WO2023217057A1 - 生产控制方法及系统 - Google Patents

生产控制方法及系统 Download PDF

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Publication number
WO2023217057A1
WO2023217057A1 PCT/CN2023/092643 CN2023092643W WO2023217057A1 WO 2023217057 A1 WO2023217057 A1 WO 2023217057A1 CN 2023092643 W CN2023092643 W CN 2023092643W WO 2023217057 A1 WO2023217057 A1 WO 2023217057A1
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WIPO (PCT)
Prior art keywords
production
module
product
information
produced
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PCT/CN2023/092643
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English (en)
French (fr)
Inventor
王勇
王军玲
吴坤林
Original Assignee
卡奥斯工业智能研究院(青岛)有限公司
卡奥斯物联科技股份有限公司
海尔数字科技(青岛)有限公司
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Publication of WO2023217057A1 publication Critical patent/WO2023217057A1/zh

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Classifications

    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/10—Office automation; Time management
    • G06Q10/103—Workflow collaboration or project management
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q30/00—Commerce
    • G06Q30/06—Buying, selling or leasing transactions
    • G06Q30/0601—Electronic shopping [e-shopping]
    • G06Q30/0633—Lists, e.g. purchase orders, compilation or processing
    • G06Q30/0635—Processing of requisition or of purchase orders
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/30—Computing systems specially adapted for manufacturing

Definitions

  • This application relates to the technical field of smart factories, specifically a production control method and system.
  • automated control is mainly used for mechanical control in product production lines, but automated control cannot be realized in other process nodes related to product production lines.
  • This application provides a production control method and system to solve the problem of low product production efficiency and increase the production efficiency of process nodes other than assembly line product production.
  • the present invention provides a production control method, which includes: the communication module receives the order information sent by the corresponding terminal device of the ordering party, and sends the order information to the processing module; the processing module extracts all key fields in the order information; according to All key fields determine the characteristic information of the product to be produced; determine the number of production units to be started based on the characteristic information of the product to be produced; send control instructions to the production module based on the number of production units to be started; the production module starts a or Multiple production units.
  • the communication module receives the order information and sends the order information to the processing module.
  • the processing module extracts the key fields in the order information, obtains the characteristic information from the key fields, and then determines the production unit that needs to be started based on the characteristic information. quantity, and sends control instructions to the production module.
  • the production module starts the production unit according to the control instructions, realizing automated control from obtaining the order to controlling the production unit for production, reducing manual calculation and operation time, and improving product production efficiency.
  • the characteristic information of the product to be produced includes the type of product to be produced, the quantity of the product to be produced, and the delivery time; accordingly, the number of production units to be started is determined based on the characteristic information of the product to be produced, Including: determining the target type of the corresponding production unit according to the type of product to be produced; obtaining the production speed of the unit production unit corresponding to the target type production unit; determining based on the quantity of the product to be produced, delivery time and the production speed of the unit production unit The number of production units to be started.
  • the target type of the production unit is determined based on the type of product to be produced, and the production speed of the unit production unit is obtained from the target type. Finally, the quantity, delivery time and unit production order of the product to be produced are finally determined. According to the production speed of Yuan, the number of production units to be started is obtained, and the number of production units to be started is automatically calculated, which reduces manual calculation time and improves product production efficiency.
  • the number of production units to be started is determined based on the quantity of products to be produced, delivery time and the production speed of the unit production unit, including: obtaining the current time and making the difference between the delivery time and the current time to obtain Time difference: Enter the quantity of products to be produced, the production speed of the unit production unit and the time difference into the preset calculation formula for the number of production units to be started to obtain the number of production units to be started.
  • the number of production units to be started is obtained, without manual labor. Calculation improves factory management efficiency.
  • the calculation formula for the number of production units to be started is as follows:
  • y represents the number of production units to be started
  • x represents the number of products to be produced
  • v represents the production speed of the unit production unit
  • ⁇ t represents the time difference
  • c represents a constant
  • round represents rounding.
  • the required number of production units is calculated based on the number of products to be produced, the production speed of the unit production unit, and the time difference, and is added to the constant to make the number of production units to be started greater than or equal to the minimum required number of production units.
  • the target type of the corresponding production unit after determining the target type of the corresponding production unit according to the type of product to be produced, it also includes: obtaining the production speed of each production unit and the production speed of each production unit corresponding to the target type production unit. Current task volume; input the quantity of products to be produced, delivery time, production speed of each production unit and current task volume of each production unit into the pre-trained production unit selection model to obtain a list of production units to be started; according to the Start the production unit list and send control instructions to the production module.
  • the current task volume of each production unit is also obtained, and the quantity of products to be produced, delivery time, production speed of each production unit and each production unit are The current task volume is input into the pre-trained production unit selection model to obtain the list of production units to be started. Finally, control instructions are sent to the production module based on the list of production units to be started. Achieve the effect of comprehensively considering the details of orders and production units, accurately selecting appropriate production units, and further improving efficiency.
  • extracting all key fields in the order information includes: in the order information, searching for all keywords in the preset keyword table, and using the keywords found in the order information as Target keywords, where the order information contains multiple keywords, each keyword has an associated value field; each target keyword in the order information, the value field associated with each target keyword, and the target keyword are associated with The mapping relationship between the value fields is determined as the key field.
  • the keyword table is used to search for keywords contained in the order information, and the searched keywords are used as target keywords, and each target keyword in the order information, the value field associated with each target keyword, and the target key are The mapping relationship between the word and the associated value field is determined as a key field, which achieves the effect of extracting key information in the order information and facilitates subsequent information extraction.
  • determining the characteristic information of the product to be produced based on all key fields includes: determining the type of product to be produced based on the value field in the first key field, where the first key field is the key field containing the first target keyword; determine the product to be produced based on the value field in the second key field Quantity, where the second key field is a key field containing the second target keyword; the delivery time is determined based on the value field in the third key field, where the third key field is a key field containing the third target keyword key fields.
  • three key fields are used to determine the type of product to be produced, the quantity of products to be produced, and the delivery time, which facilitates subsequent calculation of the number of production units to be started.
  • the system also includes: an inventory management module; accordingly, after determining the characteristic information of the product to be produced based on all key fields, the method also includes: the processing module sends an inventory acquisition instruction to the inventory management module ; The inventory management module obtains inventory information according to the inventory acquisition instruction and sends the inventory information to the processing module; the processing module determines the number of production units to be started based on the characteristic information and inventory information of the product to be produced.
  • the processing module sends an acquisition instruction to the inventory management module to obtain the inventory information.
  • the quantity of products to be manufactured can be obtained more accurately, so that the production to be started can be obtained The number of units is more accurate.
  • the system also includes: a material management module; accordingly, after extracting all key fields in the order information, it also includes: a processing module, based on the order information, determines the expected quantity of materials to be consumed, and reports it to the material management
  • the module sends the material information acquisition instruction; the material management module obtains the existing material information according to the material information acquisition instruction, and sends the material information to the processing module, where the material information contains the existing material quantity; the processing module uses the When the material quantity is determined, the material ordering information is sent to the communication module; the communication module sends the material ordering information to the supplier's corresponding terminal device.
  • the processing module compares the quantity of materials to be consumed by the order information with the quantity of existing materials obtained by the material management module, and when the quantity of materials to be consumed is greater than the quantity of existing materials, the material ordering information is sent to the communication module, and the communication module will Material ordering information is sent to the supplier's corresponding terminal device to achieve the effect of timely replenishment of materials.
  • the system also includes: a data collection module, a database and an alarm module; the method also includes: the data collection module collects operating data and fault data of the production module, stores the operating data in the database, and stores the fault data Store it in the database and send it to the processing module; the processing module controls the alarm module to start an alarm based on the fault data.
  • the operation data and fault data of the production module are collected through the data acquisition module, and are sent and stored. This achieves the effect of saving operation data and alarm data, and issuing alarms based on the alarm data, which helps to improve the safety of the production line. , as well as the tracing of operating faults and operating processes.
  • the system also includes a material turnover module; the method also includes: the data collection module collects the identification of the product and the location of the equipment corresponding to the product, and sends the identification and the location of the equipment corresponding to the product to the processing module; the processing module According to the logo and the location of the product's corresponding equipment, the target location of the product is determined, and the material turnover module is controlled to transport the product to the target location.
  • the product identification and the location of the product's corresponding equipment are collected through the data collection module and sent to the processing module, so that the processing module determines the target location of the product, and controls the material turnover module to transport the product to the target location, realizing unfinished or unfinished products.
  • the effect of transporting finished products in various production units reduces manual transportation time and improves product production efficiency. In the entire processing process of products or parts, try to ensure that the processing time of each process is roughly the same, starting from the first step of the part. From the beginning of a process to the completion of processing, there is no need to wait in the middle, zero turnover inventory is achieved, and the efficiency of the production line is maximized.
  • this application provides a production control system, including: a communication module, a processing module and a production module, where the production module contains multiple production units; the communication module is used to receive order information sent by the corresponding terminal device of the ordering party, and Send the order information to the processing module; the processing module is used to extract all key fields in the order information; determine the characteristic information of the product to be produced based on all key fields; determine the production unit to be started based on the characteristic information of the product to be produced Quantity; send control instructions to the production module according to the number of production units to be started; the production module is used to start one or more production units according to the control instructions.
  • the production control method and system provided by this application sends the order information to the processing module after receiving the order information in the communication module.
  • the processing module extracts the key fields in the order information, obtains the characteristic information from the key fields, and then determines it based on the characteristic information.
  • the number of production units that need to be started, and control instructions are sent to the production module.
  • the production module starts the production units according to the control instructions, realizing automated control from getting the order to controlling the production unit for production, reducing the time of manual calculation and operation, and improving the efficiency of production. Product production efficiency.
  • Figure 1 is a schematic diagram of the system architecture of the production control method provided by the embodiment of the present application.
  • Figure 2 is a schematic flow chart of a production control method provided by an embodiment of the present application.
  • Figure 3 is a schematic diagram 2 of the system architecture of the production control method provided by the embodiment of the present application.
  • the inventor proposed the following technical concept: by setting up a communication module, a processing module and a production module in the production line, the communication module is used to receive the order information sent by the corresponding terminal device of the ordering party, and the order information is sent to the processing module;
  • the processing module extracts all the key information in the order information, and then obtains the characteristic information of the product to be produced based on the key information, and then determines the number of production units to be started based on the characteristic information, and sends control instructions to the production module based on the number of production units to be started.
  • This allows the production module to start one or more production units according to the control instructions. Achieve automatic control of the start-up of production units according to orders, conduct production operations, automate task allocation, and improve efficiency.
