CN117234167A - Intelligent monitoring system for door curtain production line for electric welding place based on data analysis - Google Patents

Intelligent monitoring system for door curtain production line for electric welding place based on data analysis Download PDF

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CN117234167A
CN117234167A CN202311490109.3A CN202311490109A CN117234167A CN 117234167 A CN117234167 A CN 117234167A CN 202311490109 A CN202311490109 A CN 202311490109A CN 117234167 A CN117234167 A CN 117234167A
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CN117234167B (en
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魏欣
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Xinrun New Material Technology Jiangsu Co ltd
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Abstract

The application relates to the technical field of door curtain production lines, and is used for solving the problems that the production efficiency of the production line is limited by the link with the lowest production speed in the production line and part of orders can not be delivered in time easily due to artificial order arrangement production sequence, in particular to an intelligent monitoring system of the door curtain production line for electric welding places based on data analysis; according to the application, different order numbers are distributed to different production lines, so that order distribution quantity among a plurality of production lines is more reasonable, the influence of a certain link on the production line on the whole production speed of the production line is reduced through resource distribution of different stations on each production line, and the linkage adjustment of different stations among the plurality of production lines is performed, so that when all stations produce at the maximum production speed, no serious semi-finished product backlog phenomenon occurs, the whole production speed of the production line is improved, reasonable arrangement of order sequences is realized through finishing time and order delivery time, and on-time production of all orders is ensured.

Description

Intelligent monitoring system for door curtain production line for electric welding place based on data analysis
Technical Field
The application relates to the technical field of door curtain production lines, in particular to an intelligent monitoring system of a door curtain production line for electric welding places based on data analysis.
Background
The production line is the route which is passed by the production process of the product, namely, the route which is formed by a series of production line activities such as processing, conveying, assembling, checking and the like from the raw materials entering the production site, and has the equipment which is necessary for completing the processing tasks of the same type of parts, wherein the equipment and the working place are arranged and configured according to the process route and the working procedure labor amount ratio of most parts or main parts on the production line;
the production line is an indispensable facility in the production of large-scale entity enterprises, is crucial to the development work of the enterprises, but the existing production line still has some problems, the production line of most enterprises is often more than one, the problems of partial equipment old and slow down and partial equipment update and generation exist in the long-term use of the production line, the production line is limited by equipment cost, and the production side often cannot integrally update all the production equipment, so that the inconsistent productivity of each station on the production line is caused, the production efficiency of the production line is still limited by the link with the lowest production speed in the production line, thereby influencing the production efficiency of the enterprises, and meanwhile, most manufacturers need to pay a great deal of effort to arrange orders in a manual arrangement mode, so that the problem that partial orders cannot be delivered in time is easily caused;
the application provides a solution to the technical problem.
Disclosure of Invention
According to the application, different order numbers are distributed to different production lines, so that the order distribution amount among a plurality of production lines is more reasonable, the utilization rate of raw materials is improved, the phenomenon that part of production line raw materials are stacked and part of production line raw materials are insufficient is prevented, fund stacking is reduced, the capability of enterprises to deal with market change is improved, resource distribution of different stations on each production line is realized by acquiring the speeds of different stations on each production line, the influence of a certain link on the whole production speed of the production line on the production line is reduced, the linkage adjustment of different stations among the plurality of production lines is realized, the semi-finished product accumulation on a certain production line can be shared and used by the subsequent stations with higher production speed on the other production lines, so that when all stations are produced at the maximum production speed, the phenomenon of serious semi-finished product pressing does not occur, the whole production speed of the production line is improved, the complete time of the order is estimated by the whole production speed of the production line, reasonable arrangement of the order sequence is realized by acquiring the time of the complete order, the effect of a certain link on the whole production speed of the production line on the whole production line, the order sequence is still guaranteed as far as possible, the problem that the complete line is limited by the order schedule of the production line can not be completely placed by the intelligent production line, and the production line can still be fully monitored and the system is prevented from being fully due to the fact that the order schedule is not can be fully analyzed by the intelligent.
