Full-automatic production system for standard formwork

Abstract

The invention discloses a standard formwork full-automatic production system, and relates to the technical field of standard formwork automatic production, and the standard formwork full-automatic production system comprises a production management module which is used for storing production process parameters of various models of formworks and configuration information of formwork assemblies, and carrying out the calling according to the demands of production orders; the reloading module is provided with a standardized formwork interface and a positioning mechanism and is used for mounting and dismounting the formwork, and the monitoring module comprises sensors mounted at the mounting position of the formwork and key parts of production equipment. According to the full-automatic production system for the standard formwork, through the mode that software and hardware of the production management module and the reloading module are combined, the problem of formwork model switching in multi-model and large-batch production is effectively solved, and the flexibility and production efficiency of the full-automatic production system for the standard formwork are improved; manpower is effectively reduced, the efficiency is improved, the labor intensity is reduced, the safety coefficient is improved, and diversified requirements in a real production scene are met.

Description

Technical Field

[0001] The invention relates to the technical field of automatic production of standard mold frames, in particular to a full-automatic production system for standard mold frames. Background Art

[0002] In modern manufacturing, companies often receive orders from different customers for various types of standard mold frames, and the order quantity is not large but the types are wide. When switching to produce different types of mold frames, traditional production systems require a lot of manual adjustments to equipment parameters and replacement of mold frame components, which is not only time-consuming, but also prone to human errors, resulting in low production efficiency and unstable product quality. In this regard, in the actual operation of the standard mold frame fully automatic production system, how to ensure that the production switching of different types of mold frames is fast and accurate to meet the production needs of multiple models and large-scale orders. Therefore, there is an urgent need for a standard mold frame fully automatic production system that can ensure the production switching of different types of mold frames is fast and accurate to meet the production needs of multiple models and large-scale orders to solve this problem. Summary of the invention

[0003] In order to solve the above technical problems, the present invention is implemented by the following technical solutions: a fully automatic production system for standard mold frames, including a production management module, which is used to store production process parameters and mold frame component configuration information of various models, and call them according to the requirements of production orders; The replacement module is equipped with a standardized mold frame interface and positioning mechanism for installing and disassembling the mold frame, so that the mold frame can be quickly installed and disassembled in a short time; The monitoring module includes sensors installed at the mold frame installation position and key parts of the production equipment, which are used to detect the mold frame installation position and the status of the production equipment, detect deviation information during the mold frame installation process, and generate adjustment strategies based on the deviation information; The human-computer interaction module provides an operation interface to support operators to input mold frame models, view production status, and receive system prompts and alarm information; When a new production order is received, the operator inputs the mold frame model to be produced in the system operation interface, and the production management module automatically calls the corresponding process parameters and configuration information, and transmits it to the production equipment to switch between different models of mold frames.

[0004] Preferably, the production management module includes: Database unit, used to store production process parameters of different types of mold frames, mold frame component configuration information and historical production data; supports fast query and data update to ensure the timeliness and accuracy of production information; The order processing unit establishes a connection with the database unit to receive and parse new production orders, extract key information from them, and then find and call the production process parameters and mold frame component configuration information corresponding to the mold frame model according to the mold frame model in the key information; wherein the key information includes the mold frame model, order quantity, delivery period, and the complexity of the mold frame production process; The parameter control unit accurately controls the operating parameters of the production equipment based on the called production process parameters and mold frame component configuration information to ensure product quality.

[0005] Preferably, the production process parameters include the tool path, cutting speed and cutting depth of the cutting equipment, the pressure and stroke setting of the stamping equipment, the temperature and clearance of the mold frame, the processing accuracy requirements and the production rhythm requirements; the mold frame component configuration information includes the template and guide assembly of the mold frame component required for mold frame production, the ejection mechanism and demolding slope design of the demolding component, the heating element of the heating component, and the mold frame bolts and nuts, locating pins and locating sleeves of the fastening assembly, as well as the specific specifications, models, quantities and assembly relationships of each component of the required mold frame.

[0006] Preferably, the production management module also includes: The production scheduling unit optimizes the production plan, rationally schedules resources, improves production efficiency, dynamically adjusts the production sequence, and adapts to order changes and emergency orders based on order priority, production equipment status, and production capacity; The equipment monitoring unit monitors and collects the operating status data of the production equipment in real time. The operating status data includes the working parameters, fault information and maintenance requirements of the production equipment, and compares the operating status data with the standard status parameters to obtain the comparison result. When the comparison result shows an abnormality, an alarm signal is generated and an audible and visual alarm is issued to remind the operator to handle it to avoid affecting the production progress. Among them, the working parameters include the current operating speed and processing accuracy of the equipment, the fault information includes whether there is a fault and the type and severity of the fault, and the maintenance requirements include whether maintenance is required and the estimated maintenance time.

