Discrete coating manufacturing method and system

Abstract

The invention discloses a discrete coating manufacturing method and system which are suitable for small-batch and multi-variety production scenes. The system comprises an MES system, an AGV intelligent logistics device, an RFID identification module, various processing devices and a quality inspection terminal. The method comprises the following steps: an MES system issues a production task and process parameters, a material distribution worker endows each box of materials with a unique identifier and binds a process template, an AGV conveys the materials to a matching device according to a path template and carries out processing, and the device automatically reports a processing state when the materials flow in or out to realize single-box-level tracing; if the equipment bottleneck exists, the materials are fed into a cache stereoscopic warehouse and wait for redistribution; and after machining is completed, the AGV conveys the materials to a quality inspection station, quality evaluation is completed in a machine vision or manual quality inspection mode, and a detection result is uploaded to an MES system for filing. The system has the capabilities of flexible scheduling, precise process control and whole-course tracing, and the coating production efficiency and the quality control level can be remarkably improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of intelligent manufacturing and industrial automation, in particular to a discrete coating manufacturing method and system. BACKGROUND

[0002] At present, in the coating manufacturing industry, the continuous production mode is widely used, that is, the material is transmitted along the fixed production line in turn, and each process section is processed according to the established process to complete. This mode is suitable for mass production and standardized product production, but in actual application, a series of limitations are gradually exposed.

[0003] Under this mode, the formulation and adjustment of the production plan mainly depend on manual operation. The scheduling personnel manually formulate the production scheduling plan based on experience or order information, and then issue the task to each process node through paper work order or terminal instruction. This way not only has the problems of slow response speed and poor real-time performance, but also lacks flexible response mechanism when the plan is changed or orders are inserted, which easily causes plan confusion or resource conflict. More importantly, in the current manufacturing scene of small batch, multi-variety and rapid delivery, the existing continuous production mode exposes the problems of low equipment utilization rate, poor flexibility and low process switching efficiency. Especially when the process parameters are frequently changed, the production rhythm is uneven, and the product process is non-standardized, the existing system is prone to material mixing, process interference and parameter configuration errors, which causes resource waste and rising rework rate, and seriously affects the production efficiency and product consistency. Therefore, it is necessary to design a discrete coating manufacturing method and system. SUMMARY

[0004] The purpose of the present application is to provide a discrete coating manufacturing method and system to solve the problems raised in the background.

[0005] In order to solve the above technical problems, the present application provides the following technical scheme: a discrete coating manufacturing method, comprising the following steps:

[0006] S1, production task issuing and batch identification: the MES system generates a batch number according to the order and issues a process task, the material distribution personnel boxes the material according to the work order, and assigns a unique identity to each box of material through an RFID tag;

[0007] S2, process parameter issuing: the MES system automatically issues process formula parameters to each coating processing equipment to ensure that the equipment operating parameters match the material process template;

[0008] S3, process path binding and logistics scheduling: the MES system binds a process flow template for each box of material and generates a path instruction, and the AGV delivers the material to the matching station equipment in turn according to the instruction;

[0009] S4, double-station docking loading: the AGV adopts a double-station structure to complete parallel loading and unloading of materials during docking with the equipment, so as to reduce downtime;

[0010] S5, processing state feedback: each process equipment automatically reports the processing state to the MES system when the material enters or flows out, realizing single-box-level traceability;

[0011] S6, intelligent scheduling and caching: if a bottleneck exists in the subsequent equipment, the AGV temporarily stores the material in the three-dimensional caching warehouse, and continues to circulate after the equipment capacity is released;

[0012] S7, quality inspection and data collection: after processing is completed, the AGV sends the material to the quality inspection station, completes quality inspection through machine vision or manual means, and uploads the results to the MES system for archiving.

[0013] According to the above technical solution, the information stored by the RFID tag includes batch number, material number, process template ID, and current process node state.

[0014] According to the above technical solution, the MES system supports configuring process parameter templates for different types of equipment, including but not limited to coating thickness, temperature control section, speed curve, and drying time.

[0015] According to the above technical solution, the double-station docking structure of the AGV includes a front station and a rear station, which are used for feeding and unloading respectively, and the AGV control system can schedule the two stations in parallel to reduce waiting time.

[0016] According to the above technical solution, the process path can be dynamically updated, and when the MES system receives an insertion instruction, the path of the unprocessed material is re-planned to realize dynamic production scheduling.

