Data processing method and system in virtual production change process of production line

Abstract

The invention relates to the technical field of digital twinning, and discloses a data processing method and system in the virtual production switching process of a production line so as to improve the production switching efficiency and reliability. The method comprises the steps that when all equipment models on a current production line are packaged, the function relation that structural parameters of parts of a sealing part vary along with the change of geometric parameters of a machined object is increased; after a user modifies geometric parameters of processing objects corresponding to all equipment models in a task scheduler on a copy of a current production line according to an actual production switching task, an initial production switching production line is automatically generated according to modification of the task scheduler; executing automatic deformation of structural parameters of part of parts of the equipment model reserved in the production line according to the packaged function relationship along with the change of geometric parameters of a processing object; and then outputting a simulation result for a user to determine the existing resources to be reused and the new resources to be introduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of digital twinning, in particular to a data processing method and system in a production line virtual change production process. BACKGROUND

[0002] Part of the manufacturers based on their own production line products prepared by the characteristics of multi-species, small batch, high precision, high reliability production, which also makes the product production line face the severe challenge of frequent change production. The traditional change production process highly depends on manual experience, and needs to adjust the device parameters, switch the process route, and optimize the material configuration, which has the following three core pain points.

[0003] 1. Long change production cycle. Physical device joint debugging needs to shut down the whole production line, and the time consumption of single change production is 48-72 hours, which seriously restricts the comprehensive efficiency of the device.

[0004] 2. Change production leads to frequent problems. Based on the experience of change production, it is difficult to accurately predict the compatibility of tooling fixture and other problems, and the device parameter setting or process flow is difficult to adjust once. It is necessary to adjust and optimize the production line many times.

[0005] 3. Lack of timely production line evaluation method. After change production, the new production line needs to run the processed products to actually evaluate its yield, yield and other indicators. In this process, not only is the change production time prolonged, but also some products that do not meet the specifications or standards are produced, resulting in resource waste.

[0006] At present, the existing technology cannot discover and solve potential problems in advance before change production, resulting in long change production downtime, high cost, and high quality risk, which is difficult to meet the extreme pursuit of production flexibility and efficiency of intelligent manufacturing of some products. SUMMARY

[0007] The purpose of the present application is to disclose a data processing method and system in a production line virtual change production process to improve the change production efficiency and reliability.

[0008] In order to achieve the above purpose, the data processing method in the production line virtual change production process disclosed by the present application comprises: Step S1, the digital twinning simulation system software saves the 1:1 three-dimensional model of each device on the current production line constructed by the user to the three-dimensional model library for encapsulation; wherein, in the process of encapsulating the action, control program and control signal of at least part of the device model, the function relationship between the structure parameters of the encapsulated part and the geometric parameters of the processed object is changed; and in the encapsulated program, the function relationship between the driving parameters of the action part and the overall beat of the production line is set to adaptively adjust. Step S2, the digital twin simulation system software acquires the first operation of the user, the first operation comprising: arranging the packaged device model according to the layout of the current production line, segmenting the current production line according to the process, and then creating a task scheduler, the task scheduler being used to, after listening to and receiving a device model end signal, judging the next device model triggered according to a preset current production line process logic, and sending a start signal to the next device model after the trigger time arrives, wherein the preset current production line process logic is used to assign values to the overall production line beat, the buffer strategy and the geometric parameters of the processing object corresponding to each device model, and adjust the process order in response to the user's changeover demand; Step S3, the digital twin simulation system software simulates the current production line, so that the user can judge whether the simulation result is consistent with the actual situation, if yes, go to the next step; if not, prompt the user to return to step S1 to adjust the modeling, packaging, position arrangement of the device model and / or the task scheduler; Step S4, the digital twin simulation system software acquires the second operation of the user, the second operation being to modify the overall production line beat, the geometric parameters of the processing object corresponding to each device model and / or the process order in the task scheduler according to the actual changeover task on the copy of the current production line; Step S5, the digital twin simulation system software automatically generates an initial changeover production line according to the modification of the task scheduler, simulates the initial changeover production line, and then outputs the simulation result for the user to determine the existing resources to be reused and the new resources to be introduced; wherein part of the parts of the device model retained in the changeover production line automatically change according to the functional relationship of packaging, and the part of the device model corresponding to the deleted process segment is deleted in its entirety.