[0007] Preferably, the process of optimizing the production plan by the production scheduling unit is as follows: The production scheduling unit establishes a real-time data connection with the equipment monitoring unit, continuously receives the working parameters, fault information and maintenance requirements of the production equipment, and classifies and organizes them, establishes an equipment status database, and records the operating status history of the equipment in different time periods, so as to analyze the performance change trend of the equipment later; Obtain order information from the production order obtained by the order processing unit, including order number, mold frame model, quantity, delivery deadline, and customer priority, and pre-process the order information, calculate the remaining production time of each order, and determine the initial priority weight of the order according to the customer priority and the remaining production time; wherein the remaining production time is the delivery deadline minus the current time; According to the equipment status database and production process parameters, the theoretical production capacity of each production equipment in different time periods is calculated. The theoretical production capacity is the number of mold frames that can be produced per unit time. Based on the equipment maintenance plan and equipment failure history, the theoretical production capacity is corrected to obtain the actual available production capacity. Based on the initial priority weight of the order, the mold base model and the corresponding production process complexity, the heuristic algorithm is used to preliminarily sort the orders to obtain the order sorting results, including the preliminary sorting with the shortest processing time as the priority and the preliminary sorting with the earliest delivery date as the priority; According to the order sorting results and combined with the actual available production capacity of the production equipment, the orders are allocated to the appropriate production equipment, the estimated production start and end time of each order is determined, and the initial production plan is generated.

[0008] Preferably, the process of the production scheduling unit adapting to order changes and emergency orders is as follows: For order change processing: When the order processing unit detects an order change, it immediately sends the change details to the production scheduling unit, where the change details include order quantity adjustment, delivery deadline change, and mold base model change; analyzes the impact of the change details on the production plan, calculates the new priority weight and remaining production time of the order after the change; re-sorts the orders according to the new priority weight and remaining production time after the order change, obtains the order change sorting result, and obtains the changed production plan; If the number of orders increases, check the remaining capacity of the production equipment. If the capacity is sufficient, add corresponding production tasks based on the original plan. If the capacity is insufficient, consider adjusting the order production time or using overtime to meet the demand. If the delivery deadline is advanced, the order will be arranged on equipment with faster production progress first, and the production time of other orders will be shortened if necessary to ensure that the changed order can be delivered on time; If the mold model is changed, re-evaluate the production process requirements and required production resources for the mold model, and adjust equipment allocation and production time; For emergency order processing: When receiving an urgent order request, the production scheduling unit determines the priority weight of the order based on the customer's urgency, order profit, and impact on the company's reputation; evaluates the adjustable space in the current production plan, and finds time periods with ample production progress or orders that can be suspended with less impact; according to the priority weight of the order, mold frame model, and production process requirements, the urgent order is reasonably inserted into the current production plan, and the production sequence and resource allocation of related orders are adjusted to obtain the order production plan; Among them, if the production resources required for an emergency order conflict with existing orders, the resource conflict will be resolved by adjusting the order production equipment or production time, giving priority to ensuring the resource needs of the emergency order.

[0009] Preferably, the process of dynamically adjusting the production sequence is as follows: During the production process, the production scheduling unit continuously obtains the real-time operation status data of the equipment from the equipment monitoring unit, including the equipment operation status and processing progress. The equipment operation status includes normal operation, shutdown, and failure, and the processing progress is the proportion of the completed production tasks to the total number of orders. At the same time, it interacts with the data traceability module to obtain the actual execution status of the production process parameters in the production process, so as to timely discover abnormalities in the production process. If a device fails, the orders being produced on the device will be immediately transferred to other devices, and the production sequence and estimated delivery time of the related orders will be adjusted according to the estimated time for fault repair. If it is found that the order production progress is lagging behind, analyze the reasons for equipment failure and unreasonable production process parameters, and take measures such as adjusting production process parameters, increasing equipment investment, and optimizing production processes to speed up production progress; If the production schedule of an order is ahead of schedule and there is a risk of delay for other orders, adjust the production sequence, arrange the production of orders that may be delayed in advance, make full use of production resources, and ensure that all orders are completed on time; Among them, the production scheduling unit re-evaluates and optimizes the production plan every hour, adjusts the production sequence and resource allocation according to the updated equipment status, order execution status, order changes and emergency orders, to ensure that the production plan always remains in the optimal state and adapts to various dynamic changes in the production process.

[0010] Preferably, the process of the parameter control unit controlling the operating parameters of the production equipment according to the called production process parameters is as follows: Receive the production process parameters and mold frame component configuration information corresponding to the current production mold frame model from the production management module; analyze the influence of different mold frame components on the operating parameters of the production equipment according to the mold frame component configuration information, and obtain the instruction call set; Analyze the production process parameters and decompose them into process parameter variables; based on the equipment control requirements, convert the process parameter variables into the control instruction values ​​of the equipment, and convert the instruction call set into the instruction call value of the equipment; package the instruction call value and the control instruction value according to the format of the communication protocol to form a control instruction package; send the control instruction package to the production equipment through the communication link, and the production equipment performs operations according to the instruction requirements of the control instruction package; The parameter control unit monitors the execution feedback information of the equipment in real time. The execution feedback information includes the actual operating position, speed, pressure value, and temperature value of the equipment. Based on the execution feedback information, it is compared with the sent control instruction parameters to verify whether the equipment performs the operation as required; if it is found that there is a deviation between the equipment execution and the instruction requirements, the instruction is adjusted and corrected in time; During the production process, the equipment's operating data is continuously collected, including the equipment's actual operating parameters, product quality data, and environmental data, and real-time analysis is performed to evaluate the stability of the production process and product quality status and obtain analysis results. Based on the analysis results, when it is found that the equipment's operating parameters need to be optimized to improve product quality or production efficiency, the parameter control unit dynamically adjusts the process parameters. After adjusting the parameters, the equipment's execution and product quality data continue to be monitored to evaluate the adjustment effect.