[0017] According to the above technical solution, the intelligent scheduling and caching step of temporarily storing the material in the three-dimensional caching warehouse if a bottleneck exists in the subsequent equipment, and continuing to circulate after the equipment capacity is released (S6) further includes:

[0018] First, calculate the load score:

[0019] L i (t) = a Q i (t) + b R i (t) + g H i ;

[0020] Where: L i (t): the comprehensive load score of equipment i at time t;

[0021] Q i (t): the current number of queued tasks;

[0022] R i (t): current task remaining processing time

[0023] H i : historical average processing time of unit task of equipment i

[0024] α, β, γ: weighting coefficients, satisfying α+β+γ=1, used to adjust the influence weight of different factors

[0025] Then, the load score L i (t) of each equipment is compared with a preset load threshold T high :

[0026] If L i (t) > T high , the material should be buffered, otherwise, it is directly sent to the processing equipment.

[0027] According to the above technical solution, further comprising: for each box of material to be transported, calculating the distance cost between the current position (x j , y j ) of AGV and the target equipment station (x i , y i ):

[0028]

[0029] Wherein: D ij is the distance cost of AGVj transporting to equipment i; δ is a path correction coefficient (considering obstacles, path priority, etc. Settable coefficient),

[0030] For the material in the buffer area, according to the material order priority U k , the buffer residence time A k and the corresponding equipment idle degree W k , the out-of-warehouse priority P k is calculated:

[0031] P k = λ·U k + μ·A k + ν·W k ,

[0032] Wherein, λ, μ, ν are weight coefficients, satisfying λ+μ+ν=1. The system manages the buffer out-of-warehouse according to P k from high to low order.

[0033] According to the above technical solution, further comprising: MES continuously monitors the equipment load score L i (t), and when the equipment load falls below the threshold, triggering the buffered material to be sent out according to the priority P kThe AGV receives a task to send the material to the idle equipment for processing, and in addition, the system re-executes the above steps at a fixed time interval Δt.

[0034] According to the technical scheme, the total transportation distance, the waiting time and the production cycle are finally minimized, and the specific objective function is:

[0035]

[0036] D k : total transportation path cost of the material k;

[0037] W k : waiting time of the material k in the buffer area or in front of the equipment;

[0038] T k : total production cycle of the material k from the distribution to the quality inspection;

[0039] η1, η2, η3: global optimization weight coefficients.

[0040] According to the technical scheme, the system comprises:

[0041] A production preparation and identification control module is configured to initialize a production task, bind material identity and process information;

[0042] A path control and dynamic scheduling module is configured to guide the material to flow according to the process path, coordinate AGV scheduling and buffer warehouse management, dynamically respond to the equipment load state through an algorithm, and realize flexible manufacturing, capacity balancing and order insertion capability;

[0043] A processing feedback and quality traceability module is configured to collect processing node state, quality inspection result and historical trajectory information, realize single-box-level quality tracking, closed-loop data collection and abnormal processing logic.

[0044] Compared with the prior art, the present application has the following beneficial effects: the present application realizes accurate management and whole-process traceability of single-box material by adopting an MES system and RFID technology, significantly improves the identification accuracy and traceability of the material, adopts AGV double-station connection design and intelligent scheduling algorithm, optimizes the logistics path and equipment loading and unloading efficiency, effectively reduces the equipment waiting time and AGV investment cost, introduces a buffer three-dimensional warehouse and a dynamic process path binding, solves the equipment capacity bottleneck problem, realizes flexible scheduling and order insertion processing of production, and combines machine vision and artificial quality inspection to improve the accuracy and timeliness of product detection. Overall, the present application significantly improves the production efficiency, equipment utilization rate and product quality stability of the coating manufacturing, and meets the demand for small-batch and multi-variety flexible production. BRIEF DESCRIPTION OF DRAWINGS

[0045] The accompanying drawings are included to provide a further understanding of the application, and are incorporated in and constitute a part of this specification, illustrate embodiments of the application, and together with the description serve to explain the principles of the application, but are not intended to limit the application.

[0046] In the drawings:

[0047] Figure 1 A flow chart of a discrete coating manufacturing method provided for the first embodiment of the present application;

[0048] Figure 2 A schematic diagram of the module composition of a discrete coating manufacturing system provided for the second embodiment of the present application. DETAILED DESCRIPTION

[0049] The technical solutions in the embodiments of the present application will be described clearly and completely below with reference to the drawings in the embodiments of the present application. Obviously, the described embodiments are only some of the embodiments of the present application, but not all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative work fall within the protection scope of the present application.