  • This application is used in production control scenarios.
  • the acquisition, storage and application of user personal information involved are in compliance with relevant laws and regulations and do not violate public order and good customs.
  • Figure 1 is a schematic diagram of the system architecture of the production control method provided by the embodiment of the present application. As shown in Figure 1, this scenario includes: the ordering party corresponding terminal device 101, the production control system 102, the production control system 102 includes a communication module 1021, a processing module 1022 and a production module 1023, where the production unit 1023 includes multiple production units 1023N.
  • the ordering party corresponds to the terminal device 101, which can include computers, servers, tablets, mobile phones, handheld computers (Personal Digital Assistant, PDA), notebooks, etc., which can input and send data.
  • the terminal device 101 can include computers, servers, tablets, mobile phones, handheld computers (Personal Digital Assistant, PDA), notebooks, etc., which can input and send data.
  • PDA Personal Digital Assistant
  • the communication module 1021 can include an antenna, an industrial communication module, a communication chip, an interface, a router, a network card, a collector, etc.
  • the processing module 1022 may be composed of one or more of a CPU (central processing unit, central processing unit), a programmable logic device (PLD, programmable logic device), a control board, etc.
  • a CPU central processing unit, central processing unit
  • PLD programmable logic device
  • control board etc.
  • the production module 1023 may be composed of a production unit 1023N, an industrial computer that controls the production unit, etc.
  • the production unit 1023N may consist of a processor and/or production equipment in an assembly line. Specifically, it can be a turning and milling compound machining center, a flexible gantry processing unit, a CNC gantry milling machine, a CNC radial drilling and milling machine, a large gear hobbing and grinding machine, a heat treatment desktop furnace, a heat treatment pit furnace and other equipment.
  • the ordering party corresponds to the terminal equipment 101, the production control system 102, and the production control system 102 includes the communication module 1021, the processing module 1022, and the production module 1023.
  • the connection method can be through a wired connection or a wireless network connection, where the wireless network connection
  • the networks used may include various types of wired and wireless networks, such as but not limited to: Internet, LAN, Wireless Fidelity (WIFI), Wireless Local Area Networks (WLAN), General Packet Wireless Service Technology (General Packet Radio Service, GPRS), Code Division Multiple Access (Code Division Multiple Access, CDMA), 2G/3G/4G/5G cellular network, satellite communication network, etc.
  • the ordering party may send order information to the production control system 102 corresponding to the terminal device 101. Specifically, the order information may be sent to the communication module 1021 in the production control system 102.
  • the communication module 1021 is used to receive order information sent by the corresponding terminal device of the ordering party, and send the order information to the processing module 1022.
  • the processing module 1022 is used to extract all key fields in the order information; determine the characteristic information of the product to be produced based on all key fields; determine the number of production units to be started based on the characteristic information of the product to be produced; Quantity, send control instructions to the production module 1023.
  • the production module 1023 is used to start one or more production units 1023N according to the control instructions.
  • the structure illustrated in the embodiment of the present application does not constitute a specific limitation on the production control method.
  • the above architecture may include more or fewer components than shown in the figures, or combine certain components, or split certain components, or arrange different components, which may be determined according to actual applications. The scene is determined and there are no restrictions here.
  • the components shown in Figure 1 may be implemented in hardware, software, or a combination of software and hardware.
  • Figure 2 is a schematic flowchart of a production control method provided by an embodiment of the present application.
  • the execution subject of the embodiment of the present application may be in the production control system in Figure 1, and this embodiment does not place any special restrictions on this.
  • the method includes:
  • the communication module receives the order information sent by the corresponding terminal device of the ordering party and sends the order information to processing module.
  • the order information may be converted and then sent to the processing module, or the order information may be directly forwarded to the processing module.
  • the processing module extracts all key fields in the order information. Based on all key fields, determine the characteristic information of the product to be produced. Determine the number of production units to be started based on the characteristic information of the product to be produced. Send control instructions to the production module according to the number of production units to be started.
  • the characteristic information of the product to be produced may include one or a combination of the quantity of the product to be produced, the delivery time of the product to be produced, the quality requirements of the product to be produced, the type of the product to be produced, etc.
  • this step extracts all key fields in the order information, including:
  • S2021 In the order information, search for all keywords in the preset keyword table, and use the keywords found in the order information as the target keywords, where the order information contains multiple keywords, each keyword There are associated value fields.
  • the preset keyword table may contain pre-entered keywords, such as product name, product type, price, delivery time, order quantity, etc.
  • keywords such as product name, product type, price, delivery time, order quantity, etc.
  • One keyword may be written in each cell. Keywords have corresponding value fields, which can be entered by the ordering party on the terminal device.
  • the order quantity is 1,000 pieces, the order quantity is the keyword, and 1,000 is the corresponding value field; product type: cup, then the product type is the keyword, and cup is the value field.
  • S2022 Determine each target keyword in the order information, the value field associated with each target keyword, and the mapping relationship between the target keyword and the associated value field as key fields.
  • the target keyword and the value field corresponding to the target keyword are jointly determined as the key field.
  • the key fields can be stored in a dictionary or table, and this application does not place special restrictions on this.
  • Key fields include, for example, order quantity 1000, product type cups, etc.
  • the embodiment of the present application uses a keyword table to search for keywords contained in order information, uses the searched keywords as target keywords, and combines each target keyword and each target key in the order information.
  • the value field associated with the word and the mapping relationship between the target keyword and the associated value field are determined as key fields, which achieves the effect of extracting key information in the order information and facilitates subsequent information extraction.
  • the characteristic information of the product to be produced is determined based on all key fields, including:
  • S2023 Determine the type of product to be produced according to the value field in the first key field, where the first key field is a key field containing the first target keyword.
  • the first target keyword may include "product name”, “product category”, “product number” and other key fields that can represent the type of product.
  • S2024 Determine the quantity of the product to be produced according to the value field in the second key field, where the second key field is a key field containing the second target keyword.
  • the second target keyword may include "order quantity”, “product quantity”, “quantity” and other key fields that can represent the quantity of the ordered product.
  • S2025 Determine the delivery time based on the value field in the third key field, where the third key field is a key field containing the third target keyword.
  • the third target keyword can include “delivery time”, “completion time”, “delivery time” “Time” and other key fields that can indicate delivery time.
  • the embodiments of the present application determine the type of product to be produced, the quantity of the product to be produced, and the delivery time through three key fields, so as to facilitate subsequent calculation of the number of production units to be started.
  • S203 The production module starts one or more production units according to the control instruction.
  • control instruction may include the number of production units that need to be started, and may also include the type of production units that need to be started. Production units may correspond to control instructions.
  • the embodiments of the present application send the order information to the processing module after the communication module receives the order information.
  • the processing module extracts key fields in the order information, obtains feature information from the key fields, and then uses the features to The information determines the number of production units that need to be started, and sends control instructions to the production module.
  • the production module starts the production units according to the control instructions, realizing automated control from getting the order to controlling the production unit, reducing the time for manual calculation and operation. Improved product production efficiency.
  • the above characteristic information of the product to be produced includes the type of product to be produced, the quantity of the product to be produced and the delivery time.
  • the production to be started is Number of units, including:
  • S2026 Determine the target type of the corresponding production unit according to the type of product to be produced.
  • the type of product to be produced corresponds to the target type of the production unit.
  • the target type can be found according to the preset product type and the target type comparison table of the production unit.
  • the production speed of the unit production unit corresponding to the target type production unit can have a fixed mapping relationship, and can also be pre-stored in a format such as a table or dictionary.
  • This step may also be to obtain the production speed of each production unit corresponding to the target type production unit. So that in the subsequent step S2028, the appropriate production unit to be started can be selected according to the production speed of each production unit.
  • S2028 Determine the number of production units to be started based on the quantity of products to be produced, delivery time and production speed of the unit production unit.
  • this step specifically includes:
  • S2028A Get the current time and compare the delivery time with the current time to get the time difference.
  • obtaining the current time may be by obtaining the timestamp.
  • S2028B Enter the quantity of products to be produced, the production speed and time difference of the unit production unit into the preset calculation formula for the number of production units to be started, and obtain the number of production units to be started.
  • the embodiment of the present application calculates the time difference between the delivery time and the current time, and inputs the time difference, the number of products to be produced, and the production speed of the unit production unit into the preset calculation formula for the number of production units to be started, to obtain The number of production units to be started does not need to be calculated manually, which improves the management efficiency of the factory.
  • the calculation formula for the number of production units to be started in this step is as follows:
  • y represents the number of production units to be started
  • x represents the number of products to be produced
  • v represents the production speed of the unit production unit
  • ⁇ t represents the time difference
  • c represents a constant
  • round represents rounding.
  • functions other than the round function can also be used for rounding.
  • the embodiment of the present application calculates the required number of production units based on the number of products to be produced, the production speed of the unit production unit, and the time difference, and adds it to a constant, so that the number of production units to be started is greater than or Equal to the minimum required number of production units.
  • the embodiments of the present application determine the target type of the production unit based on the type of product to be produced, and then obtain the production speed of the unit production unit based on the target type. Finally, the quantity and delivery time of the product to be produced are determined. and the production speed of the unit production unit, the number of production units to be started is obtained, and the number of production units to be started is automatically calculated, which reduces manual calculation time and improves product production efficiency.
  • step S2026 determines the target type of the corresponding production unit according to the type of product to be produced, it also includes:
  • S2027A Obtain the production speed of each production unit and the current task volume of each production unit corresponding to the target type production unit.
  • obtaining the production speed can be to obtain the historical production speed, which can be the average, median, maximum, etc.
  • the current task volume of each production unit can be obtained from the production module, or directly from It can be obtained from the production unit or from the database.
  • S2027B Input the quantity of products to be produced, delivery time, production speed of each production unit and current task volume of each production unit into the pre-trained production unit selection model to obtain a list of production units to be started.
  • the pre-trained production unit selection model can be trained using the production unit number or number, the historical production speed of the production unit, and the historical task volume of the production unit.
  • the list of production units to be started contains the IDs or numbers of all production units to be started.
  • S2027C Send control instructions to the production module according to the list of production units to be started.
  • the list of production units to be started and the control instructions may include codes or identifications of all production units to be started.
  • the execution subject of the above steps S2027A to S2027C may be a processing module.
  • the embodiment of the present application not only obtains the production speed of each production unit, but also obtains the current task volume of each production unit, and combines the quantity of products to be produced, delivery time, each production unit
  • the production speed and current task volume of each production unit are input into the pre-trained production unit selection model to obtain a list of production units to be started.