[0011] Preferably, the refitting module comprises: The mold frame interface unit adopts unified mold frame interface specifications and designs standardized mold frame installation interfaces, so that mold frames of different models can be quickly installed and disassembled on the same production equipment through the mold frame installation interfaces, reducing the adjustment work when replacing mold frames; The positioning mechanism unit includes a guide device and a positioning pin. The guide device provides guidance during the mold frame installation process to prevent the mold frame from being misplaced. The positioning pin is used to locate the installation position of the mold frame to ensure position accuracy and repeatability. The locking mechanism unit uses hydraulic, pneumatic or electric devices to achieve automatic locking and release of the mold frame, shortening the mold change time; Auxiliary positioning units, including laser positioning units and visual recognition units, assist in the precise installation of the mold frame; used for automatic calibration to compensate for deviations caused by equipment wear and thermal expansion and contraction; The mold change control unit is connected to the production management module, receives the mold change instruction, and controls the replacement module to perform the disassembly and installation operations of the mold frame; arranges the mold change timing according to the production plan to reduce downtime; The safety detection unit monitors the safety status of equipment and personnel in real time during the mold changing process. When an abnormal situation is detected, the mold changing operation is immediately stopped and a safety alarm is issued to ensure safety.

[0012] Preferably, the monitoring module includes: The sensing unit includes position sensors, pressure sensors, angle sensors, temperature sensors and vibration sensors, which are installed at the mold frame installation position and key parts of the production equipment respectively, and are used to collect the operation status data of the mold frame and the equipment in real time and perform fusion analysis. The operation status data includes mold frame status data and equipment status data. Data storage unit, which stores the operation status data and establishes a historical database; it is used to trace the key parameters in the production process when quality problems or equipment failures occur; The status monitoring unit monitors the working status of each sensor in real time to ensure the normal operation of the sensor; when a sensor failure or abnormality is detected, an alarm is issued in time and maintenance personnel are notified to handle it; Among them, the process of collecting the operating status data of the mold frame and equipment and performing fusion analysis is as follows: based on the set status threshold, the operating status data collected by the sensor unit is fused and processed through the data fusion algorithm, and the status information during the mold frame installation and production equipment production process is analyzed, and the deviation information during the mold frame installation process and the abnormal information during the operation of the production equipment are identified; once deviation information or abnormal information is found, the early warning mechanism is immediately triggered; based on the triggering of the early warning mechanism, combined with changes in the environment and working conditions, an adjustment strategy is generated, and based on the adjustment strategy, the detection parameters are adjusted to guide the operator to make precise adjustments to ensure the smooth progress of the production process and maintain optimal performance.

[0013] The present invention provides a fully automatic production system for standard mold frames, which has the following beneficial effects: The fully automatic production system for standard mold frames effectively solves the problem of mold frame model switching in multi-model and large-scale production by combining the software and hardware of the production management module and the replacement module, improves the flexibility and production efficiency of the fully automatic production system for standard mold frames, effectively reduces manpower, improves efficiency, reduces labor intensity, and increases safety factors, thus meeting the diverse needs in real production scenarios. BRIEF DESCRIPTION OF THE DRAWINGS

[0014] Figure 1 It is a flowchart of the fully automatic production system of the standard mold frame of the present invention. DETAILED DESCRIPTION

[0015] The present invention is further described in detail below in conjunction with the accompanying drawings and specific embodiments. The embodiments of the present invention are provided for the purpose of illustration and description, and are not intended to be exhaustive or to limit the present invention to the disclosed forms. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments are selected and described in order to better illustrate the principles and practical applications of the present invention, and to enable those of ordinary skill in the art to understand the present invention and thereby design various embodiments with various modifications suitable for specific uses.

[0016] like Figure 1 As shown, the present invention provides a technical solution: a fully automatic production system for a standard mold frame, comprising: The production management module is used to store the production process parameters and configuration information of mold base components of various models, and call them according to the needs of production orders; The replacement module is equipped with a standardized mold frame interface and positioning mechanism for installing and disassembling the mold frame, so that the mold frame can be quickly installed and disassembled in a short time; The monitoring module includes sensors installed at the mold frame installation position and key parts of the production equipment, which are used to detect the mold frame installation position and the status of the production equipment, detect deviation information during the mold frame installation process, and generate adjustment strategies based on the deviation information; The human-computer interaction module provides an operation interface to support operators to input mold frame models, view production status, and receive system prompts and alarm information; When a new production order is received, the operator enters the mold frame model to be produced in the system operation interface. The production management module automatically calls the corresponding process parameters and configuration information, and transmits it to the production equipment to switch between different models of mold frames.

[0017] The production management module includes: Database unit, used to store production process parameters of different types of mold frames, mold frame component configuration information and historical production data; supports fast query and data update to ensure the timeliness and accuracy of production information; The order processing unit establishes a connection with the database unit to receive and parse new production orders, extract key information from them, and then find and call the production process parameters and mold frame component configuration information corresponding to the mold frame model according to the mold frame model in the key information; wherein the key information includes the mold frame model, order quantity, delivery period, and the complexity of the mold frame production process; The parameter control unit accurately controls the operating parameters of the production equipment based on the called production process parameters and mold frame component configuration information to ensure product quality.

[0018] The production process parameters include the tool path, cutting speed and cutting depth of the cutting equipment, the pressure and stroke setting of the stamping equipment, the temperature and clearance of the mold frame, the processing accuracy requirements and the production rhythm requirements; the mold frame component configuration information includes the template and guide components of the mold frame components required for mold frame production, the ejection mechanism and demolding slope design of the demolding component, the heating element of the heating component, and the mold frame bolts and nuts, locating pins and locating sleeves of the fastening component, as well as the specific specifications, models, quantities and assembly relationships of each component of the required mold frame.