[0009] Preferably, the method of the application further comprises: Step S6, after the user performs the same three-dimensional modeling, packaging and saves the new resource to be introduced into the three-dimensional model library of the digital twin simulation system software as in step S1, the digital twin simulation system software acquires the third operation of the user, the third operation being to arrange the device model corresponding to the new resource according to the changeover task, and reconstruct the task scheduler based on the device model corresponding to the new resource and the deleted process; Step S7, the digital twin simulation system software simulates the changeover production line and outputs the simulation result according to the simulation result, and then outputs the simulation result for the user to iteratively adjust the modeling, packaging, position arrangement of the related device model and / or the task scheduler until the desired result is achieved.

[0010] Preferably, the dimensions for judging whether the desired result is achieved include any one or any combination of the following dimensions: The judgment dimension one is to perform collision detection on the motion trajectory of the equipment model and the action range of the tooling fixture, and to verify whether the station spacing, motion parameters and safety distance meet the design requirements; if the detection result exists interference or unreasonable parameters, it is judged as not meeting the expectation; The judgment dimension two is to verify the correctness of the process sequence, interlocking logic and assembly path; if there is a process logic error or assembly conflict, it is judged as not meeting the expectation; The judgment dimension three is to analyze the operation time of each station and the overall production rhythm, identify the bottleneck station, and evaluate whether the production capacity of the production line meets the demand of the new product; if the production capacity is insufficient or the rhythm is unbalanced, it is judged as not meeting the expectation; The judgment dimension four is to build a material flow model, simulate the material supply, transportation and buffer process, verify the timeliness of material supply, the smoothness of logistics channel, and the rationality of buffer zone and buffer strategy; if there is material backlog, insufficient supply or congestion, it is judged as not meeting the expectation; The judgment dimension five is to calculate the energy consumption of the production line according to the running state and power parameters of the equipment model, evaluate the economy of the change production scheme combined with the equipment modification cost and operation and maintenance cost; if the energy consumption is too high or the cost exceeds the expectation, it is judged as not meeting the expectation.

[0011] Preferably, the task scheduler of the present application integrates the MES system function module to trace and control the state of at least part of the equipment model.

[0012] Preferably, the method of the present application further comprises: comparing the change production line meeting the expectation after change production with the current production line to generate a change production report.

[0013] In order to achieve the above purpose, the present application also discloses a data processing system in the virtual change production process of the production line, which comprises a memory, a processor and a computer program stored in the memory and executable on the processor, and the processor implements the above-mentioned method when executing the computer program.

[0014] The present application has the following beneficial effects: 1. The simulation of the current production line can ensure the reliability of the retained equipment model and process in the change production process.

[0015] 2. When the equipment model is packaged, the structural parameters of the increased packaging parts change with the function relationship of the geometric parameters of the machining object; and the retained parts of the equipment model in the generated initial change production line perform automatic modification of the structural parameters changing with the geometric parameters of the machining object according to the function relationship of the packaging during the subsequent adjustment of the task scheduler according to the actual change production task; while improving the efficiency, the overall adaptability of the adaptive adjustment is also ensured.

[0016] 3. In the program encapsulated by each device model, a function relationship of action part driving parameter adaptive adjustment with the overall production line beat changing is set, and during simulation simulation, adaptive action driving control can be carried out according to the adjustment beat of the task scheduler; it is convenient for users to verify the correctness of virtual change production and realize the optimization processing of the beat by comparing multiple change production beats.

[0017] 4. In the automatic generation process of the initial change production production line based on the change production task, the task scheduler can adjust the process based on the verified segmented relationship of the current production line, so as to match the flexible change production demand of the user, and assist the user in leak detection and optimization processing of the change production process.

[0018] In summary, the present application can construct a multi-dimensional, high-fidelity digital twin production line scene integrating geometric properties, physical properties, behavior rules and business logic, and can automatically generate an initial change production production line in a virtual scene, and then accurately evaluate the existing resources for reuse and new resources to be introduced according to the simulation results. Further, the effect of virtual change production can be evaluated through simulation, and if the effect does not meet the expectation, only the scheme needs to be adjusted and the change production effect needs to be re-evaluated, and so on until the actual landing change production scheme is finally determined to guide the actual change production implementation; by predicting the change production effect in advance, the cost loss caused by repeated adjustment of the actual production line equipment, process, etc. can be effectively avoided, and the change production cycle of the production line can be significantly shortened.