  • control instructions are sent to the production module based on the list of production units to be started. Achieve the effect of comprehensively considering the details of orders and production units, accurately selecting appropriate production units, and further improving efficiency.
  • FIG. 3 is a schematic diagram 2 of the system architecture of the production control method provided by the embodiment of the present application.
  • the system 102 also includes an inventory management module 1024 .
  • the inventory management module 1024 may be composed of a processor, a memory, a detection device such as a scanning device, a data input device such as a keyboard, etc., and is used to count and store inventory data.
  • Methods after determining the characteristic information of the product to be produced based on all key fields, Methods also include:
  • S301 The processing module sends an inventory acquisition instruction to the inventory management module.
  • the inventory acquisition instruction may be a string composed of letters, symbols, and numbers.
  • the inventory management module obtains inventory information according to the inventory acquisition instruction, and sends the inventory information to the processing module.
  • the inventory information may include inventory product categories and the quantity of each category of inventory products.
  • the processing module determines the number of production units to be started based on the characteristic information and inventory information of the product to be produced.
  • the characteristic information and inventory information of the product to be produced may be input into a pre-trained model to obtain the number of production units to be started. It can also be done by subtracting the quantity of products to be produced in the characteristic information of the products to be produced and the quantity of products in stock in the inventory information to obtain the actual quantity of products to be produced, and then combining it with other information in the characteristic information of the products to be produced to determine the number of products to be produced. Start production unit quantity.
  • the specific determination method is similar to the above step S2028 and will not be described again here.
  • this step may also be to determine the list of production units to be started based on the characteristic information and inventory information of the products to be produced.
  • the method of determining the list of production units to be started can be obtained by inputting the model.
  • the embodiment of the present application in the process of determining the number of production units to be started, also obtains inventory information by sending acquisition instructions to the inventory management module, and simultaneously considers the inventory information and the characteristic information of the products to be produced. , the quantity of products to be manufactured can be obtained more accurately, thereby making the number of production units to be started more accurate.
  • the system 102 also includes: a material management module 1025.
  • the material management module 1025 may be composed of a processor, a memory, a detection device such as a scanning device, a data input device such as a keyboard, etc. Used to detect and store material information.
  • step S202 extracts all key fields in the order information, it also includes:
  • the processing module determines the expected quantity of materials to be consumed based on the order information, and sends a material information acquisition instruction to the material management module.
  • the processing module determines the expected quantity of materials to be consumed based on the order information. It can determine the type of the above-mentioned product to be produced based on the order information, and searches the preset material consumption table based on the type of product to be produced to obtain the estimated unit product. The quantity of materials consumed is then multiplied by the estimated quantity of materials consumed per unit product and the quantity of the above-mentioned products to be produced to obtain the total quantity of materials consumed.
  • the material management module obtains instructions based on the material information, obtains existing material information, and sends the material information to the processing module, where the material information contains the quantity of existing materials.
  • the material information may be in tabular form or numerical form, and this application does not place special restrictions on this.
  • the ordering information may include the type of materials ordered, the quantity of materials ordered, etc.
  • the communication module sends the material ordering information to the supplier's corresponding terminal device.
  • the supplier's corresponding terminal device can be a mobile phone, tablet, server, computer, etc. Device for data reception.
  • the embodiment of the present application achieves this by comparing the quantity of materials to be consumed with the quantity of existing materials in the order information, and when the quantity of materials to be consumed is greater than the quantity of existing materials, sending material ordering information to the communication module.
  • the effect of timely replenishment of materials is not limited to the description of the above embodiments.
  • the system 102 also includes: a data collection module 1026, a database 1027, and an alarm module 1028.
  • the data collection module 1026 may be composed of a camera, a scanner, a sensor, a radio frequency identification module, etc.
  • the database 1027 may include a single database or a combination of multiple databases. For example: Oracle (Oracle) database, MySQL (relational database management system), DRDS (Distributed Relational Database Service, distributed relational database) database, ES (Elasticsearch, elastic search) database and other databases, one or more, This application does not place special restrictions on this.
  • the alarm module 1028 may be composed of an alarm, a warning light, a horn, an alarm bell, etc.
  • the above methods also include:
  • the data acquisition module collects the operating data and fault data of the production module, stores the operating data in the database, and stores the fault data in the database and sends it to the processing module.
  • the operation data and fault data are collected, which can be through video monitoring, sensor collection or directly receiving the operation data and fault data sent by the production module.
  • Fault data can include process parameter faults, equipment faults, etc.
  • the processing module controls the alarm module to start an alarm based on the fault data.
  • the processing module controls different devices in the alarm module to start alarms according to the fault type and fault degree of different fault data.
  • the embodiments of the present application achieve the effect of saving operation data and alarm data and issuing alarms based on the alarm data by collecting, sending and storing operation data and fault data, which is helpful to improve the production pipeline. security, as well as traceability of operational faults and operational processes.
  • the above system 102 also includes a material turnover module 1029.
  • the material turnover module 1029 can be composed of gears, chains, transmission belts, wheels, processors, vehicles, data receiving devices, etc. Methods also include:
  • the data collection module collects the identification of the product and the location of the equipment corresponding to the product, and sends the identification and the location of the equipment corresponding to the product to the processing module.
  • the identification of the collected product can be collected by scanning, videography, or taking pictures.
  • the location of the product corresponding to the device can be obtained based on the preset location of the collection module, or can also be obtained based on the preset location of the device.
  • products can also be semi-finished products.
  • the processing module determines the target location of the product based on the logo and the location of the product's corresponding equipment, and controls the material turnover module to transport the product to the target location.
  • the target location of the product is determined based on the logo and the location of the equipment corresponding to the product. This can be done by taking the location of the equipment corresponding to the product as the current location of the product, and searching for the steps of the production process corresponding to the current location in the production process of the product. , and the target position of the production unit for the next production process step.
  • the embodiments of this application collect the product identification and the location of the product's corresponding equipment and send them to the processing module, so that the processing module determines the target location of the product, and controls the material turnover module to transport the product to the target. position to achieve the effect of transporting unfinished or finished products in various production units, reducing manual transportation time and improving product production efficiency.
  • the quantity ensures that the processing time of each process is roughly the same. From the first process of the part to the completion of processing, there is no need to wait in the middle, zero turnover inventory is achieved, and the efficiency of the production line is maximized.
  • the system also includes a data output module.
  • a data output module corresponds to:
  • the data acquisition module collects product data and personnel data in the assembly line, and sends product data, personnel data, operation data and fault data to the processing module.
  • Personnel data can include attendance data, specifically attendance shifts and attendance times.
  • the processing module is also used to calculate personnel production efficiency, personnel hours, and product failure causes based on product data, personnel data, operating data, and failure data.
  • the latest completion time of each step of the process is calculated backwards. If it is found during the backward calculation that the delivery time requirements cannot be met, the system will recommend that the planning manager activate backup equipment or find a new one with the same processing capacity.
  • the equipment completes the preliminary optimization of the schedule through human-computer interaction.
  • the system will then schedule production tasks forward again, merge production tasks based on latest completion time, product specifications and other factors, and adjust the processing sequence.
  • the processing module is also used to allocate similar processing tasks to the same machine on the premise of meeting the delivery date. If it is found that the equipment capacity is sufficient, a message will be automatically sent out, suggesting that the planner shut down some equipment to avoid wasting resources.
  • Process parameters are issued. Produce various quality reports in real time. Real-time monitoring and alarming of process parameters. Real-time analysis of manual inspection quality data. When quality inspection personnel detect quality anomalies on site, the system will analyze the causes and processing methods of similar anomalies in the processing history of such products to provide decision support for solving quality problems. Prepare reports based on the obtained data.
  • the processing module is also used for equipment maintenance unit definition, maintenance process standard management, maintenance cycle management, maintenance job execution management, management of fault knowledge in the database, management of spare parts in the material management module, etc. Calibrate the time of all production units in the above production module. Obtain fault information (can be obtained from the data acquisition module), determine the output reduction based on the fault information, if the output reduction is greater than the preset value, send notification information to the communication module, so that the communication module sends the notification information to the operator, Operation and maintenance personnel and/or sales personnel correspond to the terminal equipment and change the production plan according to the reduction in output. If a fault causes production lag, after the plan and schedule are confirmed, the system automatically adjusts the production plan and updates equipment load, material demand and other information.
  • the upstream and downstream workshop/supplier correlation analysis is performed on the data collected by the data collection module to determine the issues that need attention in production to help operators improve production operation levels and control issues that affect product quality. Parameters, timely detection and termination of unreasonable processing.
  • the system automatically reminds you to realize full-process monitoring, online statistics, and defect traceability. Provide support for improving product quality control.
  • the processing module is also used to obtain data from the data acquisition module, and visually display the equipment processing parameters, personnel information (personnel location, personnel operations), plan execution and other data on the production site in the 3D virtual factory, so that managers and Through monitoring screens, computers and smart terminals, operators can understand the production and operation conditions of the factory and achieve tracking and feedback of the entire production process.
  • the process parameter data, equipment maintenance data (parameters, pictures and/or videos), product quality data, fault data, and personnel information collected by the data acquisition module can also be input into the 3D virtual factory for display. Receive the operation information and quality information from the information collection module, determine the operation details based on the operation information, and send the operation details to the terminal device.
  • the processing module can also interact with other data processing systems.
  • Data processing systems can include: PLM (Product Lifecycle Management), ERP (Enterprise Resource Planning), SCM (Supply Chain Management supply), supply chain management) system.
  • PLM Product Lifecycle Management
  • ERP Enterprise Resource Planning
  • SCM Storageply Chain Management supply
  • supply chain management For example, establish a connection from the above-mentioned PLM system (can be JDBC (Java DataBase Connectivity, java database connection)), read the changed data in the PLM, compare it with the local data, and then perform updates, insertions, deletions, etc., processing module
  • a data query interface is provided to the PLM system in the form of WEB (World Wide Web) service.
  • WEB World Wide Web
  • the PLM system regularly queries equipment efficiency, personnel efficiency and other data.
  • the processing module regularly counts this information based on historical data so that it can provide rapid feedback when querying external systems.
  • ERP mainly provides master production planning information and guides workshops to produce according to orders.
  • the processing module mainly feeds back manufacturing execution status to ERP and updates orders, financial and other information.
  • the ERP system releases the production plan, it calls the WEB service to push contract information, customer information, order quantity, product information, customer required delivery date and other data. After receiving these data, the processing module will perform legality verification and integrity verification, and then Do further business processing.
