WO2024082424A1 - 一种使用柔性接口的可变工位汽车产线和汽车生产方法 - Google Patents
一种使用柔性接口的可变工位汽车产线和汽车生产方法 Download PDFInfo
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- 238000012544 monitoring process Methods 0.000 claims abstract description 77
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
- B62D65/02—Joining sub-units or components to, or positioning sub-units or components with respect to, body shell or other sub-units or components
- B62D65/18—Transportation, conveyor or haulage systems specially adapted for motor vehicle or trailer assembly lines
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
- B62D—MOTOR VEHICLES; TRAILERS
- B62D65/00—Designing, manufacturing, e.g. assembling, facilitating disassembly, or structurally modifying motor vehicles or trailers, not otherwise provided for
- B62D65/005—Inspection and final control devices
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- 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
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
Definitions
- the invention relates to the field of automobile manufacturing, and in particular to a variable-station automobile production line and an automobile production method using a flexible interface.
- the common vehicle location acquisition method currently used by vehicle manufacturers is to locate the vehicle through a vehicle body recognition system 200 (AVI system) and a sensor switch 405.
- the sensor switch 405 is installed at the entrance of the conveyor line 3021 of the production line.
- the conveyor line 3021 is driven forward by the roller 3022, driving the new vehicle entering the production line and the vehicles originally on the production line to move to the next station as a whole.
- a vehicle on the production line such as vehicle A, either moves to the next workstation (for example, from workstation 1 to workstation 2) or completes the work of this production line and leaves the production line.
- Vehicle A is placed on a carrier 401 to enter the production line, and the position of the carrier 401 is fixed. Therefore, when the carrier 401 carrying vehicle A enters the production line, the induction switch 405 will be triggered to act, so that the manufacturing execution system 100 (MES system) knows that vehicle A has entered the first workstation.
- the manufacturing execution system 100 MES system
- the manufacturing execution system 100 infers that vehicle A has entered the second workstation, and so on to complete the movement of vehicle A between workstations. If it leaves the current production line, the vehicle body recognition system 200 and the manufacturing execution system 100 of the subsequent production line will record and track the new workstation of vehicle A.
- vehicle A When vehicle A moves, all vehicles on the production line, including vehicle B, vehicle C, and vehicle D, will also move forward and enter the corresponding workstation 3 respectively.
- Vehicle C moves to workstation 2, and vehicle D enters workstation 1.
- vehicle D As a new vehicle entering the production line, vehicle D will first have its vehicle information acquired by the vehicle body recognition system 200 and sent to the manufacturing execution system 100. Subsequently, when vehicle D passes through the induction switch 405, the manufacturing execution system 100 marks vehicle D as currently located at workstation 1. After entering the production line, the manufacturing execution system 100 performs the same logical processing as vehicle A and updates the workstation information of vehicle D in the manufacturing execution system 100.
- the vehicle that arrives at the workstation completes the assembly production process of the workstation under the control of the production control system 300.
- the main defects of the existing technology include:
- the current position of the vehicle cannot be obtained in real time, because there is no collection device or computing device in the entire production line to feed back information to the MES system.
- the MES system can only infer the vehicle position through the preset distance between vehicles and the notification of the vehicle entering the production line. Then, when the actual operation of the conveyor line is inconsistent with the preset constant, there will be a large deviation between the actual moving position of the vehicle and the position considered by the MES system, which may cause the production line to stop in serious cases, such as the robot at the workstation cannot match the position of the vehicle to be assembled.
- each station is determined during the design phase, and then the corresponding production module (production equipment) is installed at each station. Because the MES system cannot accurately infer the position of the vehicle, the equipment at the station needs to have sufficient margin to deal with inaccurate vehicle positions. When the margins of multiple devices at the same station are superimposed, a lot of space that could have been used to install the equipment will be lost. Especially when it is necessary to support the production of multiple models, the large number of equipment required for different models will aggravate the difficulty of production line layout. When the necessary production equipment cannot be arranged at the original station, a new production line needs to be rebuilt, which is costly.
- dedicated logic is used to implement dedicated interfaces according to different production modules.
- customization can be quickly completed for different production tools when deploying new production lines, when the production line needs to be fine-tuned, it needs to be completely redeployed, because dedicated interfaces are used from production modules to production control systems to manufacturing execution systems, which will vary depending on the type and even model of production modules. Therefore, once a new production module is introduced, it means that not only the logic of the production control system must be modified, but also the logic of the manufacturing execution system, and the amount of work required for subsequent debugging and maintenance is huge.
- the purpose of the present invention is to provide a variable-station automobile production line and an automobile production method using a flexible interface, mainly to solve the problems existing in the above-mentioned prior art.
- the technical solution adopted by the present invention is to provide a variable-station automobile production line using a flexible interface, using a conveyor line to drive the vehicles to be assembled forward, and a plurality of stations corresponding to the production process are arranged along the conveyor line, characterized in that it is composed of a manufacturing execution system, a vehicle body recognition system, a production control system and a production monitoring system; the manufacturing execution system is connected to the vehicle body recognition system, the production control system and the production monitoring system;
- the manufacturing execution system stores multiple groups of manufacturing parameters, and selects one group to be sent to the production control system based on the vehicle information collected by the vehicle body recognition system;
- the production control system includes a configuration management module and a production module; the configuration management module saves the manufacturing parameters issued by the manufacturing execution system, configures all the production processes of each workstation, and controls the actions of the production module; the production module completes the transfer, processing and assembly of the vehicle to be assembled.
- the configuration management module uses a flexible interface to connect different production modules, so that the communication connection mode between the manufacturing execution system and the production control system does not change with the production module included in the production control system;
- the production monitoring system collects production line status information and feeds it back to the manufacturing execution system to achieve closed-loop control of production line production.
- the manufacturing execution system includes a production line management module, a vehicle management module, a production management module, a production monitoring module, a database module and a fast communication module;
- the production line management module provides a human-computer interaction interface to receive the manufacturing parameters manually input, and is also used to schedule the vehicle management module and the production management module to work together;
- the vehicle management module is connected to the vehicle body identification system, and transmits the vehicle information collected by the vehicle body identification system to the production line management module;
- the production management module is connected to the production control system, and transmits the vehicle information and the manufacturing parameters to the production control system;
- the production monitoring module is connected to the production monitoring system, and transmits the production line status information collected by the production monitoring system to the production line management module;
- the fast communication module provides a direct communication connection between the production control system and the production monitoring system, and is used to bypass the production management module for fast data interaction;
- the manufacturing parameters and the vehicle information are stored in the database module.
- the vehicle body identification system includes an RFI D reading module; the RFI D reading module scans the radio frequency tag installed on the vehicle to be assembled and reads the vehicle information; the vehicle information at least includes a vehicle identification code.