[0019] The present application will be further described in detail below with reference to the accompanying drawings. BRIEF DESCRIPTION OF DRAWINGS

[0020] The accompanying drawings, which form a part of this application, are included to provide a further understanding of the application, and are incorporated in and constitute a part of this application. The embodiments of the present application and their description are used to explain the present application and do not constitute an improper limitation of the present application. In the drawings: Figure 1 is a schematic diagram of the data processing method in the production line virtual change production process disclosed by the embodiment of the present application. DETAILED DESCRIPTION

[0021] The embodiments of the present application will be described in detail below with reference to the accompanying drawings, but the present application can be implemented in various different ways limited and covered by the claims.

[0022] Embodiment 1 The embodiment discloses a data processing method in a production line virtual change production process, mainly applied to the field of mechanical manufacturing (not applicable to the assembly of precision electronic components in the process of circuit board preparation, etc.), such as Figure 1 As shown in the figure, the method comprises the following steps: Step S1, the digital twin simulation system software saves the 1:1 three-dimensional model of each device on the current production line constructed by the user to the three-dimensional model library for encapsulation; wherein, in the process of encapsulating the action, control program and control signal of at least part of the device model, the function relationship between the structure parameters of the encapsulated part and the geometric parameters of the machining object is changed; and in the encapsulated program, the function relationship between the driving parameters of the action part and the overall beat of the production line is set to adaptively adjust.

[0023] In this step, model encapsulation includes action encapsulation, control program encapsulation, control signal encapsulation, and special extensibility encapsulation based on production change.

[0024] When performing action encapsulation, first, the device is imported from the three-dimensional model library, and the static parts, moving parts and their corresponding actions in the device are analyzed, and then the dynamic characteristics of the model are encapsulated to truly reproduce the motion behavior of the device in the digital twin environment. The core of encapsulation is to abstract the kinematics and dynamics characteristics of the moving parts into adjustable parameters, and combine them with the process logic to provide a foundation for subsequent simulation and verification.

[0025] Specifically, first, the key moving parts of the device need to be managed in layers, including main shafts, sliding tables, clamps and other parts that can produce relative motion. For each part, extract its motion-related data such as motion mode, motion direction, initial position, speed, acceleration, motion time, etc., and encapsulate these parameters as standardized motion attributes. In this way, each axis of the device is defined as an object that can be independently called and adjusted, making it easy to modify during simulation and achieve comparative analysis under different working conditions and boundary conditions.

[0026] Control program encapsulation refers to the fact that production line equipment has multiple types of actions, and the actions have a sequence. After action encapsulation, the processing of the device after the material enters is analyzed, the action sequence of various moving parts of the device is written in a control program or control script to simulate the actual processing of the device, and the processing beat of the device is adjusted to the real processing scene by adjusting the moving time or speed of the moving parts in the control program or control script. Then, increase the speed / beat parameters of the specific driving time or speed of the moving parts, and when the beat of the device needs to be adjusted, the corresponding parameters can be set by adjusting them.

[0027] The control program encapsulates the processing process of the single process equipment, and the processing sequence between different equipment, and the physical production line realizes the processing sequence of different equipment through the signal interaction of the control network. Therefore, in the design of the control signal encapsulation, the device action start and end signals are set, the processing start and end of the device are realized through the transmission between the signals of different devices and the judgment of the signal value in the device, and the function relationship of the action part driving parameter is set to adaptively adjust with the overall beat of the production line. Among them, the start signal is a waiting signal, and only when the signal is input with appropriate data, the program after the waiting signal can run; the end signal is a setting signal, and the signal value can be set. The end signal can be obtained by other devices.

[0028] For example, the material is loaded by the RGV offline device, transferred by the transfer device, detected by the quality center, and finally placed in the assembly device for overall assembly. Between the RGV offline device and the transfer device, there is a same name Boolean type signal "transfer device starts to transport RGV offline device material", and the transfer device is always waiting for the start signal value to be "true". When the RGV offline device finishes loading and sets the signal value to "true", the transfer device ends waiting and starts executing the subsequent control program. By setting the start and end signals, the processing action logic of the front and rear process equipment can be realized, and the dynamic production process of the simulation production line can be achieved.

[0029] Optionally, the input and output signals can be connected through the setting panel of the digital twin simulation system, so that the input signal value of the next process equipment can be updated synchronously by setting the value of the output signal of the previous process equipment.