[0050] Embodiment one:

[0051] Figure 1 A flow chart of a discrete coating manufacturing method provided for the first embodiment of the present application, the present embodiment can be applied to the scenario of coating manufacturing, and the method can be executed by a discrete coating manufacturing system provided by the present embodiment. As shown in the figure, the method specifically includes the following steps: Figure 1

[0052] Step one: batch management and identification

[0053] In the embodiments of the present application, first, a process personnel formulates and issues a production plan through a MES (Manufacturing Execution System) platform, and the production plan contains information such as the material type, processing technology, target capacity and plan time corresponding to each product order. After the MES system receives the plan, it automatically generates a corresponding batch number for each order and establishes a batch file in the database as the basis for subsequent process flow and data tracing.

[0054] Subsequently, a material distribution operator logs in the MES system through a mobile terminal PAD at a material distribution station and receives a task work order to be distributed. The operator quantitatively divides and packs the raw materials or intermediate products according to the requirements in the work order and assigns a unique identification number to each box of the packed materials. The identification number is automatically generated by the MES system and bound to the batch information of the box of materials, and is written into a read-write RFID electronic tag.

[0055] ​Exemplarily, the RFID tag is attached to the outer surface of the material box, and the information contained includes but is not limited to: a unique box number, a batch number to which the box belongs, a material name, an initial state, a process template number to be issued, etc. The RFID tag can be read by an automatic identification system in subsequent circulation, so as to realize tracking and state updating of the material box in the whole life cycle. Through this step, each box of material has a unique identification and full-process management capability from the starting point of material distribution, which provides a data basis for subsequent process parameter matching, equipment calling, logistics scheduling and quality tracing and the like.

[0056] Step two: process parameter issuing;

[0057] In the embodiment of the application, after the MES system identifies the unique ID of each box of material and the process template bound thereto, the MES system automatically issues the matching process recipe parameters to the corresponding processing equipment according to the preset parameter configuration in the process template. The process parameters include but are not limited to temperature set value, pressure range, coating rate, coating thickness, stirring frequency, curing time and the like key process control variables, and can be set differently according to the types of equipment and process stages.

[0058] Exemplarily, when the AGV transports the material box to the target processing equipment, the MES system issues a preparation instruction to the equipment, and the equipment control system automatically completes preloading of the process parameters and initialization of the state after receiving the instruction. The system simultaneously performs equipment state checking to ensure that the processing environment meets the process execution conditions. If the parameter loading is successful and the equipment state meets the requirements, the equipment enters the processing mode, and the processing can be automatically started after the material is in place.

[0059] Exemplarily, for some old model equipment without automatic parameter configuration capability, the MES system generates a corresponding electronic work order and pushes it to the terminal (such as PAD or host computer interface) of the operator. The work order lists all process set values corresponding to the batch of material and marks the inspection items, and the operator sets and confirms the equipment item by item according to the work order. After the setting is completed, the operator needs to submit a confirmation record on the terminal, and the MES system updates the state label of the equipment according to the record and marks it as "parameter configured".

[0060] Through this step, it is ensured that the processing equipment of each box of material has completed parameter pre-setting or manual checking before entering the processing node, so as to ensure process consistency and material adaptability, and avoid product defects or material mixing phenomenon caused by incorrect equipment parameters.

[0061] Step three: process path binding and circulation;

[0062] In the embodiment of the present application, the planner binds a corresponding process template for each batch of material box in the MES system according to order demand and process flow through a graphical interface or a process configuration module. The process template presets the complete process node sequence required for the product, the processing parameter requirement of each node, the adapted equipment number and the allowable time window and other information, forming a complete process path.

[0063] For example, after each batch of material is completed, its unique ID is bound with the designated process template and stored in the MES database, and is synchronized to the on-site scheduling control system. The AGV scheduling system reads the unique identification information in the RFID tag of each batch of material, calls the process template bound in the MES, analyzes the processing path, and dynamically plans the flow route of the material according to the processing path.