[0019] The order processing unit in the production management module can quickly receive and parse new production orders, extract key information, and interact with the database unit to quickly call the corresponding production process parameters and mold component configuration information. This enables the system to determine the production plan in a short time, greatly shortening the order processing cycle and improving the company's response speed to market demand.

[0020] The production management module also includes: The production scheduling unit optimizes the production plan, rationally schedules resources, improves production efficiency, dynamically adjusts the production sequence, and adapts to order changes and emergency orders based on order priority, production equipment status, and production capacity; The equipment monitoring unit monitors and collects the operating status data of the production equipment in real time. The operating status data includes the working parameters, fault information and maintenance requirements of the production equipment, and compares the operating status data with the standard status parameters to obtain the comparison result. When the comparison result shows an abnormality, an alarm signal is generated and an audible and visual alarm is issued to remind the operator to handle it to avoid affecting the production progress. Among them, the working parameters include the current operating speed and processing accuracy of the equipment, the fault information includes whether there is a fault and the type and severity of the fault, and the maintenance requirements include whether maintenance is required and the estimated maintenance time.

[0021] The process of optimizing production plan by production scheduling unit is as follows: The production scheduling unit establishes a real-time data connection with the equipment monitoring unit, continuously receives the working parameters, fault information and maintenance requirements of the production equipment, and classifies and organizes them, establishes an equipment status database, and records the operating status history of the equipment in different time periods, so as to analyze the performance change trend of the equipment later; Obtain order information from the production order obtained by the order processing unit, including order number, mold frame model, quantity, delivery deadline, and customer priority, and pre-process the order information, calculate the remaining production time of each order, and determine the initial priority weight of the order according to the customer priority and the remaining production time; wherein the remaining production time is the delivery deadline minus the current time; According to the equipment status database and production process parameters, the theoretical production capacity of each production equipment in different time periods is calculated. The theoretical production capacity is the number of mold frames that can be produced per unit time. Based on the equipment maintenance plan and equipment failure history, the theoretical production capacity is corrected to obtain the actual available production capacity. Based on the initial priority weight of the order, the mold base model and the corresponding production process complexity, the heuristic algorithm is used to preliminarily sort the orders to obtain the order sorting results, including the preliminary sorting with the shortest processing time as the priority and the preliminary sorting with the earliest delivery date as the priority; According to the order sorting results and the actual available production capacity of the production equipment, the orders are allocated to the appropriate production equipment, the estimated production start and end time of each order is determined, and the initial production plan is generated; The initial priority weight calculation formula of the order is as follows:

[0022] Among them, P is the order priority weight, T is the remaining production time of the order, that is, the delivery deadline minus the current time; C is the customer priority, which is set as a numerical value, 3 for important customers and 1 for ordinary customers; V is the order value, which is determined according to the order amount; is the weight coefficient, determined according to the enterprise's production strategy; and

[0023] The calculation formula for the actual available production capacity of the equipment is as follows:

[0024] Among them: A is the actual available production capacity of the equipment, that is, the number of mold bases that can be produced per unit time; At is the theoretical production capacity of the equipment, which is determined based on equipment specifications and performance parameters; F is the equipment failure rate, which is calculated based on the equipment failure history data: the ratio of equipment failure time to total operating time in the past month; M is the equipment maintenance rate, which is calculated based on the equipment maintenance plan and actual maintenance time: the proportion of equipment maintenance time to total operating time in the past month; The calculation formula for the estimated production time of an order is:

[0025] Among them, Tp is the estimated production time of the order; Q is the order quantity; A is the actual available production capacity of the equipment allocated to produce the order; E is the production process efficiency coefficient, which is determined according to the complexity of the production process of the mold frame model. For complex processes, E=0.8, and for simple processes, E=1.2.

[0026] The production scheduling unit optimizes the production plan based on factors such as order priority, production equipment status, and production capacity. Through data connection with the equipment monitoring unit, it can grasp the equipment status in real time, calculate the actual available production capacity, and use heuristic algorithms to reasonably sort orders to achieve optimal resource allocation; in the face of order changes and emergency orders, it can flexibly adjust the production plan and sequence to ensure efficient and orderly production process.

[0027] The process of production scheduling unit adapting to order changes and emergency orders is as follows: For order change processing: When the order processing unit detects an order change, it immediately sends the change details to the production scheduling unit, where the change details include order quantity adjustment, delivery deadline change, and mold base model change; analyzes the impact of the change details on the production plan, calculates the new priority weight and remaining production time of the order after the change; re-sorts the orders according to the new priority weight and remaining production time after the order change, obtains the order change sorting result, and obtains the changed production plan; If the number of orders increases, check the remaining capacity of the production equipment. If the capacity is sufficient, add corresponding production tasks based on the original plan. If the capacity is insufficient, adjust the order production time to meet the demand. If the delivery deadline is advanced, the order will be arranged on equipment with faster production progress first, and the production time of other orders will be shortened if necessary to ensure that the changed order can be delivered on time; If the mold model is changed, re-evaluate the production process requirements and required production resources for the mold model, and adjust equipment allocation and production time; For emergency order processing: When receiving an urgent order request, the production scheduling unit determines the priority weight of the order based on the customer's urgency, order profit, and impact on the company's reputation; evaluates the adjustable space in the current production plan, and the orders that can be suspended with less impact; according to the priority weight of the order, mold frame model, and production process requirements, the urgent order is reasonably inserted into the current production plan, and the production sequence and resource allocation of related orders are adjusted to obtain the order production plan; Among them, if the production resources required for an emergency order conflict with existing orders, the resource conflict will be resolved by adjusting the order production time to give priority to ensuring the resource needs of the emergency order.