- the configuration management module includes a file storage unit and a communication unit; the file storage unit stores the manufacturing parameters corresponding to the vehicle to be assembled; and the communication unit is used to connect the file storage unit to the manufacturing execution system and the production module.
- the production monitoring system comprises a carrier, a vehicle monitoring module, a carrier monitoring module, a travel collection module and an induction switch;
- the carrier is fixed on the conveyor line of the production line, loaded with the vehicle to be assembled and moves forward, passing through the workstations in sequence;
- the vehicle monitoring module collects the placement status information of the vehicle to be assembled on the carrier; starting from the entrance of the production line, the carrier monitoring module and the induction switch are installed in sequence;
- the carrier monitoring module collects the in-position status information of the carrier on the track; when the carrier and the vehicle to be assembled pass the induction switch, the limit status information is reported;
- the stroke collection module collects the stroke status information of the conveyor line;
- the production line status information reported by the production monitoring system includes the placement status information, the in-position status information, the limit status information and the stroke status information.
- the travel acquisition module includes a data acquisition unit, a data calculation unit and a data storage unit;
- the data acquisition unit is an encoder;
- the data calculation unit converts the data of the encoder into the travel status information;
- the data storage unit is connected to the data acquisition unit and the data calculation unit.
- the present invention also provides a method for assembling an automobile using the above-mentioned variable-station automobile production line using a flexible interface, characterized in that it comprises the steps of:
- the production line is initialized according to the vehicle information of the vehicle to be assembled, and the number, position and length of the workstations are determined;
- the vehicle to be assembled enters the production line and starts production.
- the production control system and the production monitoring system are adjusted; in the production control system, the production module is adjusted, and the newly added production module is connected to the configuration management module by using the flexible interface, without modifying the communication interface between the production control system and the manufacturing execution system;
- the workstations, the production control system and the production monitoring system are configured in the manufacturing execution system; in the manufacturing execution system, the manufacturing parameters corresponding to the vehicle to be installed are adjusted to specify the number, location and length of the workstations included in the production line, and also to specify the production process corresponding to each workstation;
- the redundant equipment that is no longer used after the configuration is completed can be optionally removed from the production control system and the production monitoring system, including removing redundant production modules from the production control system.
- the production monitoring system is started to collect the production line status information
- the vehicle to be assembled arrives at the production line entrance, and the vehicle body recognition system reads the vehicle information;
- the manufacturing execution system selects one set of manufacturing parameters from multiple sets of manufacturing parameters stored in the manufacturing execution system based on the vehicle information reported by the vehicle body recognition system, configures the number, position and length of the workstations on the production line, and sends the selected manufacturing parameters to the production control system;
- the production control system configures the production process of each of the workstations according to the received manufacturing parameters.
- the production process of the vehicle to be assembled comprises the steps of:
- Step S1 the production monitoring system collects the production line status information and reports it to the manufacturing execution system
- Step S2 the manufacturing execution system determines the current workstation of the vehicle to be assembled based on the position and length of the workstation of the current production line and the position information of the vehicle to be assembled on the conveyor line contained in the production line status information, and sends it to the production control system;
- Step S3 the production control system executes the production process corresponding to the current workstation
- Step S4 after completing the production process of the current workstation, the manufacturing execution system drives the vehicle to be assembled to move forward along the conveyor line and returns to step S1.
- the present invention uses a variable-station automobile production line and automobile production method with a flexible interface, and uses preset manufacturing parameters to automatically adapt to different vehicle types for production without reinstalling a new production line, which greatly reduces the cost of the enterprise. It has the following advantages over the existing technology:
- the position of the vehicle to be assembled on the production line is accurately sensed by the manufacturing execution system and can be adjusted through manufacturing parameters, so the number, size and length of the workstations can be flexibly adjusted.
- the production process can be adjusted by adjusting the manufacturing parameters without reprogramming the logic in the manufacturing execution system.
- a flexible interface is used so that when a new production module is added or modified, there is no need to reprogram the interface between the manufacturing execution system and the production control system, thereby simplifying the debugging process.
- the manufacturing execution system can correctly and orderly initiate processing commands to the production control system according to the precise position of the vehicle to be assembled, thereby simplifying the production line layout and making the arrangement of production modules along the production line more compact.
- FIG1 is a schematic structural diagram of the prior art corresponding to the variable-station automobile production line using a flexible interface of the present invention
- FIG2 is a schematic structural diagram of a preferred embodiment of a variable-station automobile production line using a flexible interface according to the present invention
- FIG3 is a detailed structural diagram of a manufacturing execution system and a vehicle body recognition system in a preferred embodiment of a variable-station automobile production line using a flexible interface of the present invention
- FIG4 is a schematic diagram of the structure of a production control system in a preferred embodiment of a variable-station automobile production line using a flexible interface according to the present invention
- FIG. 5 is a schematic diagram of the structure of a flexible interface used in an andon module in a production control system of a preferred embodiment of a variable-station automobile production line using a flexible interface of the present invention
- FIG6 is a schematic diagram of the structure of a production monitoring system in a preferred embodiment of a variable-station automobile production line using a flexible interface of the present invention
- FIG. 7 is a method flow chart of a preferred embodiment of a method for producing automobiles using a variable-station automobile production line using a flexible interface according to the present invention
- FIG8 is a flowchart of a detailed method for performing production line deployment in FIG7;
- FIG9 is a flow chart of a detailed method for initializing the production line in FIG7 ;
- FIG. 10 is a flow chart of a detailed method for performing production line production in FIG. 7 .
- 100-manufacturing execution system 200-vehicle body recognition system, 300-production control system, 400-production monitoring system;
- 101-production line management module 101-production line management module, 102-vehicle management module, 103-production monitoring module, 104-production management module, 105-database module, 106-fast communication module;
- 3011- file storage unit 3012- communication unit; 3021- conveyor line, 3022- roller, 3023- tightening gun, 3024- filling equipment, 3025- glue coating equipment; 3031- first standard interface; 3032- second standard interface;
- the present invention discloses a variable-station automobile production line using a flexible interface.
- a preferred embodiment thereof is composed of a manufacturing execution system 100 (MES), a vehicle body identification system 200 (AVI), a production control system 300 and a production monitoring system 400.
- MES manufacturing execution system
- AVI vehicle body identification system
- production control system 300 production monitoring system 400.
- the automobile production line includes multiple stations that can be dynamically planned. Each station corresponds to a set of production processes, including the production actions and sequence that each production module 302 needs to complete at this station.
- the production process of each station generally corresponds to the model to be produced, and is dynamically planned according to the vehicle information when the production line is initialized.
- the vehicle information is identified by the vehicle body identification system 200 (AVI), and then the manufacturing execution system 100 (MES) completes the planning of the station and production process.
- the conveyor line 3021 drives the car to be equipped and passes through each station in turn.