[0064] For example, during the material processing, the AGV transports the material box to the pre-station of the equipment matched with the node in the template according to the sequence of the processing nodes, and completes the material handover through wireless signal interaction with the equipment. After the equipment processing is completed, the AGV is connected again to take the material, and transports the material to the next processing equipment according to the path until all the processing nodes are completed. During each process node switching process, the MES system records the node number reached by the material, the time stamp of entering and leaving, the equipment running state and whether the processing is successful, and other information, forming a complete process history of the material box. If a device in the processing path is in a fault or maintenance state, the system will automatically call the available device node in the alternative path and notify the AGV to reconfigure the path to avoid stagnation. Through this step, the precise binding and automatic flow of each batch of material and the process path are realized, breaking the limitations of traditional fixed line production and having high flexibility and dynamic adjustment capability.

[0065] Step four: double-station connection;

[0066] In the embodiment of the present application, in order to improve the material loading and unloading efficiency and optimize the AGV scheduling resources, the AGV adopts a double-station connection structure design. Specifically, two independent material carrying units are arranged on each AGV, which are used to carry the material to be processed and the processed material respectively. The two stations are physically isolated to avoid material interference, and each station is equipped with an independent lifting mechanism or a roller moving platform to realize efficient docking with the processing equipment or the buffer platform.

[0067] Exemplarily, in the material flow process, after the AGV receives the scheduling instruction issued by the MES system, it first goes to the current processing equipment station according to the process path. If there is a processed material in front of the equipment, the first docking station of the AGV completes the loading operation of the finished product; then the AGV adjusts the position or uses the transverse movement mechanism to align the second docking station with the equipment inlet, and completes the loading action of the new material. This process makes the equipment loading and unloading process completed synchronously in one AGV docking cycle, greatly reducing the equipment waiting time. Through the design of the double-station structure, the AGV can complete the bidirectional operation mode of "old material taking out + new material sending in" in one running cycle, compared with the traditional single-station AGV which can only perform unidirectional operation each time, significantly reducing the number of round trips and empty running ratio. Under the condition that the number of AGVs in the production line is unchanged, the overall material flow efficiency can be improved, and the system scheduling pressure can be reduced.

[0068] Exemplarily, in addition, the double-station structure can realize the cooperative operation logic of "buffering and transferring simultaneously" when cooperating with the buffering strategy, that is, after one side completes the production line docking operation, the other side immediately enters the buffering area or the quality inspection area for the next flow, without waiting, improving the continuity of system beat and equipment utilization. Through the implementation of this step, the equipment waiting / unloading time window is effectively shortened, the AGV deployment frequency and the number of vehicles required under unit capacity are reduced, and the operation efficiency and economy of the overall intelligent logistics system are further improved

[0069] Step five: processing state feedback;

[0070] In the embodiments of the present application, in order to realize accurate tracking and quality control of the whole material processing process, the system is provided with a data acquisition and feedback module connected with the MES system at each process node. When the AGV delivers the material box to the receiving station of the target equipment, the equipment identifies the unique ID information of the material box through the built-in RFID read-write device, and automatically retrieves the process template and processing state record bound to the box material in the MES system;

[0071] Exemplarily, after completing the feeding confirmation, the equipment automatically reports the "material arrival" state to the MES system, including time stamp, equipment number, station information, operator information (if applicable), and other key data, and marks the time node of starting processing. During the processing, the equipment can collect process parameters (such as temperature, coating speed, thickness control data, etc.) according to the specific process requirements, and real-time feedback to the MES system for dynamic recording.

[0072] After processing is completed, the equipment detects the processing completion signal through the terminal control system and automatically feeds back the "processing completed" status to the MES system. The feedback information includes the processing end time, equipment operating status code, abnormal records (if any), measured values ​​of key process parameters, and preliminary product judgment results (such as qualified / abnormal), forming a complete processing history data.

[0073] If the equipment has an automatic material conveying function, it will notify the AGV to connect and transfer the material after processing is completed via a signal. If the equipment requires manual assistance for unloading, the operator will manually confirm the completion of processing and enter the unloading command on the terminal to update the status synchronously. Regardless of the method, the MES system can achieve closed-loop recording of the entire process of each box of material from entering the station to leaving the station.

[0074] Through the implementation of this step, the system achieves refined status management based on each box of materials, ensuring that the data throughout the entire process is visible, searchable, and traceable, providing accurate data support for subsequent quality inspection, quality analysis, process optimization, and accountability.