[0028] The process of dynamically adjusting the production sequence is as follows: During the production process, the production scheduling unit continuously obtains the real-time operation status data of the equipment from the equipment monitoring unit, including the equipment operation status and processing progress. The equipment operation status includes normal operation, shutdown, and failure, and the processing progress is the proportion of the completed production tasks to the total number of orders. At the same time, it interacts with the data traceability module to obtain the actual execution status of the production process parameters in the production process, so as to timely discover abnormalities in the production process. If a device fails, the orders being produced on the device will be immediately transferred to the available devices, and the production sequence and estimated delivery time of the related orders will be adjusted according to the estimated time for fault repair. If it is found that the order production progress is lagging behind, analyze the reasons for equipment failure and unreasonable production process parameters, and take measures such as adjusting production process parameters, increasing equipment investment, and optimizing production processes to speed up production progress; If the production schedule of an order is ahead of schedule and there is a risk of delay for other orders, adjust the production sequence, arrange the production of orders that may be delayed in advance, make full use of production resources, and ensure that all orders are completed on time; Among them, the production scheduling unit re-evaluates and optimizes the production plan every hour, adjusts the production sequence and resource allocation according to the updated equipment status, order execution status, order changes and emergency orders, to ensure that the production plan always remains in the optimal state and adapts to various dynamic changes in the production process.

[0029] The process of the parameter control unit controlling the operating parameters of the production equipment according to the called production process parameters is as follows: Receive the production process parameters and mold frame component configuration information corresponding to the current production mold frame model from the production management module; analyze the influence of different mold frame components on the operating parameters of the production equipment according to the mold frame component configuration information, and obtain the instruction call set; The process of analyzing the influence of different mold frame components on the operating parameters of production equipment and obtaining the instruction set includes: determining the appropriate tool type and cutting parameter range of the cutting equipment according to the material and shape of the standard mold frame, and clarifying the tool selection instructions and cutting instructions; calculating the minimum clamping force and slide stroke required by the stamping equipment according to the template size and mold frame structure, and clarifying the template selection instructions and stamping operation instructions; Analyze the production process parameters and decompose them into independent process parameter variables; use Ethernet to establish communication connection with the cutting equipment, stamping equipment and mold frame control system. During the connection, verify the equipment through the equipment number to ensure that the parameter control unit communicates with the correct equipment to prevent control errors caused by mistaken connection to other equipment; the mold frame control system includes the mold frame temperature control system and the control unit of the mold frame gap adjustment mechanism; initialize the communication protocol according to the type of connected equipment and the communication interface standard, perform communication test, send test instructions to the equipment and receive feedback from the equipment, establish a communication link, and ensure the normal operation of the communication link; Based on the equipment control requirements, the process parameter variables are converted into control instruction values ​​that the equipment can directly understand and execute, and the instruction call set is converted into the instruction call value of the equipment; the instruction call value and the control instruction value are packaged according to the format of the communication protocol to form a complete control instruction package, which contains the equipment address, instruction type, and instruction parameters; the control instruction package is sent to the production equipment through the communication link, and the production equipment performs operations according to the instruction requirements of the control instruction package; The control instruction package clearly specifies the operating parameter values ​​that each production equipment should adopt at different production stages, including the axis motion instructions corresponding to the tool path, the motor speed instructions corresponding to the cutting speed, and the tool feed instructions corresponding to the cutting depth in the cutting process; the hydraulic system pressure setting instructions corresponding to the pressure size, and the slide position control instructions corresponding to the stroke setting in the stamping process; During the conversion of process parameter variables into control instruction values ​​for equipment: For cutting equipment, the tool path coordinate value is converted into a motion control instruction sequence in the equipment control system, including a series of linear interpolation and circular interpolation instructions; the cutting speed and depth values ​​are converted into corresponding motor drive signals, including pulse width modulation signals to control the motor speed and the step number of the feed motor; for stamping equipment, the pressure value is converted into a pressure setting signal of the hydraulic system, including converting the digital pressure value into an analog voltage signal through a digital-to-analog converter to control the opening of the proportional valve; the stroke setting value is converted into a position limit signal for the movement of the equipment slider, including determining the stroke range of the slider through the count setting of the encoder; for mold frame parameters, the temperature setting value is converted into a power control signal for the heating element, including calculating the heating power output through a PID controller; the mold frame gap value is converted into a displacement control signal for the gap adjustment mechanism, including adjusting the gap size through a motor drive; Among them, when the control instruction packet is sent to the production equipment through the communication link: during the sending process, a retransmission mechanism is used to ensure that the instruction packet can reach the equipment accurately, that is, after sending the instruction packet, wait for the device to return a confirmation signal. If the confirmation signal is not received within 0.3 seconds, the instruction packet is resent until the device receives it correctly; The parameter control unit monitors the execution feedback information of the equipment in real time. The execution feedback information includes the actual operating position, speed, pressure value, and temperature value of the equipment. Based on the execution feedback information and the sent control instruction parameters, it is compared to verify whether the equipment performs the operation as required; if it is found that there is a deviation between the equipment execution and the instruction requirements, the instruction is adjusted and corrected in time to ensure the accuracy and stability of the production process; For cutting equipment, compare the actual cutting path with the preset tool path to see if they are consistent, and whether the actual cutting speed and depth meet the set values; for stamping equipment, check whether the actual pressure and stroke meet the set requirements; for mold frames, monitor whether the actual adjustment values ​​of temperature and gap are accurate; During the production process, the equipment operation data is continuously collected, including the actual operation parameters of the equipment, product quality data and environmental data, and real-time analysis is performed to evaluate the stability of the production process and the product quality status and obtain analysis results; among which, the actual operation parameters include the actual cutting speed, stamping pressure fluctuations, and mold frame temperature changes; product quality data includes the dimensional accuracy and surface roughness of the mold frame; environmental data includes workshop temperature, humidity, and factors that may affect equipment and product quality; Furthermore, the tool wear of the cutting equipment can be calculated through data analysis algorithms, and the changing trend of product dimensional accuracy can be predicted based on the influence of tool wear on cutting quality; the relationship between the pressure fluctuation of the stamping equipment and the quality of mold frame molding can be analyzed to find out the range of abnormal pressure fluctuations that may cause product defects; the influence of mold frame temperature changes on mold frame molding cycle and quality can be monitored to determine the optimal mold frame temperature control range; According to the analysis results, when it is found that the equipment operating parameters need to be optimized to improve product quality and production efficiency, the parameter control unit dynamically adjusts the process parameters; Furthermore, if it is found that the cutting quality is reduced due to tool wear of the cutting equipment, the cutting speed is appropriately reduced to reduce the impact of tool wear on the quality, and the tool path compensation algorithm is adjusted to ensure the dimensional accuracy of the mold frame; if the pressure fluctuation of the stamping equipment affects the molding quality of the product, the PID parameters of the pressure control system are adjusted to make the pressure more stable; for the mold frame temperature, if there is a deviation between the actual temperature and the optimal molding temperature, the power output of the heating system is adjusted to keep the mold frame temperature within an appropriate range; After adjusting the parameters, continue to monitor the equipment execution and product quality data to evaluate the adjustment effect; if the adjustment effect is not ideal, further optimize the adjustment strategy until a satisfactory production status is achieved; through this dynamic adjustment and optimization mechanism, the accuracy and stability of the production process are continuously improved to ensure that product quality meets the requirements and improve production efficiency.

