simulation test is run to feed batches, when a certain batch is carried out, the balance between the utilization rate of processing equipment and the utilization rate of the AGV are stable and high, and meanwhile, when the number of cache positions of products in process is met, a balance point of batch-in-process-AGV efficiency is obtained.

Preferably, in step S9, performing iterative optimization on the simulation model according to the equipment flow blocking rate, including adjusting the priority of the overhead traveling crane and adjusting the priority of the AGV;

the strategy for adjusting the priority of the crown block is as follows:

when the public interaction position is completed by the feeding task of the material AGV, the overhead traveling crane immediately transfers the public interaction position to a front buffering position of the equipment, so that the public interaction position resource is not occupied, and the priority is a first priority;

when the equipment finishes processing, the discharging task is of a second priority;

when the parts waiting for processing on the equipment are processed, the feeding task is the third priority;

other overhead traveling crane transfer tasks, such as empty pallet transfer, are of a fourth priority;

the strategy for adjusting the AGV priority is as follows: the time sequence priority principle is adjusted to be the rear procedure discharging priority transferring principle so as to reduce the occupation of the preorder processing product on the number of buffer bits before the next procedure, reduce the waste of space, improve the circulation efficiency of the product and reduce the blocking rate of equipment.

The construction and operation of an intelligent factory are multidimensional multivariable system engineering, in the initial stage of production line construction planning, if static calculation is adopted, dynamic simulation of multiple factor variables is not carried out, in the later stage of construction, many problems may exist in the actual dynamic operation process, for example, unreasonable site planning in the early stage causes logistics blockage, insufficient equipment resource ratio causes the problems of capacity reduction and the like.

The invention has the advantages that the production line is established after the simulation optimization, and the invention has the following beneficial effects: before a real intelligent factory system is established, system design is verified, and potential problems are found; evaluating the influence caused by plan change in parallel with the existing production system; the problem that cost and time are needed to be spent for correction in the production lifting process is discovered and eliminated; the investment cost for the production line is reduced to the minimum under the condition of not influencing the productivity; optimizing the performance of a complex production system containing multiple variables.

Drawings

FIG. 1 is a flow chart of the steps of the simulation method of the present invention;

FIG. 2 is a CAD plan layout view of a hydraulic support part production shop;

FIG. 3 is a layout diagram of a three-dimensional simulation model of a hydraulic support part production workshop;

FIG. 4 is an AGV logistics routing diagram of zone A;

FIG. 5 is an AGV flow routing diagram of zone B;

FIG. 6 is an AGV logistics routing diagram of area C;

FIG. 7 is a logical schematic diagram of an AGV dispatch and transfer process;

FIG. 8 is a schematic diagram of a batch-in-process-AGV efficiency balance relationship;

FIG. 9 is a three-dimensional simulation effect diagram of a hydraulic support part production workshop;

FIG. 10 is an effect diagram of a plasma robot cutting groove station;

reference numbers in the figures: the method comprises the following steps of 1, a feeding buffer area, 2, a cutting slope area, 3, a straightening area, 4, a profiling area, 5, a boring area, 6, an edge milling area, 7, a point splicing and embedding area, 8, a part finishing buffer area and a disc matching area.

Detailed Description

Example 1: the hydraulic support production workshop mainly completes the processes of leveling, beveling, boring, profiling, edge milling, point splicing, welding and the like of related components in three structural parts of a top beam, a shield beam and a base of a coal mining hydraulic support, and provides parts in 9 categories of main reinforcing plates, top bottom plates, top shield side plates, bridge-crossing parts, reinforcing plate attaching plates, cover plate parts, lug plate parts, rib plates and arc plates for the splicing welding of the three structural parts in a subsequent splicing welding workshop, as shown in the following table 1.

TABLE 1 main parts of hydraulic support workshop

The hydraulic support production workshop has complex and various products, and the related process flow routes are various. The overall process route involved in the production plant is shown in table 2 below:

TABLE 2 related Process routes for hydraulic workshop parts and products

The analysis idea and the core problem of the hydraulic production workshop simulation model in the embodiment are as follows:

capacity analysis: the unreasonable process allocation problem in the analysis workshop area needs to be analyzed and improved under the condition of ensuring that the theoretical equipment capacity is matched with the design capacity.