[0075] Step Six: Intelligent Scheduling and Caching;

[0076] In this embodiment of the invention, in order to alleviate the problems of equipment waiting and logistics blockage caused by uneven production capacity in multi-process workflows, the system adopts a push-based production mode, combining the task distribution mechanism of the MES system and the intelligent algorithm of the AGV scheduling system to achieve dynamic and balanced allocation of resources on a global scale.

[0077] Specifically, the MES system calculates the task load index of each device in real time based on data such as the current operating status of each process segment, the quantity of work-in-process, equipment availability, and historical processing cycle time, and transmits the results to the AGV scheduling system. The AGV scheduling system prioritizes transportation tasks based on this information, determines the optimal material flow path and waiting strategy, and prioritizes the transport of materials to the transit buffer area if the equipment for the next process is operating at full capacity or experiencing a temporary malfunction after the AGV completes the material transfer from the previous process. The buffer area is an automated storage and retrieval system (AS / RS) with multi-level storage locations and an intelligent shelving management system, allowing for categorized storage according to material type, priority, and process path.

[0078] Exemplary, the material box entering the buffer area still maintains its binding state of RFID tag, the MES system continues to record its buffer time and queue number, and keeps linkage with the target device capacity state. Once the MES system detects that the target device enters the idle or low load state, it immediately generates an outbound instruction to notify the AGV to automatically transfer the waiting material box out and send it into the device for processing, thereby realizing dynamic capacity adjustment and efficient logistics response. In addition, the system supports priority scheduling of inserted tasks. If an urgent production task needs to be inserted for execution, the MES can modify the process priority of the batch, and the AGV scheduling system will automatically adjust the buffer area outbound sequence according to the priority algorithm, realizing high flexibility of personalized production scheduling.

[0079] Exemplary, more specifically, assuming there are n processing devices, the load score of the i-th device is defined as:

[0080] L i (t)=α·Q i (t)+β·R i (t)+γ·H i ;

[0081] Wherein: L i (t): the comprehensive load score of device i at time t;

[0082] Q i (t): current number of queued tasks;

[0083] R i (t): current remaining processing time of the task;

[0084] H i : the historical average processing time per task of device i;

[0085] α, β, γ: weighting coefficients, satisfying α+β+γ=1, used to adjust the influence weight of different factors.

[0086] Then compare the load score L i (t) of each device with the preset load threshold T high :

[0087] If L i (t) > T high , the material should be buffered, otherwise it is directly sent to the processing device.

[0088] For each box of material to be transported, calculate the distance cost between the current AGV position (x j , y j ) and the target device station (x i , y i ):

[0089]

[0090] D ij : the cost distance of AGVj transporting to equipment i; δ: path correction coefficient (considering obstacles, path priority, etc. can set the coefficient),

[0091] For the materials in the buffer area, the order priority U k , the buffer residence time A k and the corresponding equipment idle degree W k , the warehouse priority is calculated:

[0092] P k = λ·U k + μ·A k + ν·W k

[0093] Wherein, λ, μ, ν are weight coefficients, satisfying λ+μ+ν=1. The system manages the buffer warehouse according to P k from high to low order.

[0094] The MES continuously monitors the equipment load score L i (t), when the equipment load falls below the threshold, the buffer material is triggered according to the priority P k out of the warehouse, AGV receives the task to send the material to the idle equipment for processing, in addition, the system re-executes the above steps at fixed time interval Δt, realizes the dynamic real-time adjustment of equipment load and logistics scheduling, ensures the smooth and efficient operation of production line.

[0095] The overall goal of the above scheduling logic is to minimize the total transportation distance, waiting time and production cycle, and the specific objective function is:

[0096]

[0097] D k : the total transportation path cost of material k;

[0098] W k : the waiting time of material k in the buffer area or in front of the equipment;

[0099] T k : the total production cycle of material k from sorting to quality inspection;

[0100] η1, η2, η3: global optimization weight coefficient;

[0101] In this step, the intelligent logistics scheduling system executes the flow path determination of the material based on the equipment load function L i (t) and the material priority score function P k If the target equipment load exceeds the set threshold T high , the material enters the buffer area and is sorted according to the score function Pk = lambda * U k + mu * A k + nu * W k , and the warehouse-out prioritization is performed. The method optimizes the scheduling efficiency and equipment utilization of the entire discrete coating manufacturing system by jointly minimizing the path cost, waiting time and beat efficiency.

