CN116050122A - Digital twin deduction system and method based on flexible assembly production line of automobile - Google Patents

Abstract

The invention discloses a digital twin deduction system and a digital twin deduction method based on an automobile flexible assembly production line, wherein the system comprises a production line editing module, a twin driving display module and a production line intelligent deduction evaluation module. The method comprises the following steps: s1, deduction of a production plan; s2, verifying the beat of the production line; s3, estimating energy efficiency of the production line; s4, generating a deduction report, wherein the deduction report comprises deduction total evaluation of the current production line planning scheme, estimated risk items, production plan deduction, production line beat verification and various results of production line energy consumption evaluation. Compared with the prior art, the invention can deduce and analyze the production performance of the twin production line, verify the running condition of the production line after the production beat parameter is changed, and dynamically deduce or reproduce the whole running process of the automobile assembly service, thereby realizing the health monitoring, AGV path planning, production line balance monitoring and production line design planning optimization of the equipment, and improving the production efficiency and the equipment utilization rate.

Description

Digital twin deduction system and method based on flexible assembly production line of automobile

Technical Field

The invention relates to the technical field of intelligent manufacturing, in particular to a digital twin deduction system and method based on an automobile flexible assembly production line.

Background

Currently, in the automotive industry, single-brand and mass production methods cannot be adapted to the rapidly changing market demands, and in the face of the dynamically complex and changeable market demands, automobile manufacturers must possess the capability of customizing products according to the market demands or rapidly providing mass production of products to achieve competitive advantages. The traditional automobile production system can not meet the requirement of personalized production, so that an automobile enterprise must optimally adjust and upgrade the existing production system, the production system is more flexible, and the production mode of multi-production-line mixed production is adopted according to different customer requirements, so that the production efficiency of the manufacturing system is improved. Therefore, island-type automobile assembly technology has been developed, islands are produced by using AGV flexible links, personalized module scheduling is performed by using the AGVs, and the cooperation of pulling supply chains by industrial visual identification materials is utilized, so that flexible reconstruction can be performed between islands according to production requirements, and a complete flexible assembly line is formed. Of course, the mixed line production can be performed by a plurality of assembly islands and a traditional assembly line, so that a complete flexible assembly line is formed. A complete flexible assembly line comprises a plurality of links such as an infrastructure, automatic sorting equipment, an AGV carrier, a mechanical arm, a belt conveyor and the like.

The design of the production line is one of the most important links in the island type automobile assembly process, and the reasonable or not of the production line design directly determines the production efficiency after production. And the production line planning process involves numerous production equipment, operators and products, and virtual production line planning and optimization techniques are required in consideration of numerous factors involved in the production line planning process before the physical production line is built.

The digital twin technology is to digitally construct a digital twin body consistent with an actual production field, and simulate the behavior of a physical entity in a real environment by means of actual production data. The digital twin technology is used as a bridge between the physical world and the digital world, provides a way for solving the data interaction between the physical world and the digital world, combines historical data and an artificial intelligence algorithm to predict various states of the physical entity with high credibility, and finally acts on the physical entity through feedback control to correct or optimize the behavior of the physical entity.

The traditional production line design firstly utilizes a digital technology to establish a production field model, and then performs off-line simulation and analysis to realize the optimization of the production line, thereby being a static design method. The traditional method lacks the drive of real-time production data, cannot comprehensively consider the production line, for example, cannot verify whether the production line is abnormal after the production beat parameter changes.

Disclosure of Invention

The invention aims to provide a digital twin deduction system and a digital twin deduction method based on an automobile flexible assembly production line, which can deduct and analyze the production performance of the production line under the condition that the operation of the real production line is not interfered, and the basic characteristics of the production line are mastered by deducting and analyzing the operation process of the twin production line, so that the operation condition of the production line after the change of the production beat parameters is verified, the design parameters and configuration of the production line are further regulated to realize the verification of the design planning of the production line, and the production efficiency and the equipment utilization rate are improved.

In order to achieve the above purpose, the present invention adopts the following technical scheme:

the digital twin deduction system based on the flexible assembly production line of the automobile comprises a production line editing module, a twin driving display module and a production line intelligent deduction evaluation module, wherein the production line editing module is connected with the twin driving display module, and the twin driving display module is connected with the production line intelligent deduction evaluation module, wherein:

the production line editing module is used for establishing a twin production line;

the twin driving display module is used for simulating data interaction between the real production line and the twin production line, so that the production beats of the twin production line and the real production line are kept consistent;

The intelligent production line deduction evaluation module comprises a production plan deduction sub-module, a production line beat verification sub-module and a production line energy efficiency evaluation sub-module, wherein the production plan deduction sub-module is connected with the twin drive display module and is used for establishing a twin production line according to different production line planning schemes, inputting a production plan, deducting the different production line planning schemes to obtain deduction data so as to verify whether the device quantity configuration of each functional module of the flexible assembly production line is reasonable or not and whether the production line planning schemes are feasible or not;

the production line beat verification submodule is connected with the production plan deduction submodule and is used for adding production beat data in the production plan deduction process, adjusting production beat parameters and verifying production line running conditions under different production beat parameters through simulation so as to obtain optimal production beat parameters;

the production line energy efficiency evaluation submodule is connected with the production line beat verification submodule and is used for carrying out equipment comprehensive efficiency evaluation, production plan completion rate evaluation and production line energy consumption evaluation on the twin production line according to the deduction data and the production beat parameters so as to evaluate whether the use condition of various equipment under the current production plan is reasonable or not and whether the production plan can be completed normally or not.