The bottleneck is improved: and (4) analyzing and positioning potential bottleneck equipment resources in the workshop area and an AGV operation strategy by using an overlapping point, and providing a solution idea.

Core problem focusing: the core problem is solved preferentially, and the target workshop is produced for 20 frames every day finally; the parts are transferred in batches reasonably, so that the equipment load, the AGV utilization rate and the cache capacity are balanced, the part inventory is low, and the cost is low.

The simulation optimization method of the hydraulic support part machining nesting production line based on the digital factory comprises the following steps:

and S1, acquiring production equipment, function partitions and production resource configuration data in the production line according to the initialized production line layout of the hydraulic support part production workshop.

S2, configuring process equipment and production resources of a hydraulic support part processing production line by using digital Plant Simulation software, performing three-dimensional Simulation modeling, and building a processing production line suitable for different types of hydraulic support parts through Simulation, wherein the production line comprises a pre-order incoming material cache region, a cutting slope region, a straightening region, a profiling region, a boring hole drilling region, an edge milling region, a splicing point pre-embedding region, a part finishing cache region, a disc matching region and logistics transfer equipment; the logistics transfer equipment comprises a crown block, an intelligent AGV material transport vehicle and a half-gantry crane. The CAD plan layout of the hydraulic support part production workshop is shown in figure 2.

Wherein, the preorder incoming material buffer area: the large and small part trays buffer incoming parts cut by the steel plate in the preorder workshop;

a straightening area: 3, carrying out primary straightening and secondary straightening processing operation tasks on the part by 1000-ton straightening machine equipment;

cutting a notch area: carrying out cutting groove processing operation tasks on 20 devices such as a super-large plasma groove working platform, a plasma robot groove platform, an automatic plasma robot groove platform, a large flame groove platform, a small flame groove platform, an automatic flame platform and the like;

profiling area: the 630-ton forming press and the 1000-ton forming press are used for bending and pressing;

drilling a boring area: the gantry machining center and the vertical machining center equipment are used for performing drilling and boring machining operation tasks;

milling an edge area: the large and small double-sided edge milling centers and the horizontal machining center perform an edge milling operation task;

splicing a point embedded area: splicing points and pre-buried welding processing of parts are carried out by adopting a stepping trolley and a welding workstation;

mutual position of AGV is responsible for the transportation of part processing time material, include: the method comprises the following steps of material transferring interaction between an AGV and equipment, material transferring interaction between the AGV and a crown block, and interaction between the AGV and a finished part cache position;

parts finishing buffer area and disk allocation area: and carrying out caching and part matching operation on the finished parts, and preparing materials for a subsequent tailor-welding workshop.

A layout diagram of a three-dimensional simulation model of a hydraulic support part production workshop is shown in figure 3; the three-dimensional simulation effect diagram of the hydraulic support part production workshop is shown in fig. 9, and the effect diagram of the plasma robot cutting groove station is shown in fig. 10.

S3, acquiring the production time of each part in each machining process on the hydraulic support part machining production line in the step S2; the part production time data is the time required for machining a single part and the number of parts required for producing a single hydraulic support.

The production time of each process task of the hydraulic support part processing production line can be obtained from the ERP system, and the process time of part of the workshop is shown in the following table 3.

TABLE 3 part of the process time of the parts in the workshop

Material numbering	Name (R)	Process flow	Working time	Demand/single rack
					Y-0101-46	Cover plate	Correction device	0.83	1.00
Y-0101-43	Rib plate	Correction device	0.83	1.00
					Y-0101-37	Cover plate	Correction device	0.83	1.00
Y-0101-36	Wrapping board	Cutting, straightening and pressing	0.83+3.63+0.83+1.27	1.00
					Y-0101-32	Cover plate	Cutting-correcting	0.83+7.39+0.83	2.00
Y-0101-28	Cover plate	Correction device	0.83	1.00
					Y-0101-03	Rib plate	Correction device	0.83	2.00
Y-0101-65	Bent cover plate	Cutting, straightening and pressing	0.83+10.49+0.83+1.47+4	1.00
					Y-0101-45	Ear plate	Cutting-milling-drilling	1.83+4+5	1.00
Y-0101-44	Ear plate	Cutting-milling-drilling	1.83+4+5	1.00
					Y-0101-39	Ear plate	Cutting-milling-drilling	1.64+4+5	1.00
Y-0101-38	Ear plate	Cutting-milling-drilling	1.64+4+5	1.00
					Y-0101-40	Ear plate	Cutting-drilling machine	1.5+6.75	4.00
Y-0101-41	Anti-cutting ear	Cutting	2.14	2.00
					Y-0101-20	Cover plate	Cutting-correcting	0.83+5.71+0.83	1.00
Y-0101-23	Rib plate	Cutting	2.65	2.00
					Y-0101-24	Bent cover plate	Cutting, straightening and pressing	0.83+10.49+0.83+1.47+4	1.00
Y-0101-30	Rib plate	Milling-cutting	8+2.6	8.00
					Y-0101-07	Rib plate	Cutting-milling-straightening	0.83+6+11+7.67	2.00