  • the order status, financial information, etc. in the ERP system are updated through the interface provided by ERP.
  • the processing module is also used to perform simulations based on the received data to optimize the processes of production, transactions, and equipment maintenance. Simulation can use mathematical models, simulation software, and big data.
  • the data acquisition module is also used to collect operating status information (normal production, faults, debugging information, pay-off tension, rotation speed, etc.), test information, equipment operation information, shutdown information, maintenance information, debugging work-hour information, etc.
  • the collected data can be transferred to the on-site production management application through the interface and analyzed and used in different application scenarios.
  • the parameter data, standards, process procedures or related information required for product processing are sent to the processing module together with the scheduling operation instructions, and the processing process information is recorded.
  • Collect process parameters First inspection, patrol inspection, final inspection. Obtain the person's location data and send it to the processing module, so that the processing module controls the above-mentioned alarm module to issue an alarm when the person's location data does not meet the preset requirements (close to the dangerous area).
  • the above-mentioned alarm module is also used to monitor the received process parameters in real time according to the issued process parameter requirements (target value, upper limit, lower limit). Once the limit is exceeded, an alarm is triggered immediately.
  • the above alarm information may include: alarm production line, equipment number, alarm number, alarm text, and time information.
  • the processing module pushes information to the suspension training module according to the preset exception handling process for each parameter.
  • the communication module sends the information to the relevant responsible persons.
  • the system pushes processing suggestions to relevant personnel based on the data in the experience database.
  • the above data is stored in the database, and can be stored in the database when the data changes, so as to reduce the amount of data storage.
  • Special data can be sent directly to the processing module for processing, and the collection frequency can be configured for each parameter. If the real-time performance and changes of some parameters are not obvious and have little impact on product quality, the collection frequency can be reduced. On the contrary, the frequency can be increased, so that Resources can be effectively allocated to emergency areas.
  • the interface data used in the above data transmission module can be stored in the database, and the interface data can be sent in advance through an industrial standard (OPC) client program.
  • OPC industrial standard
  • the data acquisition module asynchronously captures the data in the interface library and writes it into the device parameter delivery buffer.
  • the above-mentioned material turnover module is also used to determine material delivery plans based on material types, production plans, and inventory. Specifically, it can be to supply materials in small batches in time and batches according to the plan; to adjust the feeding batches in real time based on the actual production conditions; to flexibly define logistics routes to achieve full coverage of the supply chain; to flexibly define feeding strategies to feed different types of materials differently. Frequency; seamless integration with automatic logistics equipment to achieve precise distribution; inventory management and delivery management.
  • R&D content includes material demand planning, logistics tracking and information processing, material integration management and intelligent distribution.
  • the above-mentioned inventory management module is also used to calculate material requirements based on future processing orders. If the inventory is lower than the warning threshold, the system automatically triggers the material procurement process.
  • Material requirements planning for processing tasks The system generates a material requirements list for the day based on the production order for the day. The system requires the material warehouse to arrange delivery in batches based on the material allocation in the processing equipment preparation area. Obtain the quantity of semi-finished products corresponding to the target product, subtract the corresponding quantity of semi-finished products from the demand quantity of the target product, and obtain the quantity of goods to be replenished.
  • the above-mentioned production units can all be labeled, barcoded or equipped with electromagnetic tags. It can also be online.
  • the above system can also communicate with terminal equipment of suppliers and sellers. Develop purchasing plans and send purchasing plans to suppliers. After the product is produced, product information can be sent to the seller's terminal device. And start the distribution, after-sales service and other processes.
  • the system can also regularly send the company's latest product information to sellers through the network, and receive quality feedback, user satisfaction and other information from sellers through the network.
  • data that has been screened for validity can be transmitted, or data can be compressed and transmitted to reduce the amount of data transmission.
  • the above-mentioned data collection module, processing module, and alarm module can implement quality alarms when the quality of parts in process is unqualified, display the production line, process, alarm number, alarm text, and alarm time of the alarm; and display the quality to the production site and office