- the conveyor line 3021 stops moving forward, the car is in a stationary state at the station, and the production modules 302 (various robots, tightening guns 3022, etc.) installed around the station complete the production process of the station, and then the conveyor line 3021 is restarted to drive the car to the next station.
- the conveyor line 3021 keeps moving forward at a constant speed, and the production modules 302 installed around the workstation follow the car moving forward at a constant speed to complete the production process of the workstation.
- the manufacturing execution system 100 is the control core of the entire automobile production line. It is used to configure the position and order of the workstations on the automobile production line, configure the production process corresponding to each workstation through the production control system 300, and guide the production control system 300 to complete the automobile assembly work according to the production process, and configure the production monitoring system 300. At the same time, it is also responsible for connecting the vehicle body recognition system 200, the production control system 300 and the production monitoring system 400, providing a communication channel between them.
- the manufacturing execution system 100 includes a production line management module 101, a vehicle management module 102, a production monitoring module 103, a production management module 104, a database module 105 and a fast communication module 106.
- the production line management module 101 provides a human-machine interface, receives user input (such as input and modification of manufacturing parameters, etc.), and then saves the user input to the database module 105, thereby completing the configuration and adjustment of various parameters of the production line.
- the complete vehicle information is saved in the database module 105, including the vehicle identification code.
- the vehicle information read from the vehicle to be assembled by the vehicle body identification system 200 at least includes the vehicle identification code.
- the production line management module 101 is the core control module in the manufacturing execution system 100.
- the vehicle management module 102 reports the vehicle information collected by the vehicle body recognition system 200 to the production line management module 101.
- the production monitoring module 103 reports the production line status information collected by the production monitoring system 400 to the production line management module 101.
- the production management module 104 sends the manufacturing parameters corresponding to the vehicle to be assembled to the production control system 300, and sends control instructions to the production control system 300 during the production process, such as a command to instruct the production module 302 to start assembly.
- the fast communication module 106 is located at the bottom layer of the system. It provides a direct communication connection between the production control system 300 and the production monitoring system 400. In this way, for some urgent commands, such as line stop instructions, and the production module 302 accessed by the manufacturing execution system 100 but managed by the production control system 300, it is possible to bypass the production monitoring module 103 and the production management module 104 to directly perform fast data interaction, thereby improving communication efficiency.
- the vehicle body identification system 200 reads the radio frequency tag installed on the vehicle to be assembled through the RFID reading module 201 to obtain vehicle information, such as the vehicle identification code.
- vehicle information may also include additional information, such as vehicle model information, to speed up data retrieval, but the complete vehicle information is still retrieved from the database module 105 of the manufacturing execution system 100 using the vehicle identification code as a keyword.
- the production control system 300 itself also has the ability to save manufacturing parameters, but it only saves the manufacturing parameters for the current production issued by the manufacturing execution system 100, and does not save the manufacturing parameters of all vehicles supported by the production line.
- the production control system 300 is composed of a configuration management module 301 and a production module 302.
- each configuration management module 301 corresponds to one or more production modules 302.
- the configuration management module 301 includes a file storage unit 3011 and a communication unit 3012.
- the manufacturing parameters guiding the current production are saved in the file storage unit 3011, and the configuration management module 301 extracts information from it to guide and control the production module 302 to complete the production process of the corresponding workstation.
- the communication unit 3012 connects the configuration management module 301 to the manufacturing execution system 100 and the production module 302.
- the communication unit 3012 provides a flexible interface between the manufacturing execution system 100 and the production module 302.
- the role of the flexible interface is that when the type of the external interface of the production module 302 itself changes, the communication unit 3012 maintains the communication capability with the changed production module 302 by extending its flexible interface, while ensuring that the communication interface between the communication unit 3012 and the manufacturing execution system 100 remains unchanged. In this way, when the production line adjustment involves the addition and modification of the production module 302, only the corresponding communication unit 3012 needs to be upgraded, avoiding the modification of other systems in the production line.
- the production module 302 includes not only assembly equipment at each workstation, such as a tightening gun 3023, a filling device 3024, and a glue coating device 3025, but also equipment related to the entire production line, such as a conveyor line 3021 and a roller 3022 attached to the conveyor line 3021.
- the roller 3022 drives the conveyor line 3021 forward to transfer the vehicles to be assembled between different workstations.
- the assembly equipment is installed at the workstation to complete the processing and assembly of the vehicles to be assembled.
- the action sequence of all the assembly equipment at a workstation constitutes the production process of this workstation.
- the production module 302 also includes equipment for manual intervention to control the operation of the production line, such as an andon module 303.
- Andon call is one of the main functions of the andon module. Its principle is that the operator calls the corresponding person in charge (team leader, security, quality, logistics, etc.) in an abnormal situation by operating the call terminal beside the production line, thereby reducing the equipment downtime rate and improving work efficiency. On the same production line, according to the characteristics of different assembly equipment, it is generally divided into different andon call areas.
- all andon modules 303 (A, B and C) use the first standard interface 3031 to communicate with the configuration management unit 301, and the configuration management unit 301 uses the second standard interface 3032 to communicate with the manufacturing execution system 100, so that when the following situations occur:
- the production monitoring system 400 is used to continuously collect production line status information, such as vehicle status and vehicle position, during normal operation, and then transmit it to the manufacturing execution system 100.
- the production monitoring system 400 is composed of a carrier 401, a vehicle monitoring module 402, a carrier monitoring module 403, a travel collection module 404, and an induction switch 405.
- the production line status information reported by the production monitoring system includes placement status information, in-position status information, limit status information, and travel status information.
- the carrier 401 is fixed on the conveyor line 3021.
- the vehicle to be assembled should be placed on the carrier 401, and then driven by the conveyor line 3021 to enter the production line, and then pass through each processing station in turn.
- the vehicle monitoring module 402 is used to identify whether the vehicle to be assembled is correctly placed on the carrier 401 and provide placement status information.
- the carrier monitoring module 403 (OMRON E3JK-TR12-C) and the induction switch 405 (OMRON WLG2-LD) are installed in sequence.
- the carrier monitoring module 403 is used to identify whether the carrier 401 itself is correctly installed on the track 3021 and provide the in-position status information.
- the vehicle monitoring module 402 is combined with the carrier monitoring module 403 to determine whether the carrier 401 itself and the vehicle to be assembled on the carrier 401 are correctly placed.
- the induction switch 405 is installed behind the carrier monitoring module 403.
- the stroke acquisition module 404 includes a data acquisition unit 4031, a data calculation unit 4032 and a data storage unit 4033, which are used to collect and calculate the stroke data of the conveyor line 3021.
- the data acquisition unit 4031 is an encoder, such as Omron E6C3-AG5C 256P/R 2M. , the encoder data is converted by the data calculation unit 4032 to obtain the travel distance of the conveyor line 3021, which is reported as the travel status information.