S4, optimizing the processing and production scheduling time of various parts according to the principle of preferential processing of long line parts; the priority principle of part processing and scheduling is as follows: the main ribs, the top and bottom plate, the reinforcing plate, the flitch, the gap bridge, the top and side plate, the ribs, the ear plates, the cover plates and the arc plates.

And S5, dividing the production workshop into different task areas, planning the AGV route, and making an AGV transfer strategy.

And (3) dividing tasks according to a region principle: dividing a production workshop into different task areas, wherein a cutting groove area is an area A, namely a first span, a profiling and splicing point area is an area B, namely a second span and a third span, and a disc matching area is an area C, namely a fourth span; the transfer tasks in each zone are performed by 5 ton AGVs and/or 10 ton AGVs on a time-sequenced priority basis.

Wherein, district A is responsible for the transportation task by 5 tons AGV (A5T), mainly includes:

a05-1 task: transporting the small part full-load tray in the preorder incoming material cache region to the loading positions of a plasma robot groove platform, an automatic plasma robot groove platform, a large flame groove platform, a small flame groove platform and an automatic flame platform cutting groove robot;

a05-2 tasks: transferring the empty tray of the material loading position on the groove platform to a vacant position of the material discharging position;

a05-3 tasks: and conveying the small parts from the previous step to the material loading position of the leveler.

Zone B is responsible for the transport tasks by a5 ton AGV (B5T) consisting essentially of:

b05-1 task: transporting the small parts of the first cross cutting groove platform to a second and third cross upper side public interaction position;

b05-3 tasks: conveying the small parts of the first cross cutting groove platform to a material loading position of a second cross upper side leveling machine;

b05-2 tasks: transporting the discharging part of the first span leveler to the public interaction position at the upper sides of the second span and the third span;

b05-3 tasks: conveying the small parts of the first cross cutting groove platform to a material loading position of a second cross lower side leveling machine;

b05-4 tasks: conveying the discharged material of the first cross cutting groove platform small part to a 1000-ton compression loading position;

b05-5 tasks: and conveying the small parts of the first cross cutting groove platform to a vertical feeding center feeding position.

Zone C is responsible for the transport tasks by a5 ton AGV (C5T) consisting essentially of:

c05-1 task: transporting the small parts on the second cross upper side public interaction position to a fourth cross small tray cache region;

c05-2 tasks: transporting the small parts on the public interaction position on the third span upper side to a fourth span small tray cache region;

c05-3 tasks: conveying the discharged materials of the second span lower side leveler to a fourth span small tray buffer area;

c05-4 tasks: transporting 1000 tons of compression type discharging materials to a fourth small tray spanning cache region;

c05-5 tasks: and conveying the material discharging position of the vertical feeding center to a fourth small tray spanning buffer area.

The transportation task for a10 ton AGV (A10T) for a production plant mainly includes:

a10-1 task: transporting a large part full-load tray in a preorder incoming material cache region to a material loading position of a groove platform of the extra-large plasma robot;

a10-2 tasks: discharging materials from the groove platform of the super-large plasma robot to the upper public interaction positions of the second span and the third span;

a10-3 tasks: discharging the material from the groove platform of the extra-large plasma robot to the material loading position of a second cross leveling machine;

a10-4 task: transporting the preorder incoming material large part full-load tray to a material loading position of a first cross leveler;

a10-task: and (4) transporting the discharging parts of the first span leveler to the public interaction positions at the upper sides of the second span and the third span.