[0030] The parameter control unit accurately controls the operating parameters of the production equipment based on the production process parameters and the mold frame component configuration information. By analyzing the impact of the mold frame components on the equipment parameters, it accurately converts and sends control instructions to ensure that the equipment operates according to the set parameters, thereby ensuring that the production quality of the mold frame is stable and consistent.

[0031] The refit module includes: The mold frame interface unit adopts unified mold frame interface specifications and designs standardized mold frame installation interfaces, so that mold frames of different models can be quickly installed and disassembled on the same production equipment through the mold frame installation interfaces, reducing the adjustment work when replacing mold frames; The positioning mechanism unit includes a guide device and a positioning pin. The guide device provides guidance during the mold frame installation process to prevent the mold frame from being misplaced. The positioning pin is used to locate the installation position of the mold frame to ensure position accuracy and repeatability. The locking mechanism unit uses a hydraulic device to achieve automatic locking and releasing of the mold frame, shortening the mold change time; Auxiliary positioning units, including laser positioning units and visual recognition units, assist in the precise installation of the mold frame; used for automatic calibration to compensate for deviations caused by equipment wear and thermal expansion and contraction; The mold change control unit is connected to the production management module, receives the mold change instruction, and controls the replacement module to perform the disassembly and installation operations of the mold frame; arranges the mold change timing according to the production plan to reduce downtime; The safety detection unit monitors the safety status of equipment and personnel in real time during the mold changing process. When an abnormal situation is detected, the mold changing operation is immediately stopped and a safety alarm is issued to ensure safety.

[0032] The mold frame interface unit in the changing module adopts unified specifications and is designed with standardized installation interfaces. Combined with the positioning mechanism unit, locking mechanism unit and auxiliary positioning unit, it realizes the rapid installation and disassembly of the mold frame; the mold changing control unit reasonably arranges the mold changing time according to the production plan, further reducing downtime and improving equipment utilization.

[0033] The monitoring modules include: The sensing unit includes position sensors, pressure sensors, angle sensors, temperature sensors and vibration sensors, which are installed at the mold frame installation position and key parts of the production equipment respectively, and are used to collect the operation status data of the mold frame and the equipment in real time and perform fusion analysis. The operation status data includes mold frame status data and equipment status data. Among them, the key parts of the production equipment include the cutting tool and tool holder, spindle and transmission system, workbench and positioning system, control system and electrical components of the cutting equipment; the slider and guide rail, crankshaft and connecting rod mechanism, clutch and brake, mold frame installation part and adjustment mechanism of the stamping equipment; the screw and barrel, injection system and nozzle, mold clamping mechanism and template, hydraulic system and control system of the injection molding equipment; as well as general motors and drive devices, sensors and detection systems, lubrication systems, and safety protection devices; Data storage unit, which stores the operation status data and establishes a historical database; in the event of equipment failure, it is used to trace the key parameters in the production process; The status monitoring unit monitors the working status of each sensor in real time to ensure the normal operation of the sensor; when a sensor failure is detected, an alarm is issued in time and maintenance personnel are notified to handle it; Among them, the process of collecting the operating status data of the mold frame and equipment and performing fusion analysis is as follows: based on the set status threshold, the operating status data collected by the sensor unit is fused and processed through the data fusion algorithm, and the status information during the mold frame installation and production equipment production process is analyzed, and the deviation information during the mold frame installation process and the abnormal information during the operation of the production equipment are identified; once the deviation information is found, the early warning mechanism is immediately triggered; based on the triggering of the early warning mechanism, combined with the changes in the environment and working conditions, an adjustment strategy is generated, and based on the adjustment strategy, the detection parameters are adjusted to guide the operator to make precise adjustments to ensure the smooth progress of the production process and maintain optimal performance.