Further provided is that: the specific process of the design layout digital flexible assembly production line comprises the following steps of:

1) Constructing an assembly procedure flow node of the flexible assembly production line to obtain a flow node diagram of the flexible assembly production line;

2) The process node diagram of the flexible assembly line is laid out to obtain a physical model of the flexible assembly line;

3) And (3) giving a digital element to the built physical model, and carrying out flexible assembly production line information modeling, actual production information digital modeling and process information modeling to obtain a twin production line.

Further provided is that: the production plan deduction submodule carries out the process of production plan deduction as follows:

1) Selecting a production line planning scheme and setting production line configuration;

2) Setting a deduction production plan;

3) And carrying out visual simulation analysis, carrying out deduction evaluation, and releasing corresponding twinning scenes after the feasibility of the production line planning scheme is passed.

Further provided is that: the production line beat verification sub-module performs the process of production line beat verification as follows:

1) Selecting a twinning scene through release;

2) Selecting equipment, setting production beat parameters of certain production line equipment and the same equipment, and changing the production beat parameters of the equipment;

3) And (5) performing beat verification: in the beat verification process, pause, double speed, replay and stop control operations are carried out on the production line equipment through the interactive buttons, and when abnormal conditions occur on the equipment, the mark red is highlighted, so that the first time is conveniently found and adjusted;

4) Generating a verification report: on one hand, whether the production line planning scheme is feasible or not under the current production beat setting is evaluated, the score of the production line planning scheme is calculated in the form of a quantization index, and on the other hand, the running states of all the devices under the current production beat parameter setting and the efficiency change trend of the devices after the production beat parameter adjustment are summarized.

Further provided is that: the abnormal conditions comprise abnormal conveying devices, abnormal special equipment and abnormal storage space, and the abnormal conditions are judged as follows:

(1) Abnormality of the conveying device: in the deduction process of the production plan, whether the abnormal phenomena such as blockage and clamping exist on the conveying device or not can be checked, and if the abnormal phenomena such as blockage and clamping exist on the conveying device, the abnormal alarm of the conveying device is carried out;

(2) Abnormal special equipment: checking the beat matching degree of special equipment in the deduction process, and if abnormal phenomena such as production equipment empty, equipment too busy and the like can occur, if the production equipment empty or the equipment too busy occurs, carrying out special equipment abnormal alarm;

(3) Storage space abnormality: and accurately reproducing the inventory condition, and if a large number of empty or full racks are present, alarming the abnormal storage space.

Further provided is that: the production line energy efficiency evaluation submodule is used for carrying out equipment comprehensive efficiency evaluation, production plan completion rate evaluation and production line energy consumption evaluation on the twin production line according to deduction data so as to evaluate whether the use condition of various equipment under the current production plan is reasonable or not and whether the production plan can be normally completed or not.

Further provided is that: the comprehensive efficiency evaluation of the equipment is to perform simulation calculation according to a set production plan, calculate the time start rate, the performance start rate and the qualified rate of the twin production line, and judge the comprehensive efficiency of special equipment on the current twin production line.

Further provided is that: the production plan completion rate evaluation is to calculate the production plan completion rate according to the production plan of the flexible assembly production line and the completion condition of the twin production line, wherein the production plan completion rate=total number of completed work orders in unit time/total number of planned work orders in unit time is 100%.

Further provided is that: the production line energy consumption evaluation comprises investment sum evaluation and production line energy consumption change evaluation, wherein the investment sum evaluation is to initially evaluate the overall equipment scale and the site of the flexible assembly production line to be planned and put into production, graphically display a flexible assembly production line framework in a two-dimensional/three-dimensional mode through a visual means, statistically analyze the equipment scale and the production line capacity to be put into production, and evaluate the investment sum;

The production line energy consumption change evaluation is to input production plan sample data to the twin production line, evaluate the energy consumption level of the twin production line under different production plans such as day, week, month and the like, and comprehensively analyze the production line energy consumption change trend.

The method for carrying out simulation deduction by the digital twin deduction system based on the flexible assembly production line of the automobile comprises the following steps:

s1, production plan deduction: establishing a twin production line according to different production line planning schemes, inputting a production plan, deducing the different production line planning schemes to obtain deduction data, verifying whether the device quantity configuration of each functional module of the flexible assembly production line is reasonable or not and whether the production line planning scheme is feasible or not, and issuing corresponding twin scenes after the feasibility of the production line planning scheme is passed;

s2, verifying the beat of the production line: selecting a twinning scene through release, adding data of production beats, adjusting production beats parameters, and verifying the operation conditions of the production line under different production beats parameters through simulation so as to obtain optimal production beats parameters;

s3, energy efficiency evaluation of the production line: performing equipment comprehensive efficiency evaluation, production plan completion rate evaluation and production line energy consumption evaluation on the twin production line according to the deduction data and the production takt parameters so as to evaluate whether the use condition of various equipment under the current production plan is reasonable or not and whether the production plan can be normally completed or not;

S4, generating a deduction report, wherein the deduction report comprises deduction total evaluation of the current production line planning scheme, estimated risk items, production plan deduction, production line beat verification and various results of production line energy consumption evaluation.