The transportation task for a10 ton AGV (B10T) for a production plant mainly includes:

b10-1 task: the second span lower side splicing point finished parts are transported to a fourth span large tray cache position from a public interaction position;

b10-2 tasks: and the third span lower side splicing point finished parts are transported to the fourth span large tray cache position from the public interaction position.

The AGV logistics path planning diagram of the area A is shown in a figure 4; the AGV flow path planning diagram in the area B is shown in a figure 5; the AGV logistics path planning diagram of the C area is shown in the figure 6.

The scheduling execution strategy of the AGV transferring task comprises the following steps:

the method comprises the following steps that firstly, global AGV polling is performed, state information of the global AGV is obtained, polling is performed according to fixed frequency, and a scheduling program is triggered;

acquiring currently available AGV based on AGV state data;

inquiring a task queue of a region corresponding to the current transfer task;

fourthly, corresponding task queues are subjected to round inspection, and sorting is carried out according to the transfer priority;

fifthly, selecting an executable task and locking a target station according to the equipment state of the station in turn;

sixthly, selecting the best matching AGV according to the shortest distance principle;

and executing the tasks according to the defined AGV transferring task sequence.

The AGV dispatch and transfer process logic is shown in FIG. 7.

The triggering conditions of the AGV transferring task comprise:

leveling machine: loading the full tray, and unloading the full tray;

groove cutting station: loading the full tray, and unloading the full tray;

and (3) immediately adding a center: loading the full tray, and unloading the full tray;

1000 ton bending machine: loading the full tray, and unloading the full tray;

public interaction bit: the manually operated tray is transferred to the public interaction site.

And S6, carrying out complete set time node inspection on the finished parts of the hydraulic support in a distribution area.

In the simulation report, the time and the number of each part to the distribution cache area can be searched, the complete set property check is performed on each part by taking the time of the shift in the day shift and the shift in the night shift as time nodes, so as to judge the type or the number of the missing complete set parts (for example, the production of the hydraulic support is preset to be 20 frames per day), and the data of the part to material time nodes are shown in the following table 4.

TABLE 4 part time to feed node data

And S7, acquiring complete set simulation data of production equipment, logistics equipment and finished parts.

In the simulation report, information such as the utilization rate, the blocking rate, the waiting rate and the like of the equipment can be searched, as shown in the following table 5; and utilization rate, blocking rate, waiting rate, etc. of the AGVs and the general crown blocks, as shown in table 6 below.

TABLE 5 partial data of station utilization rate of plasma robot cutting groove

Table 610 ton AGV utilization fraction data

S8, performing iterative optimization on the simulation model according to the equipment work utilization rate, and adjusting production equipment and AGV equipment resources; the simulation model optimization iteration and device resource adjustment specifically comprise:

adjusting the processing and production scheduling time of the parts according to the types of the missing parts, and scheduling and processing in advance to ensure that the quantity of the parts which are arranged in a complete set every day meets the preset production quantity of the hydraulic support;

secondly, the quantity of the AGV equipment is adjusted according to the production equipment in the production line and the AGV utilization rate, the blocking rate and the waiting rate, so that the overload problem is solved, and the smooth transfer of the AGV is ensured;

regulating the resource allocation principle of the bottleneck equipment, judging the bottleneck resource according to the blocking rate of the equipment in the simulation data, and performing balanced allocation of the resource according to the work utilization rate of the equipment to realize sharing of the resource;

reducing the batch of the raw parts fed in 24 hours, increasing the number of times of model changing of the equipment, and reducing the utilization rate of bottleneck equipment, but increasing the number of times of transferring, increasing the AGV load and preventing the materials from being transferred in time; according to the limited prerequisite of the buffer memory position quantity of joining in marriage the district, the material is thrown in batches to the simulation test of operation, and under a certain batch, processing equipment and AGV utilization ratio are balanced stable higher, and when work in process buffering position quantity satisfied simultaneously, obtain batch-in-process-AGV efficiency balance point. The batch-in-process-AGV efficiency balance is shown in FIG. 8.

S9, carrying out iterative optimization on the simulation model according to the equipment logistics blocking rate, adjusting the material transportation strategy to improve the utilization rate of each equipment resource and balance and stabilize the equipment resource, ensuring the integrity of parts when the logistics blocking rate is low, ensuring that the number of produced products reaches a preset value every day, and proving that the model optimization is successful; otherwise, repeating the steps S3-S9, and performing further iterative optimization of the model.