The aim of the application can be achieved by the following technical scheme:
the intelligent monitoring system for the door curtain production line for the electric welding place based on data analysis comprises an order management unit, a production evaluation unit, a multi-production-line synchronization unit, a station adjusting unit and a supervision center platform, wherein the order management unit is used for acquiring a current unfinished order and order delivery time and sending the unfinished order and the order delivery time to the supervision center platform;
the multi-production-line synchronizing unit acquires the time required by each production line to finish one order of products, records the time as one product time, and analyzes and counts the product time corresponding to all the production lines, so that different order numbers are distributed to each production line;
the station adjusting unit divides each production line into different stations, acquires the time required by each station to complete the corresponding processing step of a product of an order, and records the time as one step time, analyzes the step time on the station, adjusts the production speed of each station according to the analysis result, and reduces the step time gap between different stations on each production line;
the station adjusting unit acquires the step time of different stations among the plurality of production lines, and changes the product line of the different stations of the plurality of production lines according to the step time, and adjusts the order allocation among the different stations on the plurality of production lines;
the supervision center platform obtains the product time of each production line and the step time on each station through the multi-production-line synchronization unit and the station adjusting unit, and analyzes the product time and the step time to obtain the overall production speed of the plurality of production lines;
the production evaluation unit obtains the overall production speed of a plurality of production lines through the supervision center platform, calculates the finishing time of the unfinished orders according to the overall production speed, and sorts the unfinished orders according to the finishing time of the unfinished orders and the order delivery time.
As a preferred embodiment of the present application, the multiple production line synchronization unit marks different production lines as i, i=1, 2 …, n, and the product time record of each production line is ti, so that the ratio of the number of orders allocated to each production line to the total number of orders of the secondary production is
As a preferred embodiment of the present application, the process of adjusting the production speed of each station by the station adjusting unit is as follows:
1. marking the step time corresponding to each station on a production line as T, drawing a line graph according to the step time T, and selecting the station corresponding to the maximum step time in the step time and the station corresponding to the minimum step time in all the step time on the production line;
2. staff allocation and equipment allocation are carried out from the station corresponding to the minimum step time to the station corresponding to the maximum step time, and all step time is cleared after allocation;
3. counting the step time corresponding to different stations on each fresh article after restarting the production, and repeating the first step and the second step.
As a preferred embodiment of the present application, the process of the station adjusting unit for adjusting the order allocation amount between different stations of the plurality of production lines is as follows:
s1: sequentially sequencing the step time of different stations on each production line according to the size, selecting the median value of the step time, taking the median value as a step time reference, in the production line, marking the difference value of the step time exceeding the step time reference to be set as a negative accumulation station, and marking the difference value of the step time lower than the step time reference to be set as a positive accumulation station;
s2: repeating the step S1 for each production line once to obtain a negative accumulation station and a positive accumulation station of each production line, arranging the stations according to a construction sequence, selecting one positive accumulation station, selecting the other positive accumulation station from stations behind the construction sequence of the stations, arranging the positive accumulation stations on all the production lines according to the construction sequence, and arranging the negative accumulation stations on all the production lines according to the construction sequence;
s3: for a certain production line, two adjacent stations on the production line are marked as preface stations, stations with the construction sequence in front are marked as follow-up stations, products of the preface stations on each production line are preferentially supplied to the follow-up stations on the production line, products on the preface stations are supplied to redundant products after the follow-up stations on the production line, and redundant products are transferred to the follow-up stations in the arrangement sequence of the stations in the step S2 at regular intervals.
As a preferred embodiment of the present application, the supervision center platform obtains the step time average value of all production lines, records it as T1, obtains the step time median value of all production lines, records it as T2, calculates the production speed V of the whole production line by a formula,and k is a preset proportionality coefficient, and the supervision center platform sends the production speed V of the whole production line to the production evaluation unit.
As a preferred embodiment of the present application, the production evaluation unit calculates the completion time for completing a batch of incomplete orders according to the production speed of the whole production line, and orders the incomplete orders by analysis, wherein the ordering process is as follows:
a: the production evaluation unit draws a time axis X, the X extends rightward to be in a time positive direction, and the order delivery time of all unfinished orders is marked on the X axis;
b: calculating the finishing time of all unfinished orders, taking the finishing time as a starting point of the order delivery time on the X axis, and extending a line segment with the length equal to the finishing time to the left;
c: translating a leftmost line segment leftwards to an X-axis starting point, sequentially translating each subsequent line segment leftwards to be connected with the tail end of the previous line segment, ensuring that no overlap exists between the line segments, wherein the starting point and the ending point of each translated line segment are the production starting time and the production completion time of an unfinished order corresponding to the line segment, and the sequence of the line segments which are sequentially arranged is the production sequence of the unfinished order;
d: if overlapping occurs between the line segments and the line segment cannot be eliminated after the left Fang Xianduan of the overlapped line segment is shifted leftwards, an order delay signal is generated and sent to the outside.