Compared with the prior art, the invention has the beneficial technical effects that:

1. the planning and the previewing of the automobile assembly production line are realized: in the planning stage, the rationality of the production line planning scheme is dynamically predicted by using a deduction simulation technology, the development of the push product can be quickened through simulation, and the quality improvement and efficiency improvement of the production line planning are realized.

2. Realize the digital management and control of all elements of automobile assembly production: in the production stage, the digital twinning can construct a real-time linked three-dimensional visual factory, the real production line is changed into a twinning space which can be perceived, identified and analyzed, and the digital management and control level of the factory is improved.

3. Realize the intelligent decision of car assembly production fortune dimension: in the deduction stage, the twin production line and the real production line are in virtual-real interaction and twin parallel, virtual control is realized, scientific decision and intelligent control are carried out based on twin products and deduction data fusion multisource production operation and maintenance information by exploring flexible production line layout analysis and task scheduling, optimal management of assembly production is realized, and operation and maintenance efficiency and reliability are greatly improved.

In summary, the twin production line representing the real production line can be constructed and operated, the production performance of the analysis production line can be deduced under the condition that the operation of the real production line is not interfered, the basic characteristics of the production line are mastered by deducting and analyzing the operation process of the twin production line, the operation condition of the production line after the change of the production beat parameters is verified, the design parameters and the configuration of the production line are further regulated to realize the verification of the design planning of the production line, and meanwhile, the equipment health monitoring, the AGV path planning, the balance monitoring of the production line and the optimization of the production scheduling task scheduling can be realized. By integrating multisource information such as production line planning, equipment parameters, operation information and the like, the whole operation process of the automobile assembly business can be dynamically deduced or reproduced, physical interaction of a real production line can be improved, scene fusion service is realized, and production efficiency and equipment utilization rate are further improved.

Drawings

In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings that are needed in the description of the embodiments or the prior art will be briefly described, and it is obvious that the drawings in the description below are some embodiments of the present invention, and other drawings can be obtained according to the drawings without inventive effort for a person skilled in the art.

FIG. 1 is a block diagram of a digital twin deduction system based on an automobile flexible assembly line;

FIG. 2 is a schematic flow chart of the deduction by the deduction sub-module of the production plan of the present invention;

FIG. 3 is a schematic diagram of simulation results derived from a production plan of the present invention;

FIG. 4 is a schematic diagram of the production homomorphism deduced from the production plan of the present invention;

FIG. 5 is a schematic diagram of the health monitoring of a facility deduced from the production plan of the present invention;

FIG. 6 is a schematic diagram of line balance monitoring derived from a production plan of the present invention;

FIG. 7 is a Gantt chart of a certain work piece processing schedule deduced from the production plan of the present invention;

fig. 8 is a schematic flow chart of verification performed by the production line beat verification sub-module according to the present invention;

FIG. 9 is a schematic diagram of an abnormality of the line beat verification of the present invention;

FIG. 10 is a schematic diagram of a deduction overall evaluation of the intelligent deduction evaluation of the production line of the present invention;

FIG. 11 is a schematic diagram of risk items for intelligent deduction assessment of a production line according to the present invention;

FIG. 12 is a flow chart of a method for performing simulation deduction by the digital twin deduction system based on the flexible assembly line of the automobile;

fig. 13 is a block diagram of an electronic device according to the present invention.

Reference numerals: 1. a production line editing module; 2. a twinning driving display module; 3. the intelligent deduction evaluation module of the production line; 31. a production plan deduction sub-module; 32. a production line beat verification sub-module; 33. a production line energy efficiency evaluation sub-module; 501. a processor; 502. a memory; 503. a communication interface; 504. an external device; 505. a display; 506. a network adapter.

Detailed Description

The following description of the embodiments of the present invention will be made apparent and fully in view of the accompanying drawings, in which some, but not all embodiments of the invention are shown. All other embodiments, which can be made by those skilled in the art based on the embodiments of the invention without making any inventive effort, are intended to be within the scope of the invention.

In the description of the present invention, it should be noted that the directions or positional relationships indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. are based on the directions or positional relationships shown in the drawings, are merely for convenience of describing the present invention and simplifying the description, and do not indicate or imply that the devices or elements referred to must have a specific orientation, be configured and operated in a specific orientation, and thus should not be construed as limiting the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and are not to be construed as indicating or implying relative importance.

In the description of the present invention, it should be noted that, unless explicitly specified and limited otherwise, the terms "mounted," "connected," and "connected" are to be construed broadly, and may be either fixedly connected, detachably connected, or integrally connected, for example; can be mechanically or electrically connected; can be directly connected or indirectly connected through an intermediate medium, and can be communication between two elements. The specific meaning of the above terms in the present invention can be understood by those of ordinary skill in the art according to the specific circumstances.

The technical terms related to the present invention are first described below:

real production line: namely a flexible assembly production line of the automobile on site.

Twin line (also called digital flexible assembly line): the appearance, the size and the position of the twin model of the flexible assembly production line constructed by the production line editing module are consistent with those of the real production line.

Twin product: and inputting a production plan to the twin production line to deduce the assembled product.

Deduction data: inputting a production plan to a twin production line, and simulating various data obtained by virtual production by the twin production line.

OEE (Overall Equipment Effectiveness, comprehensive efficiency of equipment): for representing the ratio of the actual capacity of the plant with respect to the theoretical capacity.

Production beat: also known as customer demand cycle, production interval time, is a cycle time, which is the time interval required to meet the customer's need to continuously complete the same two products (or services).