  • Abnormal report information displays the production line, work section, production process, discovery time, phenomenon description, reporter and other information of the quality abnormal alarm. You can also analyze the causes of problems based on alarm data.
  • the data collection module is also used to collect the working parameters, processing progress, etc. of the processing workshop equipment and send them to the monitoring equipment.
  • the monitoring equipment displays the working parameter information of the processing equipment.
  • the working parameter information includes the equipment's working oil temperature, spindle speed and other processing parameters. , torque, power, etc.; the working status monitoring of the production unit in the processing workshop, the displayed information includes startup, normal working status, fault, shutdown, etc. Monitor and display the overall operation status of CNC processing equipment.
  • the displayed information includes: shutdown, alarm, startup, station production, blanking without parts, loading blockage, technical interruption, cycle start, etc.
  • Progress monitoring Processing progress includes the overall completion status of the daily production operation plan of the processing line.
  • the information includes the number of daily operation plans completed in the workshop, the total number of parts currently completed, the number of parts completed per hour, and the current number of work in progress. , the number of unqualified products; real-time production monitoring in the processing workshop, real-time display of the number of processed parts in each process of the processing line, the number of qualified products, the number of storage areas, the quantity on the production line, the number of unqualified products, etc.
  • the data acquisition module is also used to collect energy consumption data and send the energy consumption data to the processing module.
  • the processing module can also be used to adjust the production plan based on the energy consumption data.
  • the data collected by the data collection module can use power supply redundancy, server redundancy, and database redundancy to ensure the security of the collected data.
  • the above processing module can be integrated with a digital control program. You can also combine the data in the database to formulate a material flow information traceability table (including material movement details), a personnel operating time traceability table (time to start production, equipment used, product information, etc.), and an equipment processing traceability table (including processing time, location, etc.) Process and other data), equipment historical status table (including processing, debugging, idle, shutdown, maintenance, failure time, details, charts, etc.), equipment maintenance table (including exception description, event generation time, response time, responder, response duration, completion time time, completion person, completion time, etc.), production records of each stage (including equipment used, product information, processing time, etc.)
  • a material flow information traceability table including material movement details
  • a personnel operating time traceability table time to start production, equipment used, product information, etc.
  • an equipment processing traceability table including processing time, location, etc.
  • equipment historical status table including processing, debugging, idle, shutdown, maintenance, failure time, details, charts, etc.
  • equipment maintenance table including exception description

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Abstract

本发明实施例提供一种生产控制方法及系统，方法应用于生产控制系统，所述生产控制系统包括：通讯模块、处理模块及生产模块，其中所述生产模块含有多个生产单元；所述方法包括：所述通讯模块接收订购方对应终端设备发送的订单信息，并将所述订单信息发送至所述处理模块；所述处理模块提取所述订单信息中的所有关键字段；根据所述所有关键字段，确定待生产产品的特征信息；根据所述待生产产品的特征信息，确定待启动生产单元数量；根据所述待启动生产单元数量，向所述生产模块发送控制指令；所述生产模块根据所述控制指令启动一个或多个所述生产单元。本申请的方法，增加了产品生产效率。

Description

生产控制方法及系统
本申请要求于2022年05月12日提交中国专利局、申请号为202210514755.8、申请名称为“生产控制方法及系统”的中国专利申请的优先权，其全部内容通过引用结合在本申请中。
技术领域
本申请涉及智慧工厂技术领域，具体涉及一种生产控制方法及系统。
背景技术
随着社会经济的不断发展，为了降低商品的制造成本，通常需要大量制造相同的产品，因此商品的生产逐渐趋向于规模化、流程化、标准化。
相关技术中，自动化控制主要应用于产品生产流水线中的机械控制方面，而在流水线产品生产相关的其他流程节点中无法实现自动化控制。
然而，发明人发现相关技术至少存在如下技术问题：在流水线产品生产以外的流程节点无法采用自动化控制，导致生产效率低。
发明内容
本申请提供一种生产控制方法及系统，用以解决产品生产效率低的问题，增加在流水线产品生产以外流程节点的生产效率。
第一方面，本发明提供一种生产控制方法，包括：通讯模块接收订购方对应终端设备发送的订单信息，并将订单信息发送至处理模块；处理模块提取订单信息中的所有关键字段；根据所有关键字段，确定待生产产品的特征信息；根据待生产产品的特征信息，确定待启动生产单元数量；根据待启动生产单元数量，向生产模块发送控制指令；生产模块根据控制指令启动一个或多个生产单元。
基于上述技术内容，通过在通讯模块接收订单信息后将订单信息发送至处理模块，处理模块提取订单信息中的关键字段，从关键字段得到特征信息，再由特征信息确定需要启动的生产单元数量，并向生产模块发送控制指令，生产模块根据控制指令启动生产单元，实现了由得到订单到控制生产单元进行生产的自动化控制，减少了人工计算和操作的时间，提升了产品生产效率。
在一种可能的实现方式中，待生产产品的特征信息，包括待生产产品的种类、待生产产品的数量及交付时间；相应地，根据待生产产品的特征信息，确定待启动生产单元数量，包括：根据待生产产品的种类，确定对应的生产单元的目标种类；获取目标种类生产单元对应的单位生产单元的生产速度；根据待生产产品的数量、交付时间及单位生产单元的生产速度，确定待启动生产单元数量。
进一步的，通过由待生产产品的种类，确定生产单元的目标种类，又由目标种类得到了单位生产单元的生产速度，最后由待生产产品的数量、交付时间及单位生产单 元的生产速度，得到了待启动生产单元数量，实现自动计算待启动生产单元的数量，减少了人工计算的时间，提升了产品生产效率。
在一种可能的实现方式中，根据待生产产品的数量、交付时间及单位生产单元的生产速度，确定待启动生产单元数量，包括：获取当前时间，并将交付时间与当前时间作差，得到时间差；将待生产产品的数量、单位生产单元的生产速度及时间差，输入预设的待启动生产单元数量计算公式，得到待启动生产单元数量。
进一步的，通过计算交付时间与当前时间的时间差，并将时间差和待生产产品数量、单位生产单元的生产速度输入预设的待启动生产单元数量计算公式，得到待启动生产单元数量，无需人工手动计算，提升了工厂的管理效率。
在一种可能的实现方式中，待启动生产单元数量计算公式，如下：
其中，y表示待启动生产单元数量，x表示待生产产品的数量，v表示单位生产单元的生产速度，Δt表示时间差，c表示常数，round表示取整。
进一步的，根据待生产产品的数量、单位生产单元的生产速度、时间差计算出了需要的生产单元数量，并与常数相加，使待启动生产单元数量大于或等于最少需要的生产单元数量。
在一种可能的实现方式中，根据待生产产品的种类，确定对应的生产单元的目标种类之后，还包括：获取目标种类生产单元对应的，每个生产单元的生产速度及每个生产单元的当前任务量；将待生产产品的数量、交付时间、每个生产单元的生产速度及每个生产单元的当前任务量，输入预先训练得到的生产单元选取模型，得到待启动生产单元名单；根据待启动生产单元名单，向生产模块发送控制指令。