Compared with the prior art, the application has the beneficial effects that:
according to the application, different production speeds among the production lines are obtained, so that different order quantities are distributed to different production lines, the order distribution quantity among the production lines is more reasonable, the utilization rate of raw materials is improved, the phenomenon that raw materials of part of the production lines are stacked and raw materials of part of the production lines are insufficient is prevented, the fund stacking is reduced, and the capability of enterprises for coping with market changes is improved.
According to the application, the speed of different stations on each production line is obtained, so that the resource allocation of different stations on each production line, such as the number of workers, the number of equipment, the number of workers with different number measures, and the like, is realized, the speed difference between different stations on the production line is reduced, and the influence of a certain link on the production line on the overall production speed of the production line is reduced.
According to the application, through linkage adjustment of different stations among a plurality of production lines, the semi-finished product accumulation pressure on one production line can be shared by subsequent stations with higher production speed on other production lines, so that when all stations produce at the maximum production speed, no serious semi-finished product accumulation phenomenon occurs, and the overall production speed of the production line is improved.
In the application, the finishing time of unfinished orders is estimated through the whole production speed of the production line, and the order sequence is reasonably arranged through the finishing time and the order delivery time, so that the on-time production of all orders is ensured as much as possible.
Drawings
The present application is further described below with reference to the accompanying drawings for the convenience of understanding by those skilled in the art.
Fig. 1 is a system block diagram of the present application.
Detailed Description
The technical solutions of the present application will be clearly and completely described in connection with the embodiments, and it is obvious that the described embodiments are only some embodiments of the present application, but not all embodiments. All other embodiments, which can be made by those skilled in the art based on the embodiments of the application without making any inventive effort, are intended to be within the scope of the application.
Example 1
Referring to fig. 1, an intelligent monitoring system for a door curtain production line for an electric welding place based on data analysis comprises an order management unit, a production evaluation unit, a multi-production-line synchronization unit, a station adjustment unit and a supervision center platform, wherein the order management unit is used for acquiring a current unfinished order and order delivery time and sending the unfinished order and the order delivery time to the supervision center platform;
the multi-production-line synchronizing unit obtains the time required by each production line to complete one order product, records the time as one product time, analyzes and counts the product time corresponding to all the production lines, marks different production lines as i, i=1, 2 …, n, and records the product time of each production line as ti, wherein the ratio of the number of the allocated orders of each production line to the total number of the orders of the secondary production isTherefore, different order numbers are distributed to each production line, order distribution amounts among a plurality of production lines are more reasonable, and the utilization rate of raw materials is improved;
the station adjusting unit divides each production line into different stations, acquires the time required by each station to complete the corresponding processing step of an order product, records the time as one step time, analyzes the step time on the station, adjusts the production speed of each station according to analysis results, reduces the step time gap between different stations on each production line, and adjusts the production speed of each station by the station adjusting unit as follows:
marking the step time corresponding to each station on a production line as T, drawing a line graph according to the step time T, and selecting the station corresponding to the maximum step time in the step time and the station corresponding to the minimum step time in all the step time on the production line;
staff or equipment mobilization, such as distribution of the number of workers, the number of equipment, workers with different number of measures and the like, is carried out from the station corresponding to the minimum step time to the station corresponding to the maximum step time, and all the step time is cleared after mobilization;
counting the step time corresponding to different stations on each fresh product after restarting the production, and repeating the first step and the second step, thereby reducing the speed difference between different stations on the production line, and further reducing the influence of a certain link on the production line on the whole production speed of the production line.
The station adjusting unit obtains step time of different stations among the plurality of production lines, and changes the different stations of the plurality of production lines into a product line according to the step time, order distribution amount adjustment is carried out among the different stations on the plurality of production lines, and linkage adjustment of the different stations among the plurality of production lines is carried out, so that when all the stations are produced at the maximum production speed, serious semi-finished product backlog phenomenon cannot occur, and the process of order distribution amount adjustment among the different stations of the plurality of production lines by the station adjusting unit is as follows:
s1: sequentially sequencing the step time of different stations on each production line according to the size, selecting the median value of the step time, taking the median value as a step time reference, in the production line, marking the difference value of the step time exceeding the step time reference to be set as a negative accumulation station, and marking the difference value of the step time lower than the step time reference to be set as a positive accumulation station;
s2: repeating the step S1 for each production line once to obtain a negative accumulation station and a positive accumulation station of each production line, arranging the stations according to a construction sequence, selecting one positive accumulation station, selecting the other positive accumulation station from stations behind the construction sequence of the stations, arranging the positive accumulation stations on all the production lines according to the construction sequence, and arranging the negative accumulation stations on all the production lines according to the construction sequence;
s3: for a certain production line, two adjacent stations on the production line are marked as preface stations, stations with the construction sequence in front are marked as follow-up stations, products of the preface stations on each production line are preferentially supplied to the follow-up stations on the production line, the products on the preface stations are supplied to redundant products after the follow-up stations on the production line, and the redundant products are transferred to the follow-up stations in the arrangement sequence of the stations in the step S2 at regular intervals, so that the accumulation of semi-finished products on a certain production line can be shared by the follow-up stations with higher production speed on other production lines.