Production beat parameters: namely, various parameters affecting the production line production beat, including the horizontal moving speed, the vertical moving speed, the initial ground clearance height, the AGV conveying speed, the single operation duration, the equipment power consumption and the like of the production equipment.

Referring to fig. 1, the digital twin deduction system based on the flexible assembly line of the automobile disclosed by the invention comprises a line editing module 1, a twin driving display module 2 and a line intelligent deduction evaluation module 3, wherein the line editing module 1 is connected with the twin driving display module 2, and the twin driving display module 2 is connected with the line intelligent deduction evaluation module 3.

The production line editing module 1 is used for building a twin production line, and comprises the following specific processes: 1) And building an assembly procedure flow node of the flexible assembly production line by using the two-dimensional standard model library to obtain a flow node diagram of the flexible assembly production line. 2) And (3) laying out a flow node diagram of the flexible assembly production line by using a three-dimensional standard model library to obtain a physical model of the flexible assembly production line. 3) And giving a digital element to the built physical model, wherein the digital element comprises process flow logic, logistics information, motion definition information and the like, and carrying out flexible assembly production line information modeling, actual production information digital modeling and process information modeling to obtain the twin production line.

The flexible assembly production line information modeling is to define a production system and a production auxiliary system, and specifically comprises the following steps: 1) The appearance, size and location of the physical model of the modeled object remain consistent with the real production line. 2) Defining attributes such as classification, name, specification, model, key technical parameters and the like for each modeling object; 3) Giving static codes to the modeling objects, wherein the static codes of each modeling object are unique; 4) Defining logistics input and output equipment, information points of information flow input and output and power supply equipment for a modeling object; 5) Associating individual modeled objects with each other by the static encoding; 6) For core production devices in the modeling object, the behaviors of the core production devices are defined and the behavior codes are assigned, and the behavior codes of each core production device are unique, for example, the behaviors of a typical feeding robot can be defined as follows: the mechanical arm moves to a material taking position, grabs the workpiece, moves the workpiece to a material discharging position, discharges, resets and the like.

The actual production information digital modeling comprises information such as input production line constitution, component composition, processing technology data, processing technology equipment, bill of materials, working hour quota and the like, and provides production line entity data for production line production simulation analysis and manufacturing execution.

The process information modeling is a pure data model, no three-dimensional model data exists, and the flexible assembly production line information model is required to be used as a data carrier to provide basic data for various simulation analysis models and manufacturing execution systems. The process information modeling is to perform data modeling on technological processes, logistics paths, input and output of resources, input and output of information, operation principles and the like of a production line. For example: defining working procedures, stations and equipment; defining a logistics relationship among working procedures (stations); defining input and output data of a working procedure (station); defining the behavior of the device; the process parameters of the equipment are configured.

The twin drive display module 2 is used for simulating the data interaction of the real production line and the twin production line, so that the production beats of the twin production line and the real production line are kept consistent, and therefore each production conveying device drives the twin model to completely and synchronously produce with the real production line through real-time instructions, each mounted product part has unique codes, and the whole process tracking and tracing of the product part are realized.

The production line intelligent deduction evaluation module 3 comprises a production plan deduction sub-module 31, a production line beat verification sub-module 32 and a production line energy efficiency evaluation sub-module 33, and is used for verifying whether the device quantity configuration of each functional module of the flexible assembly production line is reasonable or not, whether the current production line planning scheme has abnormal conditions after the production beat changes or not, and evaluating whether the production plan can be completed normally or not.

In the production line planning scheme evaluation index, beats and bottlenecks are key performance indicators of the assembly line. The beats correspond to the productivity; the bottleneck is a key factor for optimizing the system and improving the productivity. And carrying out intelligent evaluation and analysis on the production line planning scheme through the production line intelligent deduction evaluation module 3, and presenting key information of each node and production simulation results in a scene roaming mode.

Production plan deduction submodule 31: the planning of the automobile assembly production line relates to a plurality of professional fields, all functional modules of the flexible assembly production line are buckled, and the construction success or failure of the whole production line can be influenced due to unreasonable device quantity configuration of any link. The production plan deduction submodule 31 establishes a twin production line according to different production line planning schemes, inputs a production plan, deducts the different production line planning schemes, and obtains deduction data to verify whether the device quantity configuration of each functional module of the flexible assembly production line is reasonable or not and whether the production line planning scheme is feasible or not. In some embodiments, the device number configuration of a single assembly island (such as a chassis assembly island) may be verified, or the device number configuration of a plurality of assembly islands combined into a complete assembly line may be verified, or the device number configuration of a hybrid line production of an assembly island combined with a conventional assembly line may be verified, which is not limited herein.

As shown in fig. 2, the specific process of production plan deduction is as follows:

1) Selecting a production line planning scheme and setting a production line configuration

Different deduction settings are carried out by selecting different production line planning schemes, and parameters, attributes and specifications of the production line model, such as AGV running speed, power, action paths and the like, are set in an important mode.

The method comprises the steps of adjusting different model parameters, wherein the parameters change to influence the deduction analysis of the twin model, and the core of deduction is to find the influence of different parameter changes on the whole twin production line so as to infer a reasonable production line planning scheme.

2) Setting a deduction production plan

Setting a deduced production plan, comprising: daily working time, single-round production time, and monthly working days.

3) And carrying out visual simulation analysis, carrying out deduction evaluation, and releasing corresponding twinning scenes after the feasibility of the production line planning scheme is passed.