进一步的，通过除了获取每个生产单元的生产速度，还获取了每个生产单元的当前任务量，并将待生产产品的数量、交付时间、每个生产单元的生产速度及每个生产单元的当前任务量输入预先训练得到的生产单元选取模型，得到待启动生产单元名单，最后根据待启动生产单元名单，向生产模块发送控制指令。实现综合考虑订单和生产单元的详细情况，准确选取合适的生产单元，进一步提升效率的效果。
在一种可能的实现方式中，提取订单信息中的所有关键字段，包括：在订单信息中，查找预设关键字表中的所有关键字，并将在订单信息中查找得到的关键字作为目标关键字，其中，订单信息包含多个关键字，每个关键字都有关联的值字段；将订单信息中的各目标关键字、各目标关键字关联的值字段，及目标关键字与关联的值字段之间的映射关系，确定为关键字段。
进一步的，通过采用关键字表查找订单信息中含有的关键字，将查找得到的关键字作为目标关键字，将订单信息中的各目标关键字、各目标关键字关联的值字段，及目标关键字与关联的值字段之间的映射关系，确定为关键字段，实现了提取订单信息中的关键信息，便于后续进行信息提取的效果。
在一种可能的实现方式中，根据所有关键字段，确定待生产产品的特征信息，包括：根据第一关键字段中的值字段，确定待生产产品的种类，其中，第一关键字段为包含第一目标关键字的关键字段；根据第二关键字段中的值字段，确定待生产产品的 数量，其中，第二关键字段为包含第二目标关键字的关键字段；根据第三关键字段中的值字段，确定交付时间，其中，第三关键字段为包含第三目标关键字的关键字段。
进一步的，通过三种关键字段，分别确定了待生产产品的种类、待生产产品的数量和交付时间，便于后续计算待启动生产单元的数量。
在一种可能的实现方式中，系统还包括：库存管理模块；相应地，在根据所有关键字段，确定待生产产品的特征信息之后，方法还包括：处理模块向库存管理模块发送库存获取指令；库存管理模块根据库存获取指令获取库存信息，并将库存信息发送至处理模块；处理模块根据待生产产品的特征信息及库存信息，确定待启动生产单元数量。
进一步的，通过处理模块向库存管理模块发送获取指令，得到了库存信息，通过同时考虑库存信息和待生产产品的特征信息，可以更准确的得到需要制造的产品数量，从而使得到的待启动生产单元数量更加准确。
在一种可能的实现方式中，系统还包括：物料管理模块；相应地，提取订单信息中的所有关键字段之后，还包括：处理模块根据订单信息，确定预计消耗物资数量，并向物料管理模块发送物料信息获取指令；物料管理模块根据物料信息获取指令，获取现有物料信息，并将物料信息发送至处理模块，其中物料信息含有现有物料数量；处理模块在预计消耗物资数量大于现有物料数量时，向通讯模块发送物料订购信息；通讯模块将物料订购信息发送至供应商对应终端设备。
进一步的，通过处理模块比较订单信息需要消耗的物料数量和物料管理模块获取的现有物料数量，并在需要消耗的物料数量大于现有物料数量时，向通讯模块发送物料订购信息，通讯模块将物料订购信息发送至供应商对应终端设备，实现及时补充物料的效果。
在一种可能的实现方式中，系统还包括：数据采集模块、数据库及告警模块；方法还包括：数据采集模块采集生产模块的运行数据及故障数据，并将运行数据存入数据库，将故障数据存入数据库并发送至处理模块；处理模块根据故障数据控制告警模块启动告警。
进一步的，通过数据采集模块采集生产模块的运行数据和故障数据，并进行发送和储存，实现了保存运行数据和告警数据，并根据告警数据进行告警的效果，有助于提升生产流水线的安全性，以及运行故障、运行流程的追溯。
在一种可能的实现方式中，系统还包括物资周转模块；方法还包括：数据采集模块采集产品的标识及产品对应设备的位置，并将标识及产品对应设备的位置发送至处理模块；处理模块根据标识及产品对应设备的位置，确定产品的目标位置，并控制物资周转模块将产品运送至目标位置。
进一步的，通过数据采集模块采集产品标识及产品对应设备的位置，并发送至处理模块，实现由处理模块确定产品的目标位置，并控制物资周转模块将产品运输至目标位置，实现未制成或已制成的产品在各个生产单元运输的效果，减少了人工运输的时间，提升了产品生产效率，在产品或零件的整个加工流程中，尽量保证每个工序加工时间大致相同，从零件的第一道工序开始，直至加工完成，中间无需等待，实现零周转库存，同时生产线效率得到最大的发挥。
第二方面，本申请提供一种生产控制系统，包括：通讯模块、处理模块及生产模块，其中生产模块含有多个生产单元；通讯模块，用于接收订购方对应终端设备发送的订单信息，并将订单信息发送至处理模块；处理模块，用于提取订单信息中的所有关键字段；根据所有关键字段，确定待生产产品的特征信息；根据待生产产品的特征信息，确定待启动生产单元数量；根据待启动生产单元数量，向生产模块发送控制指令；生产模块，用于根据控制指令启动一个或多个生产单元。
本申请提供的生产控制方法及系统，通过在通讯模块接收订单信息后将订单信息发送至处理模块，处理模块提取订单信息中的关键字段，从关键字段得到特征信息，再由特征信息确定需要启动的生产单元数量，并向生产模块发送控制指令，生产模块根据控制指令启动生产单元，实现了由得到订单到控制生产单元进行生产的自动化控制，减少了人工计算和操作的时间，提升了产品生产效率。
附图说明
图1为本申请实施例提供的生产控制方法的系统架构示意图一；
图2为本申请实施例提供的生产控制方法的流程示意图；
图3为本申请实施例提供的生产控制方法的系统架构示意图二。
具体实施方式
这里将详细地对示例性实施例进行说明，其示例表示在附图中。下面的描述涉及附图时，除非另有表示，不同附图中的相同数字表示相同或相似的要素。以下示例性实施例中所描述的实施方式并不代表与本申请相一致的所有实施方式。相反，它们仅是与如所附权利要求书中所详述的、本申请的一些方面相一致的装置和方法的例子。
当前自动控制技术逐渐成熟，并广泛应用于机械控制方面，通过控制各种生产机械，实现产品的批量、自动化生产，有效降低了产品的制造成本。
但是自动化生产当前还仅限于在机器控制方面，对于生产产品的其他过程，大多数还是人工进行处理，未采用自动化控制。这导致了生产效率较低的问题。
发明人针对上述技术问题，提出如下技术构思：通过在生产流水线中设置通讯模块、处理模块及生产模块，采用通讯模块接收订购方对应终端设备发送的订单信息，并将订单信息发送至处理模块；处理模块提取订单信息中的所有关键信息，再根据关键信息，得到待生产产品的特征信息，再根据特征信息，确定待启动生产单元数量，根据待启动生产单元数量，向生产模块发送控制指令，从而让生产模块根据控制指令启动一个或多个生产单元。实现在根据订单自动控制生产单元启动，进行生产操作，自动化执行任务分配，提升效率。
本申请应用于生产控制的场景中。本申请的技术方案中，所涉及的用户个人信息的获取，存储和应用等，均符合相关法律法规的规定，且不违背公序良俗。
图1为本申请实施例提供的生产控制方法的系统架构示意图一。如图1所示，该场景中，包括：订购方对应终端设备101，生产控制系统102，生产控制系统102包括通讯模块1021、处理模块1022及生产模块1023，其中生产单元1023包括多个生产单元1023N。
在具体实现过程中，订购方对应终端设备101，可以包括计算机、服务器、平板、手机、掌上电脑(Personal Digital Assistant，PDA)以及笔记本等，它们可以进行数据的输入和发送。
通讯模块1021，可以由天线、工业通讯模块、通讯芯片、接口、路由、网卡、采集器等。
处理模块1022，可以由CPU(central processing unit，中央处理器)、可编程逻辑器件(PLD，programmable logic device)及控制板等中的一种或多种组成。
生产模块1023，可以由生产单元1023N、控制生产单元的工控机等组成。
生产单元1023N，可以由处理器和/或流水线中的生产设备。具体可以是车铣复合加工中心、柔性龙门加工单元、数控龙门铣、数控摇臂钻铣床、大型滚齿磨齿机、热处理台式炉、热处理井式炉等设备。
订购方对应终端设备101、生产控制系统102、生产控制系统102包括通讯模块1021、处理模块1022及生产模块1023之间的连接方式，可以是通过有线连接也可以通过无线网络连接，其中无线网络连接使用的网络可以包括各种类型的有线和无线网络，例如但不局限于：互联网、局域网、无线保真(Wireless Fidelity，WIFI)、无线局域网(Wireless Local Area Networks，WLAN)、通用分组无线服务技术(General Packet Radio Service，GPRS)、码分多址(Code Division Multiple Access，CDMA)、2G/3G/4G/5G蜂窝网络、卫星通信网络等等。
订购方对应终端设备101，可以向生产控制系统102发送订单信息，具体的，可以是向生产控制系统102中的通讯模块1021发送订单信息。
通讯模块1021，用于接收订购方对应终端设备发送的订单信息，并将订单信息发送至处理模块1022。
处理模块1022，用于提取订单信息中的所有关键字段；根据所有关键字段，确定待生产产品的特征信息；根据待生产产品的特征信息，确定待启动生产单元数量；根据待启动生产单元数量，向生产模块1023发送控制指令。
生产模块1023，用于根据控制指令启动一个或多个生产单元1023N。
可以理解的是，本申请实施例示意的结构并不构成对生产控制方法的具体限定。在本申请另一些可行的实施方式中，上述架构可以包括比图示更多或更少的部件，或者组合某些部件，或者拆分某些部件，或者不同的部件布置，具体可根据实际应用场景确定，在此不做限制。图1所示的部件可以以硬件，软件，或软件与硬件的组合实现。
下面以具体地实施例对本申请的技术方案以及本申请的技术方案如何解决上述技术问题进行详细说明。下面这几个具体的实施例可以相互结合，对于相同或相似的概念或过程可能在某些实施例中不再赘述。下面将结合附图，对本申请的实施例进行描述。
图2为本申请实施例提供的生产控制方法的流程示意图。本申请实施例的执行主体可以是图1中的生产控制系统中的，本实施例对此不作特别限制。如图2所示，该方法包括：
S201：通讯模块接收订购方对应终端设备发送的订单信息，并将订单信息发送至 处理模块。
在本步骤中，可以是将订单信息进行转换后发送至处理模块，也可以是直接将订单信息转发中处理模块。
S202：处理模块提取订单信息中的所有关键字段。根据所有关键字段，确定待生产产品的特征信息。根据待生产产品的特征信息，确定待启动生产单元数量。根据待启动生产单元数量，向生产模块发送控制指令。
其中，待生产产品的特征信息可以包括待生产产品的数量、待生产产品的交付时间、待生产产品的质量要求、待生产产品的种类等中的一种或多种的组合。
在一种可能的实现方式中，本步骤提取订单信息中的所有关键字段，包括：
S2021：在订单信息中，查找预设关键字表中的所有关键字，并将在订单信息中查找得到的关键字作为目标关键字，其中，订单信息包含多个关键字，每个关键字都有关联的值字段。
在本步骤中，预设关键字表中可以包含预先输入的关键字，例如产品名、产品种类、价格、交付时间、订购数量等，可以是每个格写入一个关键字。关键字有对应的值字段，可以是订购方在终端设备输入的。
例如，订购数量1000件，订购数量为关键字，1000为对应的值字段；产品种类：杯子，则产品种类为关键字，杯子为值字段。
S2022：将订单信息中的各目标关键字、各目标关键字关联的值字段，及目标关键字与关联的值字段之间的映射关系，确定为关键字段。
在本步骤中，即将目标关键字及目标关键字对应的值字段共同确定为关键字段。关键字段的存储方式可以是以字典、表格的方式存储，本申请对此不作特殊限制。
关键字段例如，订购数量1000、产品种类杯子等。
从上述实施例的描述可知，本申请实施例通过采用关键字表查找订单信息中含有的关键字，将查找得到的关键字作为目标关键字，将订单信息中的各目标关键字、各目标关键字关联的值字段，及目标关键字与关联的值字段之间的映射关系，确定为关键字段，实现了提取订单信息中的关键信息，便于后续进行信息提取的效果。
在一种可能的实现方式中，上述步骤S202中，根据所有关键字段，确定待生产产品的特征信息，包括：
S2023：根据第一关键字段中的值字段，确定待生产产品的种类，其中，第一关键字段为包含第一目标关键字的关键字段。
在本步骤中，第一目标关键字，可以包括“产品名”、“产品类别”、“产品编号”等可以表示产品的种类的关键字段。
S2024：根据第二关键字段中的值字段，确定待生产产品的数量，其中，第二关键字段为包含第二目标关键字的关键字段。
在本步骤中，第二目标关键字，可以包括“订购数”、“产品数量”、“数量”等可以表示订购产品的数量的关键字段。
S2025：根据第三关键字段中的值字段，确定交付时间，其中，第三关键字段为包含第三目标关键字的关键字段。
在本步骤中，第三目标关键字，可以包括“交付时间”、“完成时间”、“交货 时间”等可以表示交付时间的关键字段。
从上述实施例的描述可知，本申请实施例通过三种关键字段，分别确定了待生产产品的种类、待生产产品的数量和交付时间，便于后续计算待启动生产单元的数量。
S203：生产模块根据控制指令启动一个或多个生产单元。
在本步骤中，控制指令可以包含需要启动的生产单元的数量，还可以包含需要启动的生产单元的种类。生产单元可以是与控制指令对应的。
从上述实施例的描述可知，本申请实施例通过在通讯模块接收订单信息后将订单信息发送至处理模块，处理模块提取订单信息中的关键字段，从关键字段得到特征信息，再由特征信息确定需要启动的生产单元数量，并向生产模块发送控制指令，生产模块根据控制指令启动生产单元，实现了由得到订单到控制生产单元进行生产的自动化控制，减少了人工计算和操作的时间，提升了产品生产效率。