[0030] Parameter modeling refers to abstracting the geometric parameters, travel, and action of the production line processing, assembly, and other processes, and the structure of the device into a parameterized model. The motion data extracted in the model motion encapsulation is the motion parameter. The mechanism position, structure of the mechanism part, and mechanism action distance in the device model usually have certain change rules in the production line change process, such as the length of the device base is usually related to the length of the material processed on the base, the position between the material clamps and the length of the clamp mechanism is related to the width or diameter of the material, and the detection device moving distance is related to the length of the material. In order to respond to the rapid change production demand, the embodiment adds a special extension encapsulation based on change production, which quickly changes the structure of part of the device by extracting key parameters and changing the values of the key parameters. The specific steps are as follows: 1. Extract the key parameters. The change of the production object is usually some typical parameter change. Common parameters include the length, width, height, diameter of the material, production beat, etc., and these key parameters are extracted as parameter values of single machine equipment.

[0031] 2. Analyze key parameters and determine key data. Changes in key parameters alter the structure of mechanisms within the equipment. For example, material length changes the relative position between the two clamps in the transfer device; diameter changes the clamp structure; and production cycle time changes the feeding speed of the feeding mechanism and the processing speed of the equipment, thereby altering the quantity of material on the transfer table and the length of the transfer table. This step involves analyzing which mechanisms or parts within the equipment will change due to changes in key parameters.

[0032] 3. Key Data Parameterization. Parameterization objects can include the parameterization of structure, position, movement distance, quantity, etc. This step can be viewed as representing the key data analyzed in step 2 using mathematical expressions about the attribute values ​​saved in step 1. Based on the digital twin system, the conventional graphic part structure (length, width, diameter of the part), the position of the mechanism (the position of the mechanism in the equipment), the quantity of the mechanism, etc., of the equipment are represented by key parameter attribute expressions. By changing the values ​​of key parameters, these mechanisms can be quickly modified, realizing virtual production change of some mechanisms on the production line. Key data parameterization is equivalent to expressing the structure (length, width, height), position (X, Y, Z three-axis coordinates), movement distance, etc., using mathematical expressions about the extracted parameter values. For example, the support surface length L of the support seat, in the design stage, has the following relationship with the length S of the material: L = A × S. S, as the extracted key attribute, can be used to control the support surface length L using the mathematical expression of this value. When the material length S changes, by assigning a value to S, the support surface length can change quickly to achieve the purpose of structural modification.

[0033] Therefore, in this embodiment, based on the process of encapsulating the actions, control programs, and control signals of at least a portion of the equipment model, a functional relationship is added to show how the structural parameters of some parts change with the geometric parameters of the processed object; and in the encapsulated program, a functional relationship is set to show how the driving parameters of the action parts are adaptively adjusted as the overall production line cycle time changes.

[0034] Step S2: The digital twin simulation system software acquires the user's first operation, which includes: arranging the packaged equipment models according to the current production line layout, segmenting the current production line by process, and then creating a task scheduler. The task scheduler is used to, after listening to and receiving the equipment model's end signal, determine the next equipment model to be triggered according to the preset current production line process logic, and send a start signal to the next equipment model after the trigger time arrives. The preset current production line process logic is used to assign values ​​to the overall production line cycle time, buffer strategy, and geometric parameters of the processing objects corresponding to each equipment model, and to respond to the user's production change request to adjust the process sequence.

[0035] Step S3, the digital twin simulation system software simulates the current production line, so that the user can judge whether the simulation result is consistent with the actual situation. If it is consistent, go to the next step; if it is not consistent, prompt the user to return to step S1 to adjust the modeling, packaging, position arrangement of the device model and / or the task scheduler.

[0036] In the above two steps, the production line digital twin modeling generally includes production line digital twin model layout building, control network building and beat type parameter assignment.

[0037] The process of production line digital twin model layout building can be specifically: combining the material flow direction and process route of the actual production line, determining the number and combination form of the equipment. According to the process flow and logistics channel, the front, back, left, right and up and down relationship of the equipment is reasonably arranged to ensure that the materials can be smoothly transferred according to the process sequence. Secondly, the position and attitude of the equipment are adjusted by using the three-dimensional coordinate system, and the precise assembly between the equipment is realized by means of reference surface alignment, reference point calibration, constraint positioning and the like. For example, according to the layout of the current airborne product production line, the packaged model is arranged in position.