And when the virtual layout simulation of the twin production line is completed, virtual operation simulation of the production line is carried out, namely, the production assembly flow of the automobile is simulated on the twin production line in an animation production demonstration mode according to the production process flow of the production line, and the dynamic interference condition of the key equipment is observed in real time, so that the layout rationality of the key equipment is verified. Different production line planning schemes correspondingly generate different twinning scenes, so that whether the scheme is feasible or not can be seen conveniently and intuitively, namely, the feasibility of cooperation or operation scenes of different equipment such as logistics AGVs, vehicle body conveying AGVs and chassis combination is verified preliminarily, and the corresponding twinning scenes can be issued after the feasibility of the production line planning schemes passes.

Through the steps, simulation results can be obtained, as shown in fig. 3, the daily production data of the production line and the operation efficiency of each production line can be displayed in real time, and the production plan deduction scheme of the current twin production line is analyzed from the dimensions of the station/equipment utilization rate, the production line production capacity, the station availability and the like, so that whether the production line meets the planning requirements is estimated, and meanwhile, the equipment health monitoring, the AGV path planning, the production line balance monitoring and the production scheduling scheme optimization can be realized.

1) Station/equipment utilization analysis: and counting the time of each station of the twin production line in the states of assembly processing, waiting, blocking, idling, faults and the like, calculating the time ratio of each station in the states, and evaluating whether the load rate and the number of the stations in each working area are reasonable.

2) Production line capacity analysis: and evaluating the average yield data, the maximum yield, the minimum yield, the standard deviation of the yield, the stable production time and other key indexes of the production line through twin production quality evaluation, comparing the planning yield and the planning time in the same kind, and evaluating whether the production line meets the planning requirement.

3) Station availability analysis: and (3) statistically analyzing the load rates of operators in different operation areas, visually comparing the load rates in a chart form, analyzing the duty ratio of idle operators, and evaluating whether the number of operators meets the requirement.

4) Production homomorphism

As shown in fig. 4, when the three-dimensional object is approached, the detailed information of the three-dimensional object is unfolded, and the current running state, actual yield, average yield, stable production time, station utilization rate, empty line/work/fault duration ratio and equipment health value of the equipment are displayed.

5) Device health monitoring

In the deduction process of the production plan, if abnormal conditions such as blockage, clamping, full load and the like are generated in the equipment, the generated abnormal conditions can inform a designer in a three-dimensional simulation and abnormal prompt mode, and when the equipment is abnormal, the mark red is highlighted, as shown in fig. 5.

6) AGV path planning

In automobile manufacturing, AGV route planning is a key ring, and the line of an order vehicle in a flexible assembly line can seriously affect the efficiency of the line. Because personalized custom orders are common, the model, color and configuration of each vehicle are different, and corresponding processes, materials and the like need to be dynamically adjusted. In AGV route planning, indexes such as production schedule, color, vehicle type and the like are taken as control rules to guide scheduling decisions. After the planning scheme is selected, the layout of the assembly island is considered, the layout of N automobile spare parts is designed, analyzed and verified, and the optimal final assembly workshop layout is obtained, so that the travel of the AGV is minimum, the assembly efficiency of the spare parts is highest, and the storage of the vehicle and the balance of the production beats of other process workshops are realized.

Taking an AGV scheduling planning for a certain factory assembly line as an example, before simulation verification is carried out, an AGV logistics data model is constructed firstly:

designing a logistics model by referring to the field layout of a flexible assembly line, wherein the model package assembly line AGV, assembly line equipment, assembly line space layout, different stations and loops of the assembly line and other necessary components relate to the following logistics data, and the number of the equipment in different partitions of the assembly line; the number of logistics loops in different zones is equal to the AGVs operating in the zone; the overall length and width of the assembly line; device object (unique number per class of device); a device security distance set in each of the plurality of chambers; traffic from device m to device n; an ith station in the partition or a transfer station or buffer zone of the assembly island; the safe distance of the assembly island of the ith area is partitioned, and the size of the material buffer area is indicated; logistics AGVs or operating AGVs single trolley load capacity, etc.

In the twin model, assembly logistics representative simulation starts, logistics AGVs distribute materials to stations or assembly islands according to assembly tasks and vehicle types, when the last task of a work plan is completed, simulation verification reports are output, the number, carrying capacity, average working efficiency, congestion condition and the like of the AGVs are verified, appropriate resources are further configured, the materials can be sent to a production line on time, the productivity requirement of the production line is met, production of the production line is not affected, the average utilization rate of equipment, the average utilization rate of the AGVs and the quantity of finished products which are discharged are the highest, and the total walking path length of the AGVs is the minimum.

7) Production line balance monitoring

The balance of the flexible assembly production line is a necessary condition for continuous and stable production of the production line, as shown in fig. 6, the operation rate of equipment in each link of the twin production line and the operation rate index of the assembly line are designed, the change trend of the index is monitored in real time, the abnormality is found out and timely adjusted, the balance rate of the production line is improved, bottleneck links in the production flow are relieved, and the equipment congestion and idle time are reduced.

A complete flexible assembly production line comprises a plurality of links such as an infrastructure, automatic sorting equipment, an AGV carrier, a mechanical arm, a belt conveyor and the like. Through designing the production line feasibility assessment model for just can preliminary verification commodity circulation AGV, automobile body transport AGV, chassis are equipped with the feasibility of different equipment cooperation or operation scene such as putting together in design planning stage, utilize three-dimensional digital information model, manage the design planning or reform transform in the relevant link, and carry out collaborative work and promote deduction efficiency.