在一种可能的实现方式中，上述待生产产品的特征信息，包括待生产产品的种类、待生产产品的数量及交付时间，上述步骤S202中，根据待生产产品的特征信息，确定待启动生产单元数量，包括：
S2026：根据待生产产品的种类，确定对应的生产单元的目标种类。
在本步骤中，待生产产品的种类对应生产单元的目标种类，可以根据预设的产品种类与生产单元的目标种类对照表，查找得到目标种类。
其中，产品种类与生产单元的目标种类对照表，例如表1。
表1产品种类与生产单元的目标种类对照表(示意)
S2027：获取目标种类生产单元对应的单位生产单元的生产速度。
在本步骤中，目标种类生产单元对应的单位生产单元的生产速度可以有固定的映射关系，同样可以是由表格或字典等格式预先储存的。
本步骤还可以是，获取目标种类生产单元对应的每个生产单元的生产速度。以使后续步骤S2028中可以根据每个生产单元的生产速度，选取合适的待启动生产单元。
S2028：根据待生产产品的数量、交付时间及单位生产单元的生产速度，确定待启动生产单元数量。
在一种可能的实现方式中，本步骤具体包括：
S2028A：获取当前时间，并将交付时间与当前时间作差，得到时间差。
在本步骤中，获取当前时间可以是通过获取时间戳的方式获取当前时间。
S2028B：将待生产产品的数量、单位生产单元的生产速度及时间差，输入预设的待启动生产单元数量计算公式，得到待启动生产单元数量。
从上述实施例的描述可知，本申请实施例通过计算交付时间与当前时间的时间差，并将时间差和待生产产品数量、单位生产单元的生产速度输入预设的待启动生产单元数量计算公式，得到待启动生产单元数量，无需人工手动计算，提升了工厂的管理效率。
在一种可能的实施方式中，本步骤中的待启动生产单元数量计算公式，如下：
其中，y表示待启动生产单元数量，x表示待生产产品的数量，v表示单位生产单元的生产速度，Δt表示时间差，c表示常数，round表示取整。其中，取整也可以使用round函数以外的其他函数。
从上述实施例的描述可知，本申请实施例通过待生产产品的数量、单位生产单元的生产速度、时间差计算出了需要的生产单元数量，并与常数相加，使待启动生产单元数量大于或等于最少需要的生产单元数量。
从上述实施例的描述可知，本申请实施例通过由待生产产品的种类，确定生产单元的目标种类，又由目标种类得到了单位生产单元的生产速度，最后由待生产产品的数量、交付时间及单位生产单元的生产速度，得到了待启动生产单元数量，实现自动计算待启动生产单元的数量，减少了人工计算的时间，提升了产品生产效率。
在一种可能的实现方式中，在上述步骤S2026根据待生产产品的种类，确定对应的生产单元的目标种类之后，还包括：
S2027A：获取目标种类生产单元对应的，每个生产单元的生产速度及每个生产单元的当前任务量。
在本步骤中，获取生产速度可以是获取历史的生产速度，可以是平均值、中位数、最大值等，每个生产单元的当前任务量可以是从生产模块获取的，也可以是直接从生产单元获取的，还可以是从数据库获取的。
S2027B：将待生产产品的数量、交付时间、每个生产单元的生产速度及每个生产单元的当前任务量，输入预先训练得到的生产单元选取模型，得到待启动生产单元名单。
在本步骤中，预先训练得到的生产单元选取模型可以是采用生产单元编号或编号、生产单元历史生产速度、生产单元历史任务量训练得到的。待启动生产单元名单中包含所有待启动生产单元的标识或编号。
S2027C：根据待启动生产单元名单，向生产模块发送控制指令。
本步骤中，待启动生产单元名单和控制指令可以包括所有待启动生产单元的编码或标识。上述步骤S2027A至S2027C的执行主体可以是处理模块。
从上述实施例的描述可知，本申请实施例通过除了获取每个生产单元的生产速度，还获取了每个生产单元的当前任务量，并将待生产产品的数量、交付时间、每个生产单元的生产速度及每个生产单元的当前任务量输入预先训练得到的生产单元选取模型，得到待启动生产单元名单，最后根据待启动生产单元名单，向生产模块发送控制指令。实现综合考虑订单和生产单元的详细情况，准确选取合适的生产单元，进一步提升效率的效果。
图3为本申请实施例提供的生产控制方法的系统架构示意图二。如图3所示，系统102还包括：库存管理模块1024。库存管理模块1024，可以由处理器、存储器、扫描设备等检测设备、键盘等数据输入设备等组成，用于统计并储存库存数据。
相应地，在上述步骤S202，根据所有关键字段，确定待生产产品的特征信息之后， 方法还包括：
S301：处理模块向库存管理模块发送库存获取指令。
在本步骤中，库存获取指令可以是以字母、符号、数字组成的字符串。
S302：库存管理模块根据库存获取指令获取库存信息，并将库存信息发送至处理模块。
在本步骤中，库存信息可以包括库存产品种类，每个种类的库存产品的数量。
S303：处理模块根据待生产产品的特征信息及库存信息，确定待启动生产单元数量。
在本步骤中，可以是将待生产产品的特征信息及库存信息输入预先训练好的模型，得到待启动生产单元数量。也可以是将待生产产品的特征信息中的待生产产品数量与库存信息中的库存产品数量相减，得到实际需要生产产品的数量，再结合待生产产品的特征信息中的其他信息，确定待启动生产单元数量。具体确定方式与上述步骤S2028类似，在这里不再赘述。
在一种可能的实现方式中，本步骤也可以是，根据待生产产品的特征信息及库存信息，确定待启动生产单元名单。
其中，待启动生产单元名单的确定方式，可以是输入模型得到。
从上述实施例的描述可知，本申请实施例在确定待启动生产单元数量的过程中，还通过向库存管理模块发送获取指令，得到了库存信息，通过同时考虑库存信息和待生产产品的特征信息，可以更准确的得到需要制造的产品数量，从而使得到的待启动生产单元数量更加准确。
继续参考图3。在一种可能的实现方式中，系统102还包括：物料管理模块1025。物料管理模块1025，可以由处理器、存储器、扫描设备等检测设备、键盘等数据输入设备等组成。用于检测并储存物料信息。
相应地，上述步骤S202提取订单信息中的所有关键字段之后，还包括：
S304：处理模块根据订单信息，确定预计消耗物资数量，并向物料管理模块发送物料信息获取指令。
在本步骤中，处理模块根据订单信息，确定预计消耗物资数量，可以是根据订单信息确定上述待生产产品的种类，并根据待生产产品的种类，查找预设的物资消耗表，得到单位产品预计消耗物资数量，再将单位产品预计消耗物资数量及上述待生产产品的数量相乘，得到总物资消耗数量。
S305：物料管理模块根据物料信息获取指令，获取现有物料信息，并将物料信息发送至处理模块，其中物料信息含有现有物料数量。
在本步骤中，物料信息可以是表格形式的，也可以是数值形式的，本申请对此不作特殊限制。
S306：处理模块在预计消耗物资数量大于现有物料数量时，向通讯模块发送物料订购信息。
在本步骤中，订购信息可以包括订购的物料种类，订购的物料数量等。
S307：通讯模块将物料订购信息发送至供应商对应终端设备。
在本步骤中，供应商对应终端设备可以是手机、平板电脑、服务器、电脑等可以 进行数据接收的设备。
从上述实施例的描述可知，本申请实施例通过比较订单信息需要消耗的物料数量和现有物料数量，并在需要消耗的物料数量大于现有物料数量时，向通讯模块发送物料订购信息，实现及时补充物料的效果。
继续参考图3。在一种可能的实现方式中，系统102还包括：数据采集模块1026、数据库1027及告警模块1028。数据采集模块1026可以由摄像头、扫描仪、传感器、射频识别模块等组成，数据库1027可以包括单独一种数据库也可以是多种数据库的组合。例如：Oracle(甲骨文)数据库、MySQL(关系型数据库管理系统)、DRDS(Distribute Relational Database Service，分布式关系型数据库)数据库、ES(Elasticsearch，弹性搜索)数据库等数据库中的一种或多种，本申请对此不作特殊限制，告警模块1028可以由告警器、警示灯、喇叭、警铃等组成。上述方法还包括：
S308：数据采集模块采集生产模块的运行数据及故障数据，并将运行数据存入数据库，将故障数据存入数据库并发送至处理模块。
在本步骤中，采集运行数据及故障数据，可以是通过视频监控、传感器采集或直接接收生产模块发送的运行数据及故障数据。故障数据可以包括工艺参数故障和设备故障等。
S309：处理模块根据故障数据控制告警模块启动告警。
在本步骤中，处理模块根据不同的故障数据的故障类型、故障程度，分别控制告警模块中不同的装置启动告警。
从上述实施例的描述可知，本申请实施例通过采集运行数据和故障数据，并进行发送和储存，实现了保存运行数据和告警数据，并根据告警数据进行告警的效果，有助于提升生产流水线的安全性，以及运行故障、运行流程的追溯。
继续参考图3。在一种可能的实现方式中，上述系统102还包括物资周转模块1029，物资周转模块1029可以由齿轮、链条、传输带、轮、处理器、车、数据接收装置等组成。方法还包括：
S310：数据采集模块采集产品的标识及产品对应设备的位置，并将标识及产品对应设备的位置发送至处理模块。
在本步骤中，采集产品的标识可以通过扫描、摄像、拍照的方式采集。产品对应设备的位置可以根据采集模块预设的位置获得，还可以根据设备的预设位置获得。
其中，产品也可以是半成品。
S311：处理模块根据标识及产品对应设备的位置，确定产品的目标位置，并控制物资周转模块将产品运送至目标位置。
在本步骤中，根据标识及产品对应设备的位置，确定产品的目标位置，可以是将产品对应设备的位置作为产品的当前位置，并在产品的生产流程中查找当前位置对应的生产流程的步骤，以及下一生产流程的步骤的生产单元的目标位置。
从上述申请实施例的描述可知，本申请实施例通过采集产品标识及产品对应设备的位置，并发送至处理模块，实现由处理模块确定产品的目标位置，并控制物资周转模块将产品运输至目标位置，实现未制成或已制成的产品在各个生产单元运输的效果，减少了人工运输的时间，提升了产品生产效率，在产品或零件的整个加工流程中，尽 量保证每个工序加工时间大致相同，从零件的第一道工序开始，直至加工完成，中间无需等待，实现零周转库存，同时生产线效率得到最大的发挥。
在图中未示出的部分，系统还包括数据输出模块。相应地，采集生产模块的运行数据及故障数据之后，还包括：
数据采集模块采集产品数据及流水线中的人员数据，并将产品数据、人员数据、运行数据及故障数据发送至处理模块。
采集产品数据及流水线中的人员数据，可以是通过摄像头或传感器采集。人员数据可以包括出勤数据，具体可以是出勤班次和出勤时间。
处理模块，还用于根据产品数据、人员数据、运行数据及故障数据，计算人员生产效率、人员工时、产品故障原因。计划排产优化、设备选用策略制定、生产进程监控与实时调度。根据订单的交货期，倒推计算每一步工序上的最晚完成时间，如果倒推过程中发现无法满足交货期要求，系统会建议计划管理人员启用备用设备或者找出具有相同加工能力的设备，通过人机交互，完成排程的初步优化。系统然后会再次顺向排定生产任务，并根据最晚完成时间、产品规格等因素合并生产任务，调整加工先后顺序。
处理模块，还用于在满足交期的前提下，会将相似加工任务分配到同一台机器，如果发现设备能力富余，会自动发出信息，建议计划员关闭一些设备，避免浪费资源。在上述选取生产单元时，由于离散制造本身的特性(产品复杂，物料多样性，制造过程复杂多变)可以根据加工历史数据分析出同类产品在所有备选设备交付质量最好的设备，并考虑工艺因素、交货期因素等。综合评定工序使用最优设备。工艺参数下发。实时生产各类质量报表。工艺参数实时监控与告警。人工检测质量数据实时分析。质检人员在现场检测到质量异常，系统会分析该类产品加工历史中，相似异常的原因，处理方法，为解决质量问题提供决策支持。针对得到的数据整理得到报表。
处理模块，还用于设备维修单元定义，维修工艺标准管理，维修周期管理，维修作业执行管理，管理数据库中的故障知识，管理物料管理模块中的备品备件等。校准上述生产模块中所有生产单元的时间。获取故障信息(可以是从数据采集模块处获取)，根据故障信息确定产量减少量，若产量减少量大于预设值，则向通讯模块发送通知信息，使通讯模块将通知信息发送至操作人员、运维人员和/或销售人员对应终端设备，并根据产量减少量变更生产计划，如果故障引起生产滞后，在计划调度确认后，系统自动调整生产计划，更新设备负载、物料需求等信息。根据预设的质量检测标准，对数据采集模块采集得到的之间数据进行上下游车间/供应商关联分析，确定生产中需要注意的问题，以帮助操作人员提高生产操作水平、控制影响产品质量的参数，及时发现并终止不合理的加工。当过程发生变化(人、机、料、法、环、测)系统自动提醒，实现全程监控、在线统计、缺陷追溯。为提高产品质量控制提供支持。
处理模块，还用于从数据采集模块获取数据，将生产现场的设备加工参数、人员信息(人员位置、人员操作)、计划执行情况等数据，在3D虚拟工厂中进行直观展现，使管理人员和操作人员通过监控屏幕、电脑以及智能终端，可以了解工厂生产运行情况，实现生产全过程的跟踪与反馈。实时监控每个处理单元任务的执行情况。通过在建立监控程序与生产管理应用的接口，实时抓取和计算任务完成情况，并将任务 完成情况通过上述通讯模块发送至管理人员对应终端。还可以将数据采集模块采集到的工艺参数数据、设备维修数据(参数、图片和/或视频)、产品质量数据、故障数据、人员信息输入3D虚拟工厂，以进行显示。接收信息采集模块的运行信息及质量信息，并根据运行信息确定运行详情，并将运行详情发送至终端设备。