Example two
Referring to fig. 1, a supervision center platform obtains the product time of each production line and the step time on each station through a multi-production-line synchronization unit and a station adjustment unit, calculates the step time average value of all production lines, records the step time average value as T1, calculates the step time median value of all production lines, records the step time median value as T2, calculates the production speed V of the whole production line through a formula,wherein k is a preset proportionality coefficient, the supervision center platform sends the production speed V of the whole production line to the production evaluation unit, the production evaluation unit obtains the whole production speeds of a plurality of production lines through the supervision center platform, calculates the finishing time of the unfinished orders according to the whole production speeds, and sorts the unfinished orders through the finishing time of the unfinished orders and the order delivery time, wherein the sorting process is as follows:
a: the production evaluation unit draws a time axis X, the X extends rightward to be in a time positive direction, and the order delivery time of all unfinished orders is marked on the X axis;
b: calculating the finishing time of all unfinished orders, taking the finishing time as a starting point of the order delivery time on the X axis, and extending a line segment with the length equal to the finishing time to the left;
c: translating a leftmost line segment leftwards to an X-axis starting point, sequentially translating each subsequent line segment leftwards to be connected with the tail end of the previous line segment, ensuring that no overlap exists between the line segments, wherein the starting point and the ending point of each translated line segment are the production starting time and the production completion time of an unfinished order corresponding to the line segment, and the sequence of the line segments which are sequentially arranged is the production sequence of the unfinished order;
d: if overlapping occurs between the line segments and the line segments still cannot be eliminated after the left Fang Xianduan of the overlapped line segments is horizontally shifted leftwards, an order delay signal is generated and sent to the outside, so that an administrator can timely acquire the order delay signal and timely make an increase in production speed, increase in production time or coordinate order delivery time of unfinished orders according to the order delay signal, and normal production of enterprises is achieved.
According to the application, different order numbers are distributed to different production lines, so that the order distribution amount among a plurality of production lines is more reasonable, the utilization rate of raw materials is improved, the phenomenon that part of production line raw materials are stacked and part of production line raw materials are insufficient is prevented, fund stacking is reduced, the capability of enterprises to deal with market change is improved, resource distribution of different stations on each production line is realized by acquiring the speeds of different stations on each production line, the influence of a certain link on the whole production line on the whole production speed of the production line is reduced, and the linkage adjustment of different stations among a plurality of production lines is adopted, so that the accumulation of semi-finished products on a certain production line can be shared by the subsequent stations with higher production speeds on other production lines, so that when all stations are produced at the maximum production speed, the serious semi-finished product pressing phenomenon is avoided, the whole production speed of the production line is improved, the complete time of unfinished orders is estimated by the whole production speed of the production line, reasonable arrangement of the order sequence is realized by the delivery time and the order accumulation time is ensured as much as possible.
The preferred embodiments of the application disclosed above are intended only to assist in the explanation of the application. The preferred embodiments are not intended to be exhaustive or to limit the application to the precise form disclosed. Obviously, many modifications and variations are possible in light of the above teaching. The embodiments were chosen and described in order to best explain the principles of the application and the practical application, to thereby enable others skilled in the art to best understand and utilize the application. The application is limited only by the claims and the full scope and equivalents thereof.

Claims (6)

1. The intelligent monitoring system for the door curtain production line for the electric welding place based on the data analysis is characterized by comprising an order management unit, a production evaluation unit, a multi-production-line synchronization unit, a station adjusting unit and a supervision center platform, wherein the order management unit is used for acquiring a current unfinished order and order delivery time and sending the unfinished order and the order delivery time to the supervision center platform;
the multi-production-line synchronizing unit acquires the time required by each production line to finish one order of products, records the time as one product time, and analyzes and counts the product time corresponding to all the production lines, so that different order numbers are distributed to each production line;
the station adjusting unit divides each production line into different stations, acquires the time required by each station to complete the corresponding processing step of a product of an order, and records the time as one step time, analyzes the step time on the station, adjusts the production speed of each station according to the analysis result, and reduces the step time gap between different stations on each production line;
the station adjusting unit acquires the step time of different stations among the plurality of production lines, and changes the product line of the different stations of the plurality of production lines according to the step time, and adjusts the order allocation among the different stations on the plurality of production lines;
the supervision center platform obtains the product time of each production line and the step time on each station through the multi-production-line synchronization unit and the station adjusting unit, and analyzes the product time and the step time to obtain the overall production speed of the plurality of production lines;
the production evaluation unit obtains the overall production speed of a plurality of production lines through the supervision center platform, calculates the finishing time of the unfinished orders according to the overall production speed, and sorts the unfinished orders according to the finishing time of the unfinished orders and the order delivery time.