[0102] Step seven: quality inspection and data archiving.

[0103] In the embodiment of the present application, after the entire processing process is completed, the MES system automatically identifies that each box of material has completed the entire process flow according to the process path binding relationship and the equipment processing state feedback information. At this time, the MES system generates a quality inspection dispatch instruction through the task scheduling module, and the AGV corresponding to the instruction receives the instruction and goes to the terminal processing station to take the material, and transports the processed material to the designated quality inspection station.

[0104] For example, in order to ensure traceability, each box of material needs to brush the RFID tag information during the quality inspection process, and the MES automatically calls the corresponding production process template, historical processing track and current quality inspection record to form a complete life cycle archive. Once the quality inspection result is reported, it is written into the data structure of the material in the MES system, forming a complete archive of a single box containing elements such as "production batch number, processing equipment chain, parameter record, quality inspection result". For unqualified materials, the MES system automatically generates an abnormal handling task sheet, marks the box of material as "to be reworked" or "scraped", and assigns it to the designated processing area. The AGV continues to execute the subsequent disposal scheduling according to the task.

[0105] Embodiment two:

[0106] The embodiment two of the present application provides a discrete coating manufacturing system, Figure 2 A module composition schematic diagram of the discrete coating manufacturing system provided by the embodiment two of the present application is shown in the figure, and the system comprises: Figure 2 A production preparation and identification control module for initializing production tasks, binding material identity and process information;

[0107] A path control and dynamic scheduling module for guiding material to flow according to the process path, coordinating AGV scheduling and buffer warehouse management, dynamically responding to the equipment load state through an algorithm, realizing flexible manufacturing, capacity balancing and single insertion capability;

[0108] A processing feedback and quality traceability module for collecting processing node state, quality inspection result and historical track information, realizing single-box-level quality tracking, closed-loop data collection and abnormal handling logic;

[0109]

[0110] ​In some embodiments of the present application, the production preparation and identification control module comprises:

[0111] A production task issuing module for the MES system to automatically generate production batch numbers and process tasks according to order information and issue them to the material distribution personnel;

[0112] A material identity identification module for assigning a unique ID to each box of material through an RFID tag and establishing a one-to-one mapping relationship with the MES system to achieve single-box-level traceability;

[0113] A process parameter configuration module for the MES system to automatically issue formula parameters to each device according to the process template, and for devices that do not support automatic configuration to be manually confirmed by a work order prompt;

[0114] In some embodiments of the present application, the path control and dynamic scheduling module comprises:

[0115] A process path binding module for the MES to bind a process flow template to each box of material according to the product type, determine the processing sequence and device nodes;

[0116] An AGV flow control module for executing material flow based on the process template and device state, and improving loading and unloading efficiency and reducing vehicle occupancy through a double-station docking structure;

[0117] An intelligent scheduling and buffer control module for real-time determination of whether to send to a buffer stereoscopic warehouse based on device load scoring and logistics path algorithm, and automatic warehouse out after capacity release.

[0118] In some embodiments of the present application, the processing feedback and quality traceability module comprises:

[0119] A processing state feedback module for each device to automatically report processing status to the MES system when the material enters / leaves, achieving process completion information closed loop;

[0120] A quality inspection processing module for the AGV to send the processed material to the quality inspection position, perform quality inspection by machine vision or manual method, and input into the MES;

[0121] A data archiving and exception handling module for forming a complete single-box file with the quality inspection information and processing records; generating an exception task for unqualified products, and the system guiding rework or scrapping.

[0122] It is to be noted that, in the present text, relational terms such as first and second and the like can be used solely to distinguish one entity or action from another entity or action without necessarily requiring or implying any actual such relationship or order between such entities or actions. Moreover, the terms "comprises", "comprising", or any other variations thereof, are intended to cover a non-exclusive inclusion such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but can include other elements not expressly listed or inherent to such process, method, article, or apparatus.

[0123] Finally, it should be noted that the above-mentioned only constitutes the preferred embodiments of the present application and is not intended to limit the present application. Although the present application has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that modifications, equivalent replacements, and improvements of the technical solutions described in the foregoing embodiments can be made. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present application shall fall within the scope of the present application.