8) Production scheduling task scheduling optimization

When an abnormal condition or periodical rescheduling occurs in the production line, the system refreshes the scheduling scheme, designs an automobile product processing scheduling Gantt chart for conveniently displaying the scheduling result, displays the scheduling result, and draws a Gantt chart for processing scheduling of a certain workpiece according to the scheduling scheme as shown in fig. 7, so that the sequential processing sequence of each process is specifically planned.

Line beat verification sub-module 32: adding data of production beats in the process of deduction of the production plan, adjusting production beat parameters, and verifying the operation condition of the production line under different production beat parameters through simulation to obtain the optimal production beat parameters, wherein the specific verification process is as follows:

1) Selecting a twinning scene through release;

2) The selection equipment is used for carrying out production beat parameter setting on a certain production line equipment and the like, changing the production beat parameters of the equipment, wherein the production beat parameters comprise: horizontal movement speed, vertical movement speed, initial ground clearance height, conveying speed, single operation duration and equipment power consumption;

3) Beat verification: in the beat verification process, the control operation of pause, double speed, replay and stop can be carried out on the production line equipment through the interactive buttons, and when the equipment has abnormal conditions, the mark red is highlighted, so that the first time is conveniently found and adjusted;

4) Generating a verification report: on one hand, whether the production line planning scheme is feasible or not under the current production beat setting is evaluated, the score of the production line planning scheme is calculated in the form of a quantization index, and on the other hand, the running states of all the devices under the current production beat parameter setting and the efficiency change trend of the devices after the production beat parameter adjustment are summarized.

As shown in fig. 9, the abnormal situation generated in the process of verifying the production line beat can inform the designer in a three-dimensional simulation result and abnormal prompt manner, and mainly includes the following three abnormal situations:

(1) Abnormality of conveying device

In the deduction process of the production plan, whether the conveying device is blocked, blocked and other abnormal phenomena can be checked, and if the conveying device is blocked, blocked and other abnormal phenomena exist, the conveying device is subjected to abnormal alarm.

(2) Abnormality of special equipment

The beat matching degree of the special equipment in the deduction process can be checked, whether abnormal phenomena such as production equipment empty and equipment too busy can be generated or not, and if the production equipment empty or the equipment too busy occurs, special equipment abnormal alarm is carried out.

(3) Abnormal storage space

And accurately reproducing the inventory condition, and if a large number of empty or full racks are present, alarming the abnormal storage space.

The production line energy efficiency evaluation sub-module 33 is configured to perform an equipment comprehensive efficiency evaluation, a production plan completion rate evaluation, and a production line energy consumption evaluation on the twin production line according to the deduction data and the production takt parameters, so as to evaluate whether the usage situation of various devices under the current production plan is reasonable, and whether the production plan can be completed normally.

The equipment comprehensive efficiency evaluation is to perform simulation calculation according to a set production plan, calculate the time start rate, the performance start rate and the qualified rate of the twin production line, and judge the comprehensive efficiency of special equipment on the current production line. The start time, load time, actual throughput, theoretical throughput, number of qualified products and processing amount in the deduction data are collected, and the time start rate, performance start rate and qualified product rate of the twin line are calculated, wherein the time start rate=the start time/load time, the performance start rate=the actual throughput/theoretical throughput, the qualified product rate=the number of qualified products/processing amount, and the equipment comprehensive efficiency=the time start rate×the performance start rate×the qualified product rate.

The production plan completion rate evaluation is to calculate the production plan completion rate according to the production plan of the flexible assembly production line and the completion condition of the twin production line, score the formulation of the current production plan and provide basis for the optimization of the production plan. Production plan completion rate = total number of completed work orders per unit time per total number of planned work orders per unit time 100%. Wherein, the production plan in unit time is based on the standard productivity of the flexible assembly line.

The production line energy consumption evaluation comprises investment sum evaluation and production line energy consumption change evaluation, wherein the investment sum evaluation is to primarily evaluate the overall equipment scale and the site of the flexible assembly production line to be planned and put into production, further evaluate the investment scale of the whole flexible assembly production line, graphically display the flexible assembly production line framework in a two-dimensional/three-dimensional mode through a visual means, statistically analyze the equipment scale to be put into production, the production line capacity and evaluate the investment sum. The production line energy consumption change evaluation is to input production plan sample data to a twin production line, evaluate the energy consumption level of the production line under different production plans on different time scales such as day, week, month and the like, and comprehensively analyze the production line energy consumption change trend.

After the intelligent deduction evaluation of the flexible assembly production line is completed, automatically generating a deduction report, wherein the deduction report comprises deduction total evaluation of the current production line planning scheme, estimated risk items, and various results of production plan deduction, production line beat verification and production line energy consumption evaluation. The deduction general evaluation is to carry out deduction evaluation on the whole scheme to obtain a scheme conclusion, and comprehensively consider the layout of the flexible assembly production line and key parameter configuration, such as the key parameters of the flexible assembly production line, such as the number of functional modules, the types of parts, the number of AGVs and the like, different production line planning schemes can be intelligently evaluated from two dimensions of production cost and production time, and as shown in fig. 10, the deduction general evaluation shows the general score of a certain production line planning scheme, and the scheme is shown to have excessively high power consumption. As shown in fig. 11, the risk items estimated in the scenario are listed for optimal adjustment.