- the data storage unit 4033 is connected to the data acquisition unit 4031 and the data calculation unit 4032 to provide storage support for the calculation, such as saving input parameters, intermediate results and final results. If the zero point and the travel distance of the conveyor line 3021 are known, the distance that the vehicle advances along the conveyor line 3021 can be calculated, and combined with the position and length information of the workstation in the manufacturing execution system 100, it can be determined whether the vehicle has arrived at a specific workstation and its specific position in the workstation (for example, at 30% of the workstation).
- the present invention further discloses a method for assembling an automobile using a variable-station automobile production line with a flexible interface, which is characterized by comprising the steps of:
- Step S100 deploying a production line for the vehicle to be installed.
- Step S200 initializing the production line.
- the vehicle body recognition system reads the vehicle information of the vehicle to be assembled, and then the manufacturing execution system determines the number, location and length of the workstations based on the vehicle information, issues manufacturing parameters, and completes the configuration of the workstations and production processes.
- Step S300 the vehicle to be assembled enters the production line and starts production.
- step S100 further specifically includes the following steps:
- Step S101 adjusting the equipment of the production control system and the production monitoring system.
- the flexible interface is used to connect the newly added production module to the configuration management module without modifying the communication interface between the production control system and the manufacturing execution system.
- Step S102 configuring the workstation, production control system and production monitoring system in the manufacturing execution system.
- adjusting the manufacturing parameters corresponding to the vehicle to be installed includes:
- Step S103 removing redundant equipment that is no longer used after configuration is completed from the production control system and the production monitoring system.
- step S200 further specifically includes the following steps:
- Step S201 start the production monitoring system to start collecting production line status information.
- Step S202 the vehicle body recognition system reads the vehicle information of the vehicle to be assembled.
- the vehicle body identification system identifies the vehicle information through an RFID reading module (such as SIMATIC RF360T) and transmits it to the manufacturing execution system.
- an RFID reading module such as SIMATIC RF360T
- Step S203 the manufacturing execution system completes production line planning.
- the manufacturing execution system uses the vehicle identification code in the vehicle information to select a set of manufacturing parameters from multiple sets of manufacturing parameters saved in itself, completes the planning of the number, location and length of variable workstations, and sends the manufacturing parameters to the production control system.
- Step S204 the production control system completes planning.
- the production control system configures the production process of each workstation based on the received manufacturing parameters.
- step S300 further specifically includes the following steps:
- Step S301 The production monitoring system collects production line status information and reports it to the manufacturing execution system.
- the production monitoring system sends the information to the manufacturing execution system, and the manufacturing execution system sets the zero point of the travel for the vehicle to be assembled. After that, the production monitoring system regularly reports the travel status information of the conveyor line and the execution status of the production process at each workstation to the manufacturing execution system.
- Step S302 the manufacturing execution system determines the current workstation of the vehicle to be assembled based on the position and length of the workstation of the current production line and the position information of the vehicle to be assembled on the conveyor line contained in the production line status information, and sends it to the production control system.
- the manufacturing execution system compares the position of the vehicle to be assembled on the conveyor line. When its position is within the position and length range of a certain workstation, it determines that the vehicle to be assembled enters this workstation.
- Step S303 the production control system executes the production process corresponding to the current workstation.
- Step S304 after completing the production process of the current workstation, the manufacturing execution system drives the vehicle to be assembled to move forward along the conveyor line and returns to step S301.
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Abstract
一种使用柔性接口的可变工位汽车产线以及利用该使用柔性接口的可变工位汽车产线进行汽车生产的方法，由制造执行系统（100）、车体识别系统（200）、生产控制系统（300）和生产监测系统（400）构成，包含多个由制造执行系统（100）动态规划的可变工位；制造执行系统（100）动态规划工位的数量、位置和长度；车体识别系统（200）识别待组装车辆的车辆信息，制造执行系统（100）根据车辆信息，完成对工位的规划，并将车辆信息下发至生产控制系统（300），完成生产工序规划；生产控制系统（300）使用柔性接口连接不同的生产模块（302）；生产监测系统（300）采集数据实现闭环控制。自动选择制造参数，方便快速的调整生产工序、工位顺序和数量，提高生产效率，实现更优化的产线规划。
Description
本发明涉及汽车制造领域，特别是一种使用柔性接口的可变工位汽车产线和汽车生产方法。
如图1所示，目前整车生产企业常见的车辆位置获取方法是通过车体识别系统200(AVI系统)和感应开关405来对车辆位置进行定位。感应开关405安装在产线的输送线3021入口，当新进产线的车辆经过感应开关405时，输送线3021被滚轮3022驱动前进，带动新入产线的车辆和原本在产线上的车辆整体移动到下一个工位。
请参阅图1，在产线上的车辆，例如车辆A，要么移动到下一个工位(例如从工位1移动到工位2)或完成本产线工作离开产线。车辆A是被安置在载具401上进入产线的，而载具401的位置是固定的。因此，当载有车辆A的载具401进入产线的时候，会触发感应开关405动作，从而使得制造执行系统100(MES系统)知晓车辆A进入第一个工位。当车辆A所在载具401的后续载具401通过感应开关405时，制造执行系统100推断车辆A进入第二个工位，以此类推完成车辆A在工位间的移动。如果是离开本产线，则交由后续产线的车体识别系统200和制造执行系统100记录并跟踪车辆A的新工位。
当车辆A移动时，在产线上的全部车辆，包含车辆B、车辆C和车辆D也会往前移动，分别进入对应的工位3，车辆C移动到工位2，车辆D进入工位1。车辆D作为新进入产线的车辆，首先会被车体识别系统200获取车辆D的车辆信息并发送给制造执行系统100。随后，当车辆D通过感应开关405时，制造执行系统100将车辆D标记此车目前位于工位1。进入产线后，制 造执行系统100和车辆A的一样的逻辑处理，更新制造执行系统100中车辆D的所在工位信息。到达工位的车辆，在生产控制系统300的控制下完成该工位的组装生产工序。
现有技术存在的主要缺陷包含：
1、不能实时的获取当前车辆的位置，因为整个产线没有采集装置或者计算装置向MES系统反馈信息，MES系统仅能通过载具间预设距离以及载具进入产线的通知，来推断车辆位置。那么，当输送线实际运行情况和预设常数不一致时，就会在车辆实际移动位置和MES系统认为的位置之间发生较大的偏差，严重的会导致产线停产，例如工位上的机器人无法和待组装车辆的位置匹配。
2、无法满足产线扩展工位的需求。在现有技术中，每个工位在设计阶段就已经确定，然后根据每个工位安装对应的生产模块(生产设备)。因为MES系统中的无法准确推断车辆位置，工位上的设备就需要留有足够的余量来应对车辆位置不准的情况。当同一工位多个设备的余量叠加后，会损失很多原本可以安装设备的空间。特别当需要支持多车型生产的时候，不同车型需要的大量设备，会加剧产线布局的困难。当在原本一个工位无法布置必要的生产设备时，就需要重新修建新的产线，成本高。
3、在制造执行系统和生产控制系统的集成中，根据生产模块的不同，使用专用的逻辑实现专用接口，虽然在新产线部署的时候，可以快速的为不同的生产工具完成定制，但当产线需要微调时，就需要完全重新部署，因为从生产模块到生产控制系统到制造执行系统之间，均使用的是专用接口，它会随着生产模块类别甚至型号的不同而不同。因此一旦涉及引入新的生产模块，就意味着不仅要修改生产控制系统的逻辑，还得修改制造执行系统的逻辑，后期调试维护的工程量巨大。
发明内容
本发明的目的在于提供一种使用柔性接口的可变工位汽车产线和汽车生产方法，主要解决上述现有技术存在的问题。
为了实现上述目的，本发明所采用的技术方案是提供一种使用柔性接口的可变工位汽车产线，使用输送线带动待组装车辆前进，沿所述输送线设置有多个与生产工序对应的工位，其特征在于，由制造执行系统、车体识别系统、生产控制系统和生产监测系统构成；所述制造执行系统连接到所述车体识别系统、所述生产控制系统和所述生产监测系统；