处理模块，还可以与其他数据处理系统进行数据交互，数据处理系统可以包括：PLM(Product Lifecycle Management，产品生命周期管理)、ERP(Enterprise Resource Planning，企业资源计划)、SCM(Supply Chain Management supply，供应链管理)系统。例如，从上述PLM系统建立连接(可以是JDBC(Java DataBase Connectivity,java数据库连接))，并读取PLM中变化的数据，与本地数据比对，然后做更新、插入、删除等处理，处理模块以WEB(World Wide Web，广域网)服务方式对PLM系统提供数据查询接口，PLM系统定期查询设备效率，人员效率等数据。处理模块根据历史数据定时统计这些信息，以备外系统查询时能迅速反馈。ERP主要提供主生产计划信息，指导车间按订单生产。而处理模块主要向ERP反馈制造执行情况，更新订单、财务等信息。ERP系统下达生产计划时，调用WEB服务，推送合同信息、客户信息、订单数量，产品信息，客户要求交期等数据，处理模块接到这些数据后，会做合法性验证，完整性验证，然后做进一步的业务处理。在处理模块中，产品完工后，通过ERP提供的接口，更新ERP系统中的订单状态，财务信息等。
处理模块，还用于根据接收到的数据进行仿真，以优化生产、交易、设备维护的流程。仿真可以是采用数学模型、仿真软件、大数据的方式。
数据采集模块，还用于采集运行状态信息(正常生产、故障、调试信息、放线张力、转速等)、测试信息、设备运行信息、停工信息、维护信息、调试各项工时信息等。采集得到的数据可以是通过接口传递到现场生产管理应用程序中，在不同应用场景下分析使用的。将产品加工所需的参数数据、标准、工艺规程或相关信息连同调度作业指令一起送达处理模块，并记录加工过程信息。采集工艺参数。首检，巡检，末检。获取人员位置数据并发送至处理模块，使处理模块在人员位置数据不符合预设要求(靠近危险区域)时控制上述告警模块进行告警。
上述告警模块，还用于根据下发的工艺参数要求(目标值、上限、下限)，实时监控接收到的工艺参数。一旦超限，立刻触发告警。
上述告警信息可以包括：告警的生产线、设备编号、告警号、告警文本、时间信息。告警信息经网络传输后，到达处理模块。处理模块根据每个参数预设的异常处理流程，推送信息到停训模块，通讯模块将信息发送至相关责任人，同时系统根据经验库中的数据，推送处理建议给相关人员。
上述数据存储进入数据库，可以是数据发生变化时存入数据库，以减小数据储存量。特殊数据可以直接发送至处理模块进行处理，每个参数可以配置采集频率，如果某些参数实时性和变化情况不明显，对产品质量的影响较小，可以降低采集频率，相反则增加频率，这样可以有效的把资源分配到紧急的地方。
上述数据传输模块，采用的接口数据可以存储在数据库，接口数据可以是预先通过工业标准(OPC)客户端程序发送的。数据采集模块异步抓取接口库中的数据，写入设备参数下发缓冲区中。
上述物资周转模块，还用于根据材料种类、生产计划、库存确定物资运送计划。具体的，可以是按照计划，分时、分批小批量供料；结合生产实际状况，实时调整送料批量；灵活定义物流路线，实现供应链的全覆盖；灵活定义送料策略，不同种类材料不同送料频次；和自动物流设备无缝集成，实现精准配送；库存管理，发货管理。研发内容包括物料需求计划、物流跟踪和信息处理、物料集成管理与智能配送。
上述库存管理模块，还用于根据未来加工订单情况，计算出物料需求。如果库存低于警戒阀值，系统自动触发物料采购流程。加工任务物料需求计划：系统根据当日生产订单，生成当日物料需求清单。系统根据加工设备准备区域物料配备情况，分批要求物料仓库安排送货。获取目标产品对应的半成品数量，将目标商品的需求数量减去对应的半成品数量，得到待补充商品数量。
上述生产单元，可以都贴有标签、条形码或带有电磁标签。还可以是联网的。
上述系统还可以与供应商、销售商的终端设备通信连接。制定采购计划、并将采购计划发送至供应商。在产品生产好后，可以将产品信息发送至销售商的终端设备。并启动配送、售后服务等流程。系统还可以定期将企业最新产品信息通过网络发送给销售商，通过网络接收来自销售商的质量反馈、用户满意度等信息。
在上述所有数据的传输过程中，可以是传递经过有效性筛选的数据，也可以是经数据压缩后传输，减少数据传输量。
上述数据采集模块、处理模块、告警模块可以实现当出现在制零件质量不合格时，进行质量告警，显示告警的生产线、工序、告警号、告警文本、告警时间；并向生产现场和办公室显示质量异常报告信息，显示质量异常告警的生产线、工段、生产工序、发现时间、现象描述、报告人等信息。还可以根据告警数据分析问题出现的原因。
数据采集模块，还用于采集加工车间设备的工作参数、加工进度等，并发送至监控设备，监控设备显示加工设备的工作参数信息，工作参数信息包括设备的工作油温、主轴转速等加工参数、扭矩、功率等；加工车间生产单元的工作状态监控，显示信息包括开机、正常工作状态、故障、停机等。监控显示数控加工设备总体运行情况，显示信息包括：关机、告警、开机、工位生产、下料无件、上料堵塞、技术中断、循环开始等。进度监控：加工进度包括，加工线的日生产作业计划的总体完成情况，信息包括车间日作业计划完成数量、当前已完成的总的零件数量、每小时完成的零件数量、当前的在制品的数量、不合格品的数量；加工车间实时生产情况监控，实时显示加工线各工序的加工零件数量、合格品的数量、存料区的数量、生产线上的数量、不合格品的数量等。
数据采集模块，还用于采集能耗数据，并将能耗数据发送至处理模块，处理模块还可以用于根据能耗数据，调整生产方案。数据采集模块采集得到的数据可以采用电源冗余、服务器冗余、数据库冗余的方式保障采集到的数据的安全。
上述处理模块，可以集成了数字控制程序。还可以结合数据库中的数制定物料流动信息追溯表(含有物料移动详情)、人员作业时间追溯表(开始生产的时间、采用的设备、产品信息等)、设备加工追溯表(含有加工时间、所在工序等数据)、设备历史状态表(含有加工、调试、空闲、关机、维修、故障的时间、详情、图表等)、设备维护表(含有异常描述、事件生成时间、响应时间、响应人、响应时长、完成时 间、完成人、完成时长等)、各阶段生产记录(含有使用设备、产品信息、加工时间等)
以上描述仅为本申请的较佳实施例以及对所运用技术原理的说明。本领域技术人员应当理解，本申请中所涉及的公开范围，并不限于上述技术特征的特定组合而成的技术方案，同时也应涵盖在不脱离上述公开构思的情况下，由上述技术特征或其等同特征进行任意组合而形成的其它技术方案。例如上述特征与本申请中公开的(但不限于)具有类似功能的技术特征进行互相替换而形成的技术方案。
本领域技术人员在考虑说明书及实践这里公开的发明后，将容易想到本申请的其它实施方案。本申请旨在涵盖本申请的任何变型、用途或者适应性变化，这些变型、用途或者适应性变化遵循本申请的一般性原理并包括本申请未公开的本技术领域中的公知常识或惯用技术手段。说明书和实施例仅被视为示例性的，本申请的真正范围和精神由下面的权利要求书指出。
应当理解的是，本申请并不局限于上面已经描述并在附图中示出的精确结构，并且可以在不脱离其范围进行各种修改和改变。本申请的范围仅由所附的权利要求书来限制。

Claims (12)

  1. 一种生产控制方法，其特征在于，所述方法应用于生产控制系统，所述生产控制系统包括：通讯模块、处理模块及生产模块，其中所述生产模块含有多个生产单元；所述方法包括：
    所述通讯模块接收订购方对应终端设备发送的订单信息，并将所述订单信息发送至所述处理模块；
    所述处理模块提取所述订单信息中的所有关键字段；根据所述所有关键字段，确定待生产产品的特征信息；根据所述待生产产品的特征信息，确定待启动生产单元数量；根据所述待启动生产单元数量，向所述生产模块发送控制指令；
    所述生产模块根据所述控制指令启动一个或多个所述生产单元。
  2. 根据权利要求1所述的方法，其特征在于，所述待生产产品的特征信息，包括待生产产品的种类、待生产产品的数量及交付时间；
    相应地，所述根据所述待生产产品的特征信息，确定待启动生产单元数量，包括：
    根据所述待生产产品的种类，确定对应的生产单元的目标种类；
    获取目标种类生产单元对应的单位生产单元的生产速度；
    根据所述待生产产品的数量、所述交付时间及所述单位生产单元的生产速度，确定待启动生产单元数量。
  3. 根据权利要求2所述的方法，其特征在于，所述根据所述待生产产品的数量、所述交付时间及单位生产单元的生产速度，确定待启动生产单元数量，包括：
    获取当前时间，并将所述交付时间与所述当前时间作差，得到时间差；
    将所述待生产产品的数量、所述单位生产单元的生产速度及所述时间差，输入预设的待启动生产单元数量计算公式，得到待启动生产单元数量。
  4. 根据权利要求3所述的方法，其特征在于，所述待启动生产单元数量计算公式，如下：
    其中，y表示所述待启动生产单元数量，x表示所述待生产产品的数量，v表示所述单位生产单元的生产速度，Δt表示所述时间差，c表示常数，round表示取整。
  5. 根据权利要求2至4任一项所述的方法，其特征在于，所述根据所述待生产产品的种类，确定对应的生产单元的目标种类之后，还包括：
    获取目标种类生产单元对应的，每个生产单元的生产速度及每个生产单元的当前任务量；
    将所述待生产产品的数量、所述交付时间、所述每个生产单元的生产速度及每个生产单元的当前任务量，输入预先训练得到的生产单元选取模型，得到待启动生产单元名单；
    根据所述待启动生产单元名单，向所述生产模块发送控制指令。
  6. 根据权利要求1至5任一项所述的方法，其特征在于，所述提取所述订单信息中的所有关键字段，包括：
    在所述订单信息中，查找预设关键字表中的所有关键字，并将在订单信息中查找得到的关键字作为目标关键字，其中，订单信息包含多个关键字，每个关键字都有关联的值字段；
    将所述订单信息中的各目标关键字、各目标关键字关联的值字段，及目标关键字与关联的值字段之间的映射关系，确定为关键字段。
  7. 根据权利要求6所述的方法，其特征在于，所述根据所述所有关键字段，确定待生产产品的特征信息，包括：
    根据第一关键字段中的值字段，确定待生产产品的种类，其中，所述第一关键字段为包含第一目标关键字的关键字段；
    根据第二关键字段中的值字段，确定待生产产品的数量，其中，所述第二关键字段为包含第二目标关键字的关键字段；
    根据第三关键字段中的值字段，确定交付时间，其中，所述第三关键字段为包含第三目标关键字的关键字段。
  8. 根据权利要求1至7任一项所述的方法，其特征在于，所述系统还包括：库存管理模块；相应地，在根据所述所有关键字段，确定待生产产品的特征信息之后，所述方法还包括：
    所述处理模块向所述库存管理模块发送库存获取指令；
    所述库存管理模块根据所述库存获取指令获取库存信息，并将所述库存信息发送至所述处理模块；
    所述处理模块根据所述待生产产品的特征信息及所述库存信息，确定待启动生产单元数量。
  9. 根据权利要求1至8中任一项所述的方法，其特征在于，所述系统还包括：物料管理模块；相应地，所述提取所述订单信息中的所有关键字段之后，还包括：
    所述处理模块根据所述订单信息，确定预计消耗物资数量，并向所述物料管理模块发送物料信息获取指令；
    所述物料管理模块根据所述物料信息获取指令，获取现有物料信息，并将所述物料信息发送至所述处理模块，其中所述物料信息含有现有物料数量；
    所述处理模块在所述预计消耗物资数量大于现有物料数量时，向所述通讯模块发送物料订购信息；
    所述通讯模块将所述物料订购信息发送至供应商对应终端设备。
  10. 根据权利要求1至8中任一项所述的方法，其特征在于，所述系统还包括：数据采集模块、数据库及告警模块；所述方法还包括：
    所述数据采集模块采集所述生产模块的运行数据及故障数据，并将所述运行数据存入所述数据库，将所述故障数据存入数据库并发送至处理模块；
    所述处理模块根据所述故障数据控制所述告警模块启动告警。
  11. 根据权利要求10所述的方法，其特征在于，所述系统还包括物资周转模块；所述方法还包括：
    所述数据采集模块采集产品的标识及所述产品对应设备的位置，并将所述标识及所述产品对应设备的位置发送至所述处理模块；
    所述处理模块根据所述标识及所述产品对应设备的位置，确定所述产品的目标位置，并控制所述物资周转模块将所述产品运送至所述目标位置。
  12. 一种生产控制系统，其特征在于，包括：通讯模块、处理模块及生产模块，其中所述生产模块含有多个生产单元；
    所述通讯模块，用于接收订购方对应终端设备发送的订单信息，并将所述订单信息发送至所述处理模块；
    所述处理模块，用于提取所述订单信息中的所有关键字段；根据所述所有关键字段，确定待生产产品的特征信息；根据所述待生产产品的特征信息，确定待启动生产单元数量；根据所述待启动生产单元数量，向所述生产模块发送控制指令；
    所述生产模块，用于根据所述控制指令启动一个或多个所述生产单元。
PCT/CN2023/092643 2022-05-12 2023-05-08 生产控制方法及系统 WO2023217057A1 (zh)

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