Referring to fig. 12, a method for performing simulation deduction by using the digital twin deduction system based on the flexible assembly line of the automobile includes the following steps:

s1, production plan deduction: establishing a twin production line according to different production line planning schemes, inputting a production plan, deducing the different production line planning schemes to obtain deduction data, verifying whether the device quantity configuration of each functional module of the flexible assembly production line is reasonable or not and whether the production line planning scheme is feasible or not, and issuing corresponding twin scenes after the feasibility of the production line planning scheme is passed;

s2, verifying the beat of the production line: selecting a twinning scene through release, adding data of production beats, adjusting production beats parameters, and verifying the operation conditions of the production line under different production beats parameters through simulation so as to obtain optimal production beats parameters;

s3, energy efficiency evaluation of the production line: performing equipment comprehensive efficiency evaluation, production plan completion rate evaluation and production line energy consumption evaluation on the twin production line according to the deduction data and the production takt parameters so as to evaluate whether the use condition of various equipment under the current production plan is reasonable or not and whether the production plan can be normally completed or not;

s4, generating a deduction report, wherein the deduction report comprises deduction total evaluation of the current production line planning scheme, estimated risk items, production plan deduction, production line beat verification and various results of production line energy consumption evaluation.

The beneficial effects of the invention are as follows:

the twin production line representing the real production line can be constructed and operated, the production performance of the analysis production line can be deduced under the condition that the operation of the real production line is not interfered, the basic characteristics of the production line are mastered by deducting and analyzing the operation process of the twin production line, so that the operation condition of the production line after the change of the production beat parameters is verified, the design parameters and the configuration of the production line are further regulated to realize the verification of the design planning of the production line, and meanwhile, the equipment health monitoring, the AGV path planning, the balance monitoring of the production line and the scheduling optimization of the production scheduling task can be realized. By integrating multisource information such as production line planning, equipment parameters, operation information and the like, the whole operation process of the automobile assembly business can be dynamically deduced or reproduced, physical interaction of a real production line can be improved, scene fusion service is realized, and production efficiency and equipment utilization rate are further improved.

For the complete life cycle of automobile assembly, the longitudinal integration of design, process and production integration, production, quality and management is realized in a virtual digital environment. By monitoring and analyzing the running condition of each device, the method helps factories to make a more intelligent decision scheme, rapidly improves production efficiency, reduces cost and achieves quality targets.

Referring to fig. 13, the present invention also provides an electronic device including: one or more processors 501, and a memory 502 for storing executable instructions for the processors 501, the memory 502 being electrically connected to the processors 501.

The processor 501 is configured to execute the method corresponding to the foregoing method embodiment by executing the executable instruction, and the specific implementation process of the method embodiment may be referred to in the foregoing method embodiment and will not be described herein.

Optionally, the electronic device may further include: a communication interface 503, through which communication interface 503 the electronic device may be communicatively coupled to one or more external devices 504 (e.g., keyboard, pointing device, display 505, etc.).

Optionally, the electronic device may further include: network adapter 506, through network adapter 606, may communicate with one or more networks such as a Local Area Network (LAN), a Wide Area Network (WAN), and/or a public network, such as the Internet.

The present invention also provides a computer readable storage medium, on which a computer program is stored, where the computer program when executed by the processor 501 implements a method corresponding to the foregoing method embodiment, and a specific implementation process of the method may refer to the foregoing method embodiment and will not be described herein.

Finally, it should be noted that: the above embodiments are only for illustrating the technical solution of the present invention, and are not limiting; although the invention has been described in detail with reference to the foregoing embodiments, it will be understood by those of ordinary skill in the art that: the technical scheme described in the foregoing embodiments can be modified or some or all of the technical features thereof can be replaced by equivalents; such modifications and substitutions do not depart from the spirit of the invention.

Claims (10)

1. Digital twin deduction system based on flexible assembly production line of car, its characterized in that includes production line edit module (1), twin drive display module (2), produces line intelligence deduction evaluation module (3), produce line edit module (1) and twin drive display module (2) and be connected, twin drive display module (2) are connected with production line intelligence deduction evaluation module (3), wherein:

the production line editing module (1) is used for establishing a twin production line;

the twin driving display module (2) is used for simulating data interaction between the real production line and the twin production line, so that the production beats of the twin production line and the real production line are kept consistent;

The intelligent production line deduction evaluation module (3) comprises a production plan deduction sub-module (31), a production line beat verification sub-module (32) and a production line energy efficiency evaluation sub-module (33), wherein the production plan deduction sub-module (31) is connected with the twin drive display module (2) and is used for establishing a twin production line according to different production line planning schemes, inputting production plans, deducting the different production line planning schemes and obtaining deduction data so as to verify whether the device quantity configuration of each functional module of the flexible assembly production line is reasonable or not and whether the production line planning schemes are feasible or not;

the production line beat verification sub-module (32) is connected with the production plan deduction sub-module (31) and is used for adding production beat data in the production plan deduction process, adjusting production beat parameters and verifying production line operation conditions under different production beat parameters through simulation so as to obtain optimal production beat parameters;

the production line energy efficiency evaluation sub-module (33) is connected with the production line beat verification sub-module (32) and is used for carrying out equipment comprehensive efficiency evaluation, production plan completion rate evaluation and production line energy consumption evaluation on the twin production line according to the deduction data and the production beat parameters so as to evaluate whether the use condition of various equipment under the current production plan is reasonable or not and whether the production plan can be completed normally or not.