所述制造执行系统保存多组制造参数，并根据所述车体识别系统采集的车辆信息，选择其中一组下发给所述生产控制系统；
所述生产控制系统包含配置管理模块和生产模块；所述配置管理模块保存由所述制造执行系统下发的所述制造参数，配置每个所述工位的全部所述生产工序，并控制所述生产模块动作；所述生产模块完成所述待组装车辆的转移、加工和组装工作。所述配置管理模块使用柔性接口连接不同的所述生产模块，使得所述制造执行系统与所述生产控制系统之间的通信连接方式不随所述生成控制系统包含的所述生产模块变化；
所述生产监测系统采集产线状态信息，反馈至所述制造执行系统，对产线生产实现闭环控制。
进一步地，所述制造执行系统包含产线管理模块、车辆管理模块、生产管理模块、生产监测模块、数据库模块和快速通信模块；
所述产线管理模块提供人机交互接口接收人工输入的所述制造参数，还用于调度所述车辆管理模块和所述生产管理模块协同工作；所述车辆管理模块连接到所述车体识别系统，将所述车体识别系统采集到的所述车辆信息传递给所述产线管理模块；所述生产管理模块连接到所述生产控制系统，向所 述生产控制系统传递的所述车辆信息和所述制造参数；所述生产监测模块连接到所述生产监测系统，将所述生产监测系统采集到的所述产线状态信息传递给所述产线管理模块；所述快速通信模块提供所述生产控制系统和所述生产监测系统之间的直接通信连接，用于绕开所述生产管理模块进行快速数据交互；所述制造参数、所述车辆信息保存在所述数据库模块中。
进一步地，所述车体识别系统包含RFI D读取模块；所述RFI D读取模块扫描安装在所述待组装车辆上的射频标签，读取所述车辆信息；所述车辆信息至少包含车辆识别码。
进一步地，所述配置管理模块包含文件存储单元和通信单元；所述文件存储单元保存对应所述待组装车辆的所述制造参数；所述通信单元用于将所述文件存储单元连接到所述制造执行系统和所述生产模块。
进一步地，所述生产监测系统包含载具、车辆监测模块、载具监测模块、行程采集模块和感应开关；
所述载具固定在产线的所述输送线上，装载所述待组装车辆前进，依次经过所述工位；所述车辆监测模块采集所述待组装车辆在所述载具上的安置状态信息；从产线入口开始，依次安装所述载具监测模块和所述感应开关；所述载具监测模块采集所述载具在所述履带上的就位状态信息；当所述载具和所述待组装车辆越过所述感应开关时，上报限位状态信息；所述行程采集模块采集所述输送线的行程状态信息；由所述生产监测系统上报的所述产线状态信息，包含所述安置状态信息、所述就位状态信息、所述限位状态信息和所述行程状态信息。
进一步地，所述行程采集模块包含数据采集单元、数据计算单元和数据存储单元；所述数据采集单元是编码器；所述数据计算单元将所述编码器的数据，转换为所述行程状态信息；所述数据存储单元连接到所述数据采集单 元和所述数据计算单元。
本发明还提供一种利用上述使用柔性接口的可变工位汽车产线进行汽车组装的方法，其特征在于，包含步骤：
首先，针对所述待安装车辆部署产线；
其次，根据所述待组装车辆的所述车辆信息初始化产线，确定所述工位的数量、位置和长度；
最后，所述待组装车辆进入产线，开始生产。
进一步地，在对所述待安装车辆进行产线部署时，
首先，调整所述生产控制系统和所述生产监测系统；在所述生产控制系统中，调整生产模块，并利用所述柔性接口将新增的所述生产模块连接到所述配置管理模块，而不修改所述生产控制系统与所述制造执行系统之间的通信接口；
然后，在所述制造执行系统中配置所述工位、所述生产控制系统和所述生产监测系统；在所述制造执行系统中，调整对应所述待安装车辆的所述制造参数,用于指定产线包含的所述工位的数量、位置和长度，也用于指定每个所述工位对应的所述生产工序；
最后，可选的将配置完成后不再使用的多余设备在所述生产控制系统和所述生产监测系统中移除，包含在所述生产控制系统中，移除多余的所述生产模块。
进一步地，在初始化产线的过程时：
首先，启动所述生产监测系统开始采集所述产线状态信息；
其次，所述待组装车辆到达产线入口，所述车体识别系统读取所述车辆信息；
然后，所述制造执行系统基于所述车体识别系统上报的车辆信息，从自 身保存的多组制造参数中选择一组，配置产线上所述工位的数量、位置和长度，并将选中的所述制造参数下发给所述生产控制系统；
最后，所述生产控制系统根据收到的所述制造参数，配置每个所述工位的所述生产工序。
进一步地，所述待组装车辆的生产过程，包含步骤：
步骤S1，所述生产监测系统采集所述产线状态信息上报给所述制造执行系统；
步骤S2，所述制造执行系统结合当前产线的所述工位的位置和长度，以及所述产线状态信息中包含的所述待组装车辆在所述输送线上的位置信息，确定所述待组装车辆的当前工位，发送给所述生产控制系统；
步骤S3，所述生产控制系统执行所述当前工位对应的所述生产工序；
步骤S4，完成所述当前工位的所述生产工序后，所述制造执行系统驱动所述待组装车辆沿着所述输送线前进，并回到步骤S1。
鉴于上述技术特征，本发明使用柔性接口的可变工位汽车产线和汽车生产方法，利用预设的制造参数，自动适配不同的车辆类型进行生产，而无需重新安装一条新的生产线，极大的降低了企业的成本。它相对现有技术，具有如下优点：，
1、本发明中，待组装车辆在产线的位置被制造执行系统精确感知，且可以通过制造参数调整，因此可以灵活的调整工位的数量、大小和长度。
2、本发明中，通过调整制造参数就可以调整生产工序，而不需要重新编程制造执行系统中的逻辑。
3、本发明中，通过了柔性接口，使得新增或者修改生产模块的时候，不需要重新编程制造执行系统和生产控制系统的接口，简化了调试过程。
4、本发明中，在同一工位中，制造执行系统可以根据待组装车辆的精确 位置，正确有序的向生产控制系统发起加工命令，简化了产线布局，使得生产模块沿着产线的布置更加紧凑。
图1是本发明使用柔性接口的可变工位汽车产线对应的现有技术的结构示意图；
图2是本发明使用柔性接口的可变工位汽车产线的一个较佳实施例的结构示意图；
图3是本发明使用柔性接口的可变工位汽车产线的一个较佳实施例中的制造执行系统和车体识别系统的详细结构示意图；
图4是本发明使用柔性接口的可变工位汽车产线的一个较佳实施例中的生产控制系统的结构示意图；
图5是本发明使用柔性接口的可变工位汽车产线的一个较佳实施例中的生产控制系统中安灯模块使用柔性接口的结构示意图；
图6是本发明使用柔性接口的可变工位汽车产线的一个较佳实施例中的生产监测系统的结构示意图；
图7是本发明利用使用柔性接口的可变工位汽车产线进行汽车的生产方法的一个较佳实施例的方法流程图；
图8是图7中进行产线部署的详细方法流程图；
图9是图7中进行产线初始化的详细方法流程图；
图10是图7中进行产线生产的详细方法流程图。
图中：100-制造执行系统，200-车体识别系统，300-生产控制系统，400-生产监测系统；
101-产线管理模块，102-车辆管理模块，103-生产监测模块，104-生产管理模块，105-数据库模块，106-快速通信模块；
201-RFID读取模块；
301-配置管理模块，302-生产模块；303-安灯模块；
3011-文件存储单元，3012-通信单元；3021-输送线，3022-滚轮，3023-拧紧枪，3024-加注设备,3025-涂胶设备；3031-第一标准接口；3032-第二标准接口；
401-载具，402-车辆监测模块，403-载具监测模块，404-行程采集模块，405-感应开关；4031-数据采集单元，4032-数据计算单元，4033-数据存储单元。
下面结合具体实施方式，进一步阐述本发明。应理解，这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解，在阅读了本发明讲授的内容之后，本领域技术人员可以对本发明作各种改动或修改，这些等价形式同样落于本申请所附权利要求书所限定的范围。
请参阅图2至图6，本发明公开了一种使用柔性接口的可变工位汽车产线。如图所示，它的一个较佳实施例由制造执行系统100(MES)、车体识别系统200(AVI)、生产控制系统300和生产监测系统400构成。