The strategy for adjusting the priority of the crown block comprises the following steps:

when the public interaction position is completed by the feeding task of the material AGV, the overhead traveling crane immediately transfers the public interaction position to a front buffering position of the equipment, so that the public interaction position resource is not occupied, and the priority is a first priority;

when the equipment finishes processing, the discharging task is of a second priority;

when the parts waiting for processing on the equipment are processed, the feeding task is the third priority;

other overhead traveling crane transfer tasks such as empty pallet transfer are of a fourth priority;

the strategy for adjusting the AGV priority is as follows:

the time sequence priority principle is adjusted to be the rear procedure discharging priority transferring principle so as to reduce the occupation of the preorder processing product on the number of buffer bits before the next procedure, reduce the waste of space, improve the circulation efficiency of the product and reduce the blocking rate of equipment.

The hydraulic support part machining nesting production line simulation method based on the digital factory is applied to different product types, the adjustment optimization iteration of the multiple series of operation strategies is adopted, the workshop capacity reaches the target fixed number of frames produced every day, the delivery period of products is guaranteed, meanwhile, under the condition that the parts are reasonably transported in batches, the equipment load, the AGV utilization rate and the cache capacity are balanced, the energy consumption of a workshop is reduced, the cost is reduced, and the benefit is increased.

Although the present invention has been described in detail with reference to the embodiments, it will be understood by those skilled in the art that various changes in the specific parameters of the embodiments may be made without departing from the spirit of the present invention, and a plurality of specific embodiments are formed, which are common variations of the present invention, and will not be described in detail herein.

Claims (9)

1. A simulation optimization method of a hydraulic support part machining complete set production line based on a digital factory is characterized by comprising the following steps:

s1, acquiring production equipment, function partitions and production resource configuration data in the production line according to the initialized production line layout of the hydraulic support part production workshop;

s2, carrying out three-dimensional Simulation modeling on a hydraulic support part processing production line by using digital Plant Simulation software, and building a processing production line suitable for different types of hydraulic support parts through Simulation, wherein the production line comprises a preorder incoming material cache region, a cutting slope region, a straightening region, a profiling region, a boring hole drilling region, an edge milling region, a splicing point pre-embedding region, a part finishing cache region, a disc matching region and logistics transfer equipment; the logistics transfer equipment comprises a crown block, an intelligent AGV material transport vehicle and a half gantry crane;

s3, acquiring the production time of each part in each machining process on the hydraulic support part machining production line in the step S2;

s4, optimizing the processing and production scheduling time of various parts according to the principle of preferential processing of long line parts;

s5, dividing the production workshop into different task areas, planning the AGV route, and making an AGV transfer strategy;

s6, checking complete set of time nodes of finished parts of the hydraulic support in a distribution area;

s7, acquiring complete set of simulation data of production equipment, logistics equipment and finished parts;

s8, performing iterative optimization on the simulation model according to the equipment work utilization rate, and adjusting production equipment and AGV equipment resources;

s9, performing iterative optimization on the simulation model according to the equipment logistics blockage rate, adjusting the material transportation strategy to improve the utilization rate of each equipment resource, balance and stabilize the equipment resource, reduce the logistics blockage rate, ensure the integrity of parts, and prove that the model optimization is successful when the number of produced products reaches a preset value every day; otherwise, repeating the steps S3-S9, and performing further iterative optimization of the model.

2. The simulation optimization method for the hydraulic support complete machining production line based on the digital factory as claimed in claim 1, wherein the part production time data in the step S3 is the time required for machining a single part and the number of parts required for producing a single hydraulic support.

3. The simulation optimization method for the hydraulic support part machining nesting production line based on the digital factory as claimed in claim 1, wherein the part machining scheduling priority rule in the step S4 is as follows: the main ribs, the top and bottom plate, the reinforcing plate, the flitch, the gap bridge, the top and side plate, the ribs, the ear plates, the cover plates and the arc plates.

4. The simulation optimization method for the hydraulic support part machining nesting production line based on the digital factory as claimed in claim 1, wherein the step S5 specifically comprises:

and (3) dividing tasks according to a region principle: dividing a production workshop into different task areas, wherein a cutting groove area is an area A, namely a first span, a profiling and splicing point area is an area B, namely a second span and a third span, and a disc matching area is an area C, namely a fourth span; the transfer tasks in each zone are performed by 5 ton AGVs and/or 10 ton AGVs on a time-sequenced priority basis.