2. The digital twin deduction system based on the flexible assembly line of the automobile according to claim 1, wherein the specific process of establishing the twin production line comprises the following steps:

1) Constructing an assembly procedure flow node of the flexible assembly production line to obtain a flow node diagram of the flexible assembly production line;

2) The process node diagram of the flexible assembly line is laid out to obtain a physical model of the flexible assembly line;

3) And (3) giving a digital element to the built physical model, and carrying out flexible assembly production line information modeling, actual production information digital modeling and process information modeling to obtain a twin production line.

3. The digital twin deduction system based on the flexible assembly line of the automobile according to claim 1, wherein the process of the production plan deduction by the production plan deduction sub-module (31) is as follows:

1) Selecting a production line planning scheme and setting production line configuration;

2) Setting a deduction production plan;

3) And carrying out visual simulation analysis, carrying out deduction evaluation, and releasing corresponding twinning scenes after the feasibility of the production line planning scheme is passed.

4. A digital twin deduction system based on a flexible assembly line of a car according to claim 3, wherein the process of the line beat verification sub-module (32) for line beat verification is as follows:

1) Selecting a twinning scene through release;

2) Selecting equipment, setting production beat parameters of certain production line equipment and the same equipment, and changing the production beat parameters of the equipment;

3) And (5) performing beat verification: in the beat verification process, pause, double speed, replay and stop control operations are carried out on the production line equipment through the interactive buttons, and when abnormal conditions occur on the equipment, the mark red is highlighted, so that the first time is conveniently found and adjusted;

4) Generating a verification report: on one hand, whether the production line planning scheme is feasible or not under the current production beat setting is evaluated, the score of the production line planning scheme is calculated in the form of a quantization index, and on the other hand, the running states of all the devices under the current production beat parameter setting and the efficiency change trend of the devices after the production beat parameter adjustment are summarized.

5. The digital twin deduction system based on the flexible assembly line of the automobile according to claim 4, wherein the abnormal condition comprises an abnormality of a conveying device, an abnormality of special equipment and an abnormality of a storage space, and the abnormal condition is determined as follows:

(1) Abnormality of the conveying device: in the deduction process of the production plan, whether the conveying device is blocked or not and the blocking position is abnormal or not can be checked, and if the blocking position is blocked, abnormal alarm of the conveying device is carried out;

(2) Abnormal special equipment: checking the beat matching degree of special equipment in the deduction process, and if the special equipment is empty and the equipment is too busy, carrying out special equipment abnormality alarm;

(3) Storage space abnormality: and accurately reproducing the inventory condition, and if a large number of empty or full racks are present, alarming the abnormal storage space.

6. The digital twin deduction system based on the automobile flexible assembly line according to claim 1, wherein the equipment comprehensive efficiency evaluation is to calculate the time start rate, the performance start rate and the qualified rate of the twin production line according to the set production plan, and determine the comprehensive efficiency of special equipment on the current twin production line.

7. The digital twin deduction system based on the flexible assembly line of the automobile according to claim 1, wherein the production plan completion rate evaluation is to calculate a production plan completion rate according to the production plan of the flexible assembly line and the completion condition of the twin production line, and the production plan completion rate=total number of completed work orders per unit time/total number of planned work orders per unit time is 100%.

8. The digital twin deduction system based on the flexible assembly line of the automobile according to claim 1, wherein the production line energy consumption assessment comprises an investment sum assessment and a production line energy consumption change assessment, wherein the investment sum assessment is to preliminarily assess the overall equipment scale and the place of the flexible assembly line to be planned and put into production, the flexible assembly line framework is graphically displayed in a two-dimensional/three-dimensional mode through a visual means, the equipment scale to be put into production and the production line capacity are statistically analyzed, and the investment sum is assessed; the production line energy consumption change evaluation is to input production plan sample data to a twin production line, evaluate the energy consumption level of the twin production line under different production plans on different days, weeks and months, and comprehensively analyze the production line energy consumption change trend.

9. The method for carrying out simulation deduction by the digital twin deduction system based on the flexible assembly production line of the automobile is characterized by comprising the following steps:

s1, production plan deduction: establishing a twin production line according to different production line planning schemes, inputting a production plan, deducing the different production line planning schemes to obtain deduction data, verifying whether the device quantity configuration of each functional module of the flexible assembly production line is reasonable or not and whether the production line planning scheme is feasible or not, and issuing corresponding twin scenes after the feasibility of the production line planning scheme is passed;

s2, verifying the beat of the production line: selecting a twinning scene through release, adding data of production beats, adjusting production beats parameters, and verifying the operation conditions of the production line under different production beats parameters through simulation so as to obtain optimal production beats parameters;

s3, energy efficiency evaluation of the production line: performing equipment comprehensive efficiency evaluation, production plan completion rate evaluation and production line energy consumption evaluation on the twin production line according to the deduction data and the production takt parameters so as to evaluate whether the use condition of various equipment under the current production plan is reasonable or not and whether the production plan can be normally completed or not;

s4, generating a deduction report, wherein the deduction report comprises deduction total evaluation of the current production line planning scheme, estimated risk items, production plan deduction, production line beat verification and various results of production line energy consumption evaluation.

10. An electronic device, comprising a processor (501) and a memory (502), the memory (502) being electrically connected to the processor (501), the memory (502) being configured to store executable instructions of the processor (501); wherein the processor (501) is configured to perform the method of claim 9 via execution of the executable instructions.

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