汽车产线包含多个可以动态规划的工位，每个工位对应一组生产工序，包含此工位上各个生产模块302需要完成的生产动作以及先后次序。每个工位的生产工序一般与需要生产的车型对应，在产线初始化的时候根据车辆信息动态规划。待装配的汽车进入产线前，由车体识别系统200(AVI)识别车辆信息，然后制造执行系统100(MES)完成工位和生产工序的规划。然后，输送线3021带动待装备汽车，依次经过每一个工位。当汽车进入一个工位后，根据不同产线的配置，有静态装配方式和动态装配方式。静态装配方式中，输送线3021停止前进，汽车在工位上处于静止的状态，由安装在工位周围的 生产模块302(各类机器人，拧紧枪3022等)完成该工位的生产工序，然后重新启动输送线3021，带动汽车进入下个工位。动态装配方式中，输送线3021保持匀速前进，安装在工位周围的生产模块302跟随匀速前进的汽车，完成该工位的生产工序。
制造执行系统100是整个汽车产线的控制核心，它被用于配置汽车产线上工位的位置和次序，通过生产控制系统300配置每个工位对应的生产工序，并指导生产控制系统300依照生产工序完成汽车组装工作，以及配置生产监测系统300。同时，它还负责连接车体识别系统200、生产控制系统300和生产监测系统400，提供它们之间相互的通信渠道。
制造执行系统100包含产线管理模块101、车辆管理模块102、生产监测模块103、生产管理模块104、数据库模块105和快速通信模块106。产线管理模块101提供人机接口，接收用户输入(例如制造参数的输入、修改等)，然后将用户输入保存到数据库模块105，从而完成产线各类参数的配置和调整。在数据库模块105中保存车辆完整信息，其中包含车辆识别码。而车体识别系统200从待组装车辆上读取的车辆信息中，至少包含车辆识别码。因此将车辆识别码作为关键字，结合数据库模块105，就可以获得待组装车辆的车辆完整信息，例如与其匹配的制造参数。同时，产线管理模块101是制造执行系统100中的核心控制模块，它结合数据库模块105，通过车辆管理模块102连接到车体识别系统200，通过生产监测模块103连接到生产监测系统400，通过生产管理模块104连接到生产控制系统300，协同它们之间的工作：当产线管理模块101利用生产监测模块103连接的生产监测系统400识别到待组装车辆随输送线3021前进到达设定工位时，通过生产管理模块104发送指令给到生产控制系统300进行组装。车辆管理模块102将车体识别系统200采集到的车辆信息上报给产线管理模块101。生产监测模块103 将生产监测系统400采集到的产线状态信息上报给产线管理模块101。生产管理模块104向生产控制系统300下发对应待组装车辆的制造参数，并在生产过程中向生产控制系统300发送控制指令，例如指示生产模块302开始组装的命令。快速通信模块106位于系统的底层，它为生产控制系统300和生产监测系统400之间的提供了直接通信连接，这样对于一些紧急的命令，例如停线指令，以及利用制造执行系统100接入的但归属生产控制系统300管理的生产模块302等，就可以绕开生产监测模块103和生产管理模块104直接进行快速数据交互，提升通信效率。
车体识别系统200通过其包含RFID读取模块201来读取安装在待组装车辆上的射频标签，获取车辆信息，例如车辆识别码。车辆信息还可以包含额外的信息，例如车型信息等，以加快数据检索的速度，但车辆完整信息还是通过车辆识别码为关键字，利用制造执行系统100的数据库模块105中检索获得。
生产控制系统300本身也具备保存制造参数的能力，但它只保存由制造执行系统100下发的用于当前生产的制造参数，并不保存产线支持的全部车辆的制造参数。具体而言，生产控制系统300由配置管理模块301和生产模块302构成。根据不同的汽车产线，每个配置管理模块301对应一个或者多个生产模块302。配置管理模块301包含文件存储单元3011和通信单元3012。在文件存储单元3011中保存有指导当前生产的制造参数，配置管理模块301从中提取信息，来指导和控制生产模块302完成对应工位的生产工序。通信单元3012将配置管理模块301连接到制造执行系统100和生产模块302。通信单元3012在制造执行系统100和生产模块302之间提供了柔性接口。柔性接口的作用在于：当生产模块302自身对外的接口类型发生变化时，通信单元3012通过扩展其柔性接口的方式保持与变化后的生产模块302的通信能 力，同时确保通信单元3012与制造执行系统100的通信接口不变。这样，当产线调整涉及到生产模块302的新增和修改时，只需要升级对应的通信单元3012即可，避免了产线中其他系统的修改。
生产模块302不仅包含在每个工位上的组装设备，例如拧紧枪3023、加注设备3024和涂胶设备3025，还包含和整个产线相关的设备，例如输送线3021和贴合输送线3021的滚轮3022。滚轮3022驱动输送线3021前进，在不同工位间转移待组装车辆。组装设备安装在工位上，用于完成待组装车辆的加工和组装工作。一个工位上全部组装设备的动作序列构成了此工位的生产工序。
请参阅图5，除此之外，生产模块302还包含用于人工介入控制产线运行的设备，例如安灯模块303。安灯呼叫是安灯模块主要功能之一，其原理是由操作员通过操作生产线边的呼叫终端，在异常情况下呼叫相应的负责人(班组长、保全、质量、物流等)，从而降低设备停机率,提高工作效率。在同一个生产线上，根据不同组装设备的特点，一般会针对性的划分为不同的安灯呼叫区域。不同于在现有设计中不同安灯呼叫区域使用不同的接口标准，在本实施例中全部的安灯模块303(A、B和C)均使用第一标准接口3031与配置管理单元301通信，而配置管理单元301使用第二标准接口3032与制造执行系统100通信，从而使得当发生下列情况时：
1、呼叫区域的调整，需要更换不同类型的安灯模块303
2、安灯模块303的数量或类型的调整
只需在制造参数中调整配置，然后交由配置管理模块301处理，而不需要做程序的二次开发，也不需要现场停止生产进行联调，即可实现安灯呼叫系统的自动适配(柔性化)。
生产监测系统400用于在正常工作中持续采集产线状态信息，例如车辆 状态和车辆位置，然后传递给制造执行系统100。生产监测系统400由载具401、车辆监测模块402、载具监测模块403、行程采集模块404和感应开关405构成。生产监测系统上报的产线状态信息，包含安置状态信息、就位状态信息、限位状态信息和行程状态信息。载具401固定在输送线3021上，待组装车辆应当被安置在载具401上，然后由输送线3021带动进入产线，然后依次经过每个加工工位。车辆监测模块402用于识别在载具401上是否正确的安置了待组装车辆，提供安置状态信息。从产线入口开始，依次安装载具监测模块403(欧姆龙E3JK-TR12-C)和感应开关405(欧姆龙WLG2-LD)。载具监测模块403用于识别载具401本身是否正确安装在履带3021上，提供就位状态信息。车辆监测模块402和载具监测模块403结合，则可以确定载具401本身以及载具401上的待组装车辆均被正确安置。感应开关405安装在载具监测模块403后方，它提供限位状态信息，和行程采集模块404结合，用于确定待组装车辆在产线上的精确位置。具体而言，当待组装车辆越过感应开关405时，上报限位状态信息通知到制造执行系统100确定对应该待组装车辆的零点。行程采集模块404包含数据采集单元4031、数据计算单元4032和数据存储单元4033，用于采集并计算输送线3021的行程数据。数据采集单元4031是编码器，例如欧姆龙E6C3-AG5C 256P/R 2M。，编码器数据经数据计算单元4032转换，得到输送线3021的行进距离，作为行程状态信息上报。数据存储单元4033连接到数据采集单元4031和数据计算单元4032，为计算提供存储支持，例如保存输入参数、中间结果和最终结果。已知零点和输送线3021的行进距离，则可以计算出车辆随输送线3021前进的距离，再结合制造执行系统100中的工位的位置以及长度信息，可以判断车辆是否抵达特定工位，以及在该工位中的具体位置(例如在该工位的30％的位置)。
请参阅图7，本发明还公开了利用一种使用柔性接口的可变工位汽车产 线进行汽车组装的方法，其特征在于，包含步骤：
步骤S100，针对待安装车辆部署产线。
步骤S200，初始化产线。
车体识别系统读取待组装车辆的车辆信息，然后由制造执行系统根据车辆信息，确定所述工位的数量、位置和长度，下发制造参数，完成工位和生产工序的配置。
步骤S300，待组装车辆进入产线，开始生产。