2. The intelligent monitoring system for door curtain production lines for electric welding sites based on data analysis according to claim 1, wherein the multiple production line synchronization unit marks different production lines as i, i=1, 2 …, n, and the product time record of each production line is ti, the ratio of the number of orders allocated to each production line to the total number of orders produced at the time is
3. The intelligent monitoring system for door curtain production lines for electric welding sites based on data analysis according to claim 1, wherein the production speed adjustment process of the station adjusting unit for each station is as follows:
marking the step time corresponding to each station on a production line as T, drawing a line graph according to the step time T, and selecting the station corresponding to the maximum step time in the step time and the station corresponding to the minimum step time in all the step time on the production line;
staff allocation and equipment allocation are carried out from the station corresponding to the minimum step time to the station corresponding to the maximum step time, and all step time is cleared after allocation;
counting the step time corresponding to different stations on each fresh article after restarting the production, and repeating the first step and the second step.
4. The intelligent monitoring system for door curtain production lines for electric welding sites based on data analysis according to claim 1, wherein the process of order allocation amount adjustment between different stations of the plurality of production lines by the station adjustment unit is as follows:
s1: sequentially sequencing the step time of different stations on each production line according to the size, selecting the median value of the step time, taking the median value as a step time reference, in the production line, marking the difference value of the step time exceeding the step time reference to be set as a negative accumulation station, and marking the difference value of the step time lower than the step time reference to be set as a positive accumulation station;
s2: repeating the step S1 for each production line once to obtain a negative accumulation station and a positive accumulation station of each production line, arranging the stations according to a construction sequence, selecting one positive accumulation station, selecting the other positive accumulation station from stations behind the construction sequence of the stations, arranging the positive accumulation stations on all the production lines according to the construction sequence, and arranging the negative accumulation stations on all the production lines according to the construction sequence;
s3: for a certain production line, two adjacent stations on the production line are marked as preface stations, stations with the construction sequence in front are marked as follow-up stations, products of the preface stations on each production line are preferentially supplied to the follow-up stations on the production line, products on the preface stations are supplied to redundant products after the follow-up stations on the production line, and redundant products are transferred to the follow-up stations in the arrangement sequence of the stations in the step S2 at regular intervals.
5. The intelligent monitoring system for door curtain production lines for electric welding sites based on data analysis according to claim 1, wherein the monitoring center platform obtains the time average value of the steps of all production lines and records the time average value as T1, and obtains all production linesThe median value of the step time of (2) is recorded as T2, the production speed V of the whole production line is calculated through a formula,and k is a preset proportionality coefficient, and the supervision center platform sends the production speed V of the whole production line to the production evaluation unit.
6. The intelligent monitoring system for door curtain production lines for electric welding sites based on data analysis according to claim 1, wherein the production evaluation unit calculates the completion time of completing a batch of incomplete orders according to the production speed of the whole production line, and orders the incomplete orders by analysis, and the ordering process is as follows:
a: the production evaluation unit draws a time axis X, the X extends rightward to be in a time positive direction, and the order delivery time of all unfinished orders is marked on the X axis;
b: calculating the finishing time of all unfinished orders, taking the finishing time as a starting point of the order delivery time on the X axis, and extending a line segment with the length equal to the finishing time to the left;
c: translating a leftmost line segment leftwards to an X-axis starting point, sequentially translating each subsequent line segment leftwards to be connected with the tail end of the previous line segment, ensuring that no overlap exists between the line segments, wherein the starting point and the ending point of each translated line segment are the production starting time and the production completion time of an unfinished order corresponding to the line segment, and the sequence of the line segments which are sequentially arranged is the production sequence of the unfinished order;
d: if overlapping occurs between the line segments and the line segment cannot be eliminated after the left Fang Xianduan of the overlapped line segment is shifted leftwards, an order delay signal is generated and sent to the outside.
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