Claims

1. A discrete coating manufacturing method characterized by, Comprise the following steps: S1, production task assignment and batch identification: the MES system generates a batch number according to the order and assigns a process task, and the material distribution personnel boxes the materials according to the work order and assigns a unique identity to each box of materials through an RFID tag; S2, process parameter assignment: the MES system automatically assigns process recipe parameters to each coating processing equipment to ensure that the equipment operating parameters match the material process template; S3, process path binding and logistics scheduling: the MES system binds a process flow template to each box of materials and generates path instructions, and the AGV delivers the materials to the matching station equipment in turn according to the instructions; S4, double-station docking and loading: the AGV uses a double-station structure to complete the parallel loading and unloading of materials during docking with the equipment to reduce downtime; S5, processing state feedback: each process equipment automatically reports the processing state to the MES system when the material enters or exits, realizing single-box-level tracking; S6, intelligent scheduling and caching: if a bottleneck is detected in the subsequent equipment, the AGV temporarily stores the materials in a three-dimensional cache warehouse, and continues to circulate after the equipment capacity is released; S7, quality inspection and data collection: after processing is completed, the AGV delivers the materials to the quality inspection station, completes quality inspection through machine vision or manual means, and uploads the results to the MES system for archiving.

2. A discrete coating manufacturing method according to claim 1, wherein, The information stored in the RFID tag includes batch number, material number, process template ID, and current process node state.

3. A discrete coating manufacturing method according to claim 1, wherein The MES system supports configuring process parameter templates for different types of equipment, including but not limited to coating thickness, temperature control section, speed curve, and drying time.

4. The discrete coating manufacturing method of claim 1, wherein, The double-station docking structure of the AGV includes a front station and a rear station for loading and unloading respectively, and the AGV control system can schedule both stations in parallel to reduce waiting time.

5. The method of claim 1, wherein the method is a discrete coating manufacturing method. The process path can be dynamically updated, and when the MES system receives an order insertion instruction, it re-plans the path for unprocessed materials, achieving dynamic production scheduling.

6. The method of claim 1 wherein, The intelligent scheduling and caching step further includes: First, calculate the load score: L i (t) = a · Q i (t) + b · R i (t) + g · H i ; wherein: L i (t): the overall load score of device i at time t; Q i (t): number of currently queued tasks; R i (t): current task remaining processing time; H i : historical average processing time of unit task of device i; α, β, γ: weighting coefficients, satisfying α+β+γ=1, used to adjust the influence weight of different factors, Subsequently, each device is load-scored L i (t) in comparison with a preset load threshold T high comparison: If L i (t) > T high , the material should be buffered, otherwise it is sent directly to the processing equipment.

7. A discrete coating manufacturing method according to claim 6, wherein Further comprising: For each box of material to be transported, the distance cost between the AGV's current position (x j , y j ) and the target device station (x i , y i ) is calculated: Where: D ij is the cost distance of AGVj transporting to equipment i; δ is the path correction coefficient (considering obstacles, path priority, etc. can be set coefficient), For the material in the buffer area, according to the material order priority U k , the buffer residence time A k and the corresponding equipment idle degree W k , the warehouse priority is calculated: P k = λ · U k + μ · A k + ν · W k , Wherein λ, μ, ν are weight coefficients, satisfying λ+μ+ν=1, the system according to P k The cache is managed in a high-to-low order.

8. A discrete coating manufacturing method according to claim 7, wherein Further comprising: MES continuously monitors the equipment load score L i (t), when the equipment load falls below the threshold, trigger the buffer material according to the priority P k outbound, AGV receives the task to send the material to the idle equipment for processing, in addition, the system re-executes the above steps at fixed time intervals Δt.

9. A discrete coating manufacturing method according to claim 8, wherein, Finally, minimize the total transportation distance, waiting time, and production cycle, with the specific objective function being: wherein: D k : total transport path cost of material k; W k : waiting time of material k in front of the buffer or the device; T k : total production cycle time of material k from splitting to quality inspection; η1, η2, η3: global optimization weight coefficients.

10. A discrete coating manufacturing system, characterized by, The system comprises: A production preparation and identification control module for initializing production tasks, binding material identity and process information; A path control and dynamic scheduling module for guiding material flow according to the process path, coordinating AGV scheduling and cache management, dynamically responding to equipment load state through algorithms, achieving flexible manufacturing, capacity balancing, and order insertion capability; A processing feedback and quality tracking module for collecting processing node state, quality inspection results, and historical trajectory information, realizing single-box-level quality tracking, closed-loop data collection, and abnormal handling logic.

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