请参阅图8，步骤S100中，还具体包含步骤：
步骤S101，调整生产控制系统和生产监测系统的设备。
在生产控制系统中，利用所述柔性接口将新增的生产模块连接到配置管理模块，而不修改生产控制系统与制造执行系统之间的通信接口。步骤S102，在制造执行系统中配置工位、生产控制系统和生产监测系统。
在制造执行系统中，调整对应待安装车辆的制造参数包含：
1、指定产线的工位配置，即包含的工位的数量、位置和长度。
2、指定每个工位对应的生产工序，即每个工位有多少生产模块参与，各个生产模块需要执行的操作以及其先后顺序。
步骤S103，将配置完成后不再使用的多余设备在生产控制系统和生产监测系统中移除。
在生产控制系统中，移除多余的生产模块。此步骤可选，只要满足产线规划，也可以保留各个模块不变，只是不再制造参数中引用，以备后续再次被使用到。
请参阅图9，步骤S200中，还具体包含步骤：
步骤S201，启动生产监测系统开始采集产线状态信息。
步骤S202，车体识别系统读取待组装车辆的车辆信息。
待组装车辆进入产线后，车体识别系统通过RFID读取模块(如SIMATIC RF360T)识别车辆信息，传输给制造执行系统。
步骤S203，制造执行系统完成产线规划。
制造执行系统利用车辆信息中的车辆识别码，从自身保存的多组制造参数中选择一组，完成对可变工位的数量、位置和长度的规划，并将制造参数下发给生产控制系统。
步骤S204，生产控制系统完成规划。
生产控制系统根据收到的制造参数，配置每个工位的生产工序。
请参阅图10，步骤S300中，还具体包含步骤：
步骤S301，生产监测系统采集产线状态信息上报给制造执行系统。
当待组装车辆通过感应开关所在位置时，生产监测系统将信息发送给制造执行系统，制造执行系统为待组装车辆设置在行程的零点。之后，生产监测系统定期上报输送线的行程状态信息，以及每个工位上生产工艺的执行情况,上报给制造执行系统。
步骤S302，制造执行系统结合当前产线的工位的位置和长度，以及产线状态信息中包含的待组装车辆在输送线上的位置信息，确定待组装车辆的当前工位，发送给生产控制系统。
制造执行系统比对待组装车辆在输送线上的位置，其位置处于某个工位的位置和长度区间内时，判定待组装车辆进入此工位。
步骤S303，生产控制系统执行当前工位对应的生产工序。
步骤S304，完成当前工位的生产工序后，制造执行系统驱动待组装车辆沿着输送线前进，并回到步骤S301。
Claims (10)
- 一种使用柔性接口的可变工位汽车产线，使用输送线带动待组装车辆前进，沿所述输送线设置有多个与生产工序对应的工位，其特征在于，由制造执行系统、车体识别系统、生产控制系统和生产监测系统构成；所述制造执行系统连接到所述车体识别系统、所述生产控制系统和所述生产监测系统；所述制造执行系统保存多组制造参数，并根据所述车体识别系统采集的车辆信息，选择其中一组下发给所述生产控制系统；所述生产控制系统包含配置管理模块和生产模块；所述配置管理模块保存由所述制造执行系统下发的所述制造参数，配置每个所述工位的全部所述生产工序，并控制所述生产模块动作；所述生产模块完成所述待组装车辆的转移、加工和组装工作。所述配置管理模块使用柔性接口连接不同的所述生产模块，使得所述制造执行系统与所述生产控制系统之间的通信连接方式不随所述生成控制系统包含的所述生产模块变化；所述生产监测系统采集产线状态信息，反馈至所述制造执行系统，对产线生产实现闭环控制。
- 根据权利要求1所述的使用柔性接口的可变工位汽车产线，其特征在于，所述制造执行系统包含产线管理模块、车辆管理模块、生产管理模块、生产监测模块、数据库模块和快速通信模块；所述产线管理模块提供人机交互接口接收人工输入的所述制造参数，还用于调度所述车辆管理模块和所述生产管理模块协同工作；所述车辆管理模块连接到所述车体识别系统，将所述车体识别系统采集到的所述车辆信息传递给所述产线管理模块；所述生产管理模块连接到所述生产控制系统，向所述生产控制系统传递的所述车辆信息和所述制造参数；所述生产监测模块连接到所述生产监测系统，将所述生产监测系统采集到的所述产线状态信息传 递给所述产线管理模块；所述快速通信模块提供所述生产控制系统和所述生产监测系统之间的直接通信连接，用于绕开所述生产管理模块进行快速数据交互；所述制造参数、所述车辆信息保存在所述数据库模块中。
- 根据权利要求1所述的使用柔性接口的可变工位汽车产线，其特征在于，所述车体识别系统包含RFID读取模块；所述RFID读取模块扫描安装在所述待组装车辆上的射频标签，读取所述车辆信息；所述车辆信息至少包含车辆识别码。
- 根据权利要求1所述的使用柔性接口的可变工位汽车产线，其特征在于，所述配置管理模块包含文件存储单元和通信单元；所述文件存储单元保存对应所述待组装车辆的所述制造参数；所述通信单元用于将所述文件存储单元连接到所述制造执行系统和所述生产模块。
- 根据权利要求1所述的使用柔性接口的可变工位汽车产线，其特征在于，所述生产监测系统包含载具、车辆监测模块、载具监测模块、行程采集模块和感应开关；所述载具固定在产线的所述输送线上，装载所述待组装车辆前进，依次经过所述工位；所述车辆监测模块采集所述待组装车辆在所述载具上的安置状态信息；从产线入口开始，依次安装所述载具监测模块和所述感应开关；所述载具监测模块采集所述载具在所述履带上的就位状态信息；当所述载具和所述待组装车辆越过所述感应开关时，上报限位状态信息；所述行程采集模块采集所述输送线的行程状态信息；由所述生产监测系统上报的所述产线状态信息，包含所述安置状态信息、所述就位状态信息、所述限位状态信息和所述行程状态信息。
- 根据权利要求5所述的使用柔性接口的可变工位汽车产线，其特征在于，所述行程采集模块包含数据采集单元、数据计算单元和数据存储单元； 所述数据采集单元是编码器；所述数据计算单元将所述编码器的数据，转换为所述行程状态信息；所述数据存储单元连接到所述数据采集单元和所述数据计算单元。
- 一种利用如权利要求1所述的使用柔性接口的可变工位汽车产线进行汽车组装的方法，其特征在于，包含步骤：首先，针对所述待安装车辆部署产线；其次，根据所述待组装车辆的所述车辆信息初始化产线，确定所述工位的数量、位置和长度；最后，所述待组装车辆进入产线，开始生产。
- 根据权利要求7所述的汽车组装的方法，其特征在于，在对所述待安装车辆进行产线部署时，首先，调整所述生产控制系统和所述生产监测系统；在所述生产控制系统中，调整生产模块，并利用所述柔性接口将新增的所述生产模块连接到所述配置管理模块，而不修改所述生产控制系统与所述制造执行系统之间的通信接口；然后，在所述制造执行系统中配置所述工位、所述生产控制系统和所述生产监测系统；在所述制造执行系统中，调整对应所述待安装车辆的所述制造参数,用于指定产线包含的所述工位的数量、位置和长度，也用于指定每个所述工位对应的所述生产工序；最后，可选的将配置完成后不再使用的多余设备在所述生产控制系统和所述生产监测系统中移除，包含在所述生产控制系统中，移除多余的所述生产模块。
- 根据权利要求7所述的汽车组装的方法，其特征在于，在初始化产线的过程时：首先，启动所述生产监测系统开始采集所述产线状态信息；其次，所述待组装车辆到达产线入口，所述车体识别系统读取所述车辆信息；然后，所述制造执行系统基于所述车体识别系统上报的车辆信息，从自身保存的多组制造参数中选择一组，配置产线上所述工位的数量、位置和长度，并将选中的所述制造参数下发给所述生产控制系统；最后，所述生产控制系统根据收到的所述制造参数，配置每个所述工位的所述生产工序。
- 根据权利要求7所述的汽车组装的方法，其特征在于，所述待组装车辆的生产过程，包含步骤：步骤S1，所述生产监测系统采集所述产线状态信息上报给所述制造执行系统；步骤S2，所述制造执行系统结合当前产线的所述工位的位置和长度，以及所述产线状态信息中包含的所述待组装车辆在所述输送线上的位置信息，确定所述待组装车辆的当前工位，发送给所述生产控制系统；步骤S3，所述生产控制系统执行所述当前工位对应的所述生产工序；步骤S4，完成所述当前工位的所述生产工序后，所述制造执行系统驱动所述待组装车辆沿着所述输送线前进，并回到步骤S1。
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