[0034] It should be further explained that in the specific implementation process, an intelligent production management module is used to pre-store the production process parameters and mold frame component configuration information of various mold frames; when a new production order is received, the operator only needs to enter the mold frame model in the system interface, and the software can automatically transmit the corresponding parameters and configuration information to the production equipment to achieve rapid switching; In terms of equipment hardware, a mold-changing control unit is designed; standardized mold frame interfaces and positioning mechanisms are adopted so that the mold frame can be quickly installed and disassembled in a short time; at the same time, sensor technology is used to monitor the installation position and status of the mold frame in real time to ensure the accuracy of the mold frame installation; once a deviation in the mold frame installation is detected, the system immediately issues an alarm and provides adjustment suggestions to ensure the smooth progress of the production process; this combination of software and hardware can effectively solve the problem of mold frame model switching in multi-model, large-scale production, improve the flexibility and production efficiency of the standard mold frame fully automatic production system, achieve quality control of standard mold frames, and meet the diverse needs in real production scenarios.

[0035] Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field and related fields without creative work should fall within the scope of protection of the present invention. The structures, devices and operating methods not specifically described and explained in the present invention are implemented according to the conventional means in the field unless otherwise specified and limited.

Claims

1. Standard mold frame fully automatic production system, characterized by: include: The production management module is used to store the production process parameters and configuration information of mold base components of various models, and call them according to the needs of production orders; The replacement module is provided with a standardized mold frame interface and positioning mechanism for installing and disassembling the mold frame; The monitoring module includes sensors installed at the mold frame installation position and key parts of the production equipment, which are used to detect the mold frame installation position and the status of the production equipment, detect deviation information during the mold frame installation process, and generate adjustment strategies based on the deviation information; The human-computer interaction module provides an operation interface to support operators to input mold frame models, view production status, and receive system prompts and alarm information.

2. The fully automatic production system for standard mold frames according to claim 1 is characterized in that: The production management module includes: Database unit, used to store production process parameters of different types of mold frames, mold frame component configuration information and historical production data; supports fast query and data update; The order processing unit establishes a connection with the database unit to receive and parse new production orders, extract key information from them, and then find and call the production process parameters and mold frame component configuration information corresponding to the mold frame model according to the mold frame model in the key information; wherein the key information includes the mold frame model, order quantity, delivery period, and the complexity of the mold frame production process; The parameter control unit controls the operating parameters of the production equipment based on the called production process parameters and mold frame component configuration information.

3. The fully automatic production system for standard mold frames according to claim 2 is characterized in that: The production process parameters include the tool path, cutting speed and cutting depth of the cutting equipment, the pressure size and stroke setting of the stamping equipment, the temperature and clearance of the mold frame, the processing accuracy requirements and the production rhythm requirements; the mold frame component configuration information includes the template and guide components of the mold frame components required for mold frame production, the ejection mechanism and demolding slope design of the demolding component, the heating element of the heating component, and the mold frame bolts and nuts, locating pins and locating sleeves of the fastening component, as well as the specific specifications, models, quantities and assembly relationships of the various components of the required mold frame.

4. The fully automatic production system for standard mold frames according to claim 3 is characterized in that: The production management module also includes: The production scheduling unit optimizes the production plan and dynamically adjusts the production sequence according to order priority, production equipment status and production capacity to accommodate order changes and emergency orders; The equipment monitoring unit monitors and collects the operating status data of the production equipment in real time. The operating status data includes the working parameters, fault information and maintenance requirements of the production equipment, and compares the operating status data with the standard status parameters to obtain the comparison result. When the comparison result shows an abnormality, an alarm signal is generated and an audible and visual alarm is issued to remind the operator to handle it.

5. The fully automatic production system for standard mold frames according to claim 4 is characterized in that: The process of optimizing production plan by production scheduling unit is as follows: The production scheduling unit establishes a data link with the equipment monitoring unit to receive the working parameters, fault information and maintenance requirements of the production equipment, classify and organize them, and establish an equipment status database; Obtain order information from the production order obtained by the order processing unit, including order number, mold frame model, quantity, delivery deadline, and customer priority, and pre-process the order information, calculate the remaining production time of each order, and determine the initial priority weight of the order according to the customer priority and the remaining production time; wherein the remaining production time is the delivery deadline minus the current time; Calculate the theoretical production capacity of each production equipment in different time periods based on the equipment status database and production process parameters; and revise the theoretical production capacity based on the equipment maintenance plan and equipment failure history to obtain the actual available production capacity; Based on the initial priority weight of the order, the mold base model and the corresponding production process complexity, the heuristic algorithm is used to preliminarily sort the orders to obtain the order sorting results, including the preliminary sorting with the shortest processing time as the priority and the preliminary sorting with the earliest delivery date as the priority; According to the order sorting results and combined with the actual available production capacity of the production equipment, the orders are allocated to the production equipment, the estimated production start and end time of each order is determined, and the initial production plan is generated.