5. The simulation optimization method of the hydraulic support part processing complete set production line based on the digital factory as claimed in claim 4,

the scheduling execution strategy of the AGV transferring task comprises the following steps:

the method comprises the following steps that firstly, global AGV polling is performed, state information of the global AGV is obtained, polling is performed according to fixed frequency, and a scheduling program is triggered;

acquiring currently available AGV based on AGV state data;

inquiring a task queue of a region corresponding to the current transfer task;

fourthly, corresponding task queues are subjected to round inspection, and sorting is carried out according to the transfer priority;

fifthly, selecting an executable task and locking a target station according to the equipment state of the station in turn;

sixthly, selecting the best matching AGV according to the shortest distance principle;

and executing the tasks according to the defined AGV transferring task sequence.

6. The simulation optimization method for the hydraulic support part machining complete production line based on the digital factory as claimed in claim 5, wherein the trigger conditions of the AGV transferring task comprise:

leveling machine: loading the full tray, and unloading the full tray;

groove cutting station: loading the full tray, and unloading the full tray;

and (3) immediately adding a center: loading the full tray, and unloading the full tray;

1000 ton bending machine: loading the full tray, and unloading the full tray;

public interaction bit: the manually operated tray is transferred to the public interaction site.

7. The simulation optimization method for hydraulic support part machining nesting production line based on digital factory as claimed in claim 1, wherein in step S6, the hydraulic support part nesting time node check includes:

and taking the time of the white shift and the night shift as time nodes, acquiring the time and the quantity data of each part in the simulation model when reaching the distribution cache region, and judging the type and the quantity of the missing complete parts by taking the preset number of the complete parts required for producing the X-piece hydraulic support every day as the limit according to the type and the quantity of each part when reaching the distribution cache region at the time nodes every day.

8. The simulation optimization method for the hydraulic support part machining complete set production line based on the digital factory as claimed in claim 7, wherein the simulation model optimization iteration and the adjustment of the equipment resources in the step S8 specifically include:

adjusting the processing and production scheduling time of the parts according to the types of the missing parts, and scheduling and processing in advance to ensure that the quantity of the parts which are arranged in a complete set every day meets the preset production quantity of the hydraulic support;

secondly, the quantity of the AGV equipment is adjusted according to the production equipment in the production line and the AGV utilization rate, the blocking rate and the waiting rate, so that the overload problem is solved, and the smooth transfer of the AGV is ensured;

regulating the resource allocation principle of the bottleneck equipment, judging the bottleneck resource according to the blocking rate of the equipment in the simulation data, and performing balanced allocation of the resource according to the work utilization rate of the equipment to realize sharing of the resource;

and fourthly, reducing the batch of the loaded parts in the tray: the feeding batch of unprocessed parts in 24 hours is reduced, and the number of times of model changing of equipment is increased; under the premise that the number of cache storage positions in a distribution area is limited, a simulation test is run to feed batches, when a certain batch is carried out, the balance between the utilization rate of processing equipment and the utilization rate of the AGV are stable and high, and meanwhile, when the number of cache positions of products in process is met, a balance point of batch-in-process-AGV efficiency is obtained.

9. The simulation optimization method for the hydraulic support part machining nesting production line based on the digital factory as claimed in claim 7, wherein in step S9, the simulation model is iteratively optimized according to the equipment flow blocking rate, wherein the simulation model comprises the steps of adjusting the priority of a crown block and adjusting the priority of an AGV;

the strategy for adjusting the priority of the crown block is as follows:

when the public interaction position is completed by the feeding task of the material AGV, the overhead traveling crane immediately transfers the public interaction position to a front buffering position of the equipment, so that the public interaction position resource is not occupied, and the priority is a first priority;

when the equipment finishes processing, the discharging task is of a second priority;

when the parts waiting for processing on the equipment are processed, the feeding task is the third priority;

the other overhead traveling crane transfer tasks have a fourth priority;

the strategy for adjusting the AGV priority is as follows:

the time sequence priority principle is adjusted to be the rear procedure discharging priority transferring principle so as to reduce the occupation of the preorder processing product on the number of buffer bits before the next procedure, reduce the waste of space, improve the circulation efficiency of the product and reduce the blocking rate of equipment.

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