6. The fully automatic production system for standard mold frames according to claim 5 is characterized in that: The process of the production scheduling unit adapting to order changes and emergency orders is as follows: For order change processing: When the order processing unit detects an order change, it sends the change details to the production scheduling unit; analyzes the impact of the change details on the production plan, and calculates the new priority weight and remaining production time of the order after the change; According to the new priority weight and remaining production time after the order change, the orders are re-sorted to obtain the order change sorting results and the changed production plan; If the number of orders increases, check the remaining capacity of the production equipment. If the capacity is sufficient, add corresponding production tasks based on the original plan. If the capacity is insufficient, consider adjusting the order production time or using overtime to meet the demand. If the delivery deadline is advanced, the order will be assigned to the production equipment first; if the mold frame model is changed, the production process requirements and required production resources of the mold frame model will be re-evaluated, and the equipment allocation and production time will be adjusted; For emergency order processing: When receiving an emergency order request, the production scheduling unit determines the priority weight of the order based on the customer's urgency, order profit, and impact on the company's reputation; evaluates the adjustable space in the current production plan, and finds time periods with ample production progress or orders that can be suspended with less impact; according to the priority weight of the order, mold frame model, and production process requirements, the emergency order is inserted into the current production plan, and the production sequence and resource allocation of related orders are adjusted to obtain the order production plan; Among them, if the production resources required for the emergency order conflict with the existing orders, the resource conflict can be resolved by adjusting the order production equipment or production time.

7. The fully automatic production system for standard mold frames according to claim 6 is characterized in that: The process of dynamically adjusting the production sequence is as follows: During the production process, the production scheduling unit continuously obtains the real-time operation status data of the equipment from the equipment monitoring unit, including the equipment operation status and processing progress; at the same time, it interacts with the data traceability module to obtain the actual execution status of the production process parameters in the production process, so as to timely discover abnormalities in the production process; If a device fails, immediately transfer the orders being produced on the device to available devices, and adjust the production sequence and estimated delivery time of the related orders based on the estimated time for repairing the failure; If it is found that the order production progress is lagging behind, analyze the reasons for equipment failure and unreasonable production process parameters, and take measures such as adjusting production process parameters, increasing equipment investment, and optimizing production processes to speed up production progress; if the order production progress is ahead of schedule and there is a risk of delay, adjust the production sequence and arrange the production of orders that may be delayed in advance.

8. The fully automatic production system for standard mold frames according to claim 7 is characterized in that: The process of the parameter control unit controlling the operating parameters of the production equipment according to the called production process parameters is as follows: Receive the production process parameters and mold frame component configuration information corresponding to the current production mold frame model from the production management module; analyze the influence of different mold frame components on the operating parameters of the production equipment according to the mold frame component configuration information, and obtain the instruction call set; analyze the production process parameters and decompose them into process parameter variables; Based on the equipment control requirements, the process parameter variables are converted into the control instruction values ​​of the equipment, and the instruction call set is converted into the instruction call value of the equipment; the instruction call value and the control instruction value are packaged according to the format of the communication protocol to form a control instruction package; the control instruction package is sent to the production equipment through the communication link, and the production equipment performs operations according to the instruction requirements of the control instruction package.

9. The fully automatic production system for standard mold frames according to claim 8 is characterized in that: The refitting module comprises: The mold frame interface unit adopts unified mold frame interface specifications and designs standardized mold frame installation interfaces, so that mold frames of different models can be quickly installed and disassembled on the same production equipment through the mold frame installation interfaces, reducing the adjustment work when replacing mold frames; The positioning mechanism unit includes a guide device and a positioning pin, wherein the guide device provides guidance during the installation of the mold frame, and the positioning pin is used to locate the installation position of the mold frame; The locking mechanism unit uses hydraulic, pneumatic or electric devices to achieve automatic locking and release of the mold frame; Auxiliary positioning units, including laser positioning units and visual recognition units, assist in the precise installation of the mold frame; The mold change control unit is connected to the production management module, receives the mold change instruction, controls the replacement module to perform the disassembly and installation operations of the mold frame; and arranges the mold change timing according to the production plan; The safety detection unit monitors the safety status of equipment and personnel in real time during the mold changing process. When an abnormal situation is detected, the mold changing operation is immediately stopped and a safety alarm is issued.

10. The fully automatic production system for standard mold frames according to claim 9 is characterized in that: The monitoring module comprises: The sensing unit includes position sensors, pressure sensors, angle sensors, temperature sensors and vibration sensors, which are installed at the mold frame installation position and key parts of the production equipment respectively, and are used to collect the operation status data of the mold frame and the equipment in real time and perform fusion analysis. The operation status data includes mold frame status data and equipment status data. A data storage unit stores the operation status data and establishes a historical database; The status monitoring unit monitors the working status of each sensor in real time to ensure the normal operation of the sensor; when a sensor failure or abnormality is detected, an alarm is issued in time and maintenance personnel are notified to handle it; Among them, the process of collecting the operating status data of the mold frame and equipment and performing fusion analysis is as follows: based on the set status threshold, the operating status data collected by the sensor unit is fused and processed through the data fusion algorithm, and the status information during the mold frame installation and the production equipment production process is analyzed, and the deviation information during the mold frame installation process and the abnormal information during the operation of the production equipment are identified; once deviation information or abnormal information is found, the early warning mechanism is immediately triggered; based on the triggering of the early warning mechanism, combined with changes in the environment and working conditions, an adjustment strategy is generated, and the detection parameters are adjusted based on the adjustment strategy.

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