[0038] The process of control network building can be specifically: for the real simulation of the production line processing process, a task scheduler is created in the digital twin model, the end signal of the equipment is received through the scheduler, the internal logic program is judged, and the start signal of the equipment is issued to realize the control of the equipment processing. Create various signals, realize the judgment of various states through the interaction between the signals, and then control the execution of the high-level method of the model (such as mechanical arm movement, conveyor belt operation, etc.) to achieve the dynamic control between the production lines. The core of control network building is the writing of the internal logic program of the scheduler, which logically processes and issues the start signal of each equipment processing according to the actual production line processing sequence to realize the control of equipment processing.

[0039] The beat type parameter assignment can be realized by collecting the on-site action process parameters and assigning the parameter values related to the action beat to the packaged parameters to restore the real processing scene of the equipment processing beat.

[0040] Through the above two steps, the real processing scene of the current production line can be restored in the digital twin simulation system software.

[0041] Step S4, the digital twin simulation system software obtains the second operation of the user, and the second operation is to modify the overall beat of the production line, the geometric parameters of the corresponding processing object of each equipment model and / or the process sequence in the task scheduler according to the actual changeover task on the copy of the current production line.

[0042] In this step, a copy of the current production line can be generated by copying or cloning, etc.; and the task scheduler is modified according to the identified production line change driving factors. The process of identifying the production line change driving factors can be specifically as follows: firstly, the differences between the new and old products in design and process need to be clarified, because these differences will directly determine the direction of the production line modification. Usually, product model changes will bring changes in geometric size, structure form, assembly process, process requirements, etc. For example, the increase in the size of the fuselage section of an airborne product will lead to the redesign or expansion of the tooling fixture; the change in the connection method of the structural part may introduce new processes or adjust the process sequence. These product-level differences will be transmitted to the workstation setting, process path, beat allocation, and logistics organization of the production line, thereby forming the driving factors for the modification of the production line.

[0043] Step S5, the digital twin simulation system software automatically generates an initial change production line according to the modification of the task scheduler, simulates the initial change production line, and then outputs the simulation results for the user to determine the existing resources to be reused and the new resources to be introduced; wherein part of the parts of the equipment model retained in the change production line automatically change according to the packaged functional relationship as the geometric parameters of the machining object change, and part of the equipment model corresponding to the deleted process section is deleted in whole.

[0044] In this step, the initial change production line is not perfect in most change production tasks, and the significance of the simulation results is to determine the existing resources to be reused and the new resources to be introduced in addition to the user. In addition, the simulation results are mainly used to output the problems to be improved to the user based on the analysis logic (including but not limited to the subsequent algorithms related to judging whether the change production scheme meets the expectations in multiple dimensions) of the bottom layer of the digital twin simulation system software. Therefore, preferably, the method of the embodiment can further include the following steps S6 and S7 (not shown in the figure).

[0045] Step S6, after the user performs the same three-dimensional modeling, packaging, and saving to the three-dimensional model library of the digital twin simulation system software as in step S1 on the new resources to be introduced, the digital twin simulation system software obtains a third operation of the user, which is to arrange the equipment model corresponding to the new resources according to the change production task, and reconstruct the task scheduler based on the equipment model corresponding to the new resources and the deleted process.

[0046] Step S7, the digital twin simulation system software simulates the change production line and outputs the simulation results according to the simulation results, and then outputs the simulation results for the user to iteratively adjust the modeling, packaging, position arrangement of the related equipment model and / or the task scheduler until the desired result is achieved.

[0047] In the above steps, the driving factor configuration parameters and control program adjustment are needed. For example: for the equipment structure change driven by the product geometric size change factor, the equipment structure adaptive change is completed by setting the parameter value according to the product size. At the same time, for the new product processing procedure change driven factor, the control program in the equipment is re-adjusted.

[0048] Under the condition of changing production, the process equipment required by the process route is determined. Due to the differences in size (length, width, height, diameter, etc.), material properties, and process time (such as normalizing, annealing, quenching, and tempering) of the new product from the original product, part of the structure and cycle of the equipment cannot meet the processing requirements of the new product, and the equipment needs to be adjusted adaptively. Therefore, based on the structure parameterization, cycle parameter assignment, and signal logic adjustment of the equipment virtual variant method, the equipment can be quickly adapted in a virtual environment.

[0049] Structure variant mainly refers to: through the establishment of key parameter driven attribute packaging mechanism, the product geometric size and process cycle are converted into parameter input of equipment geometric characteristics. The conventional geometric structure (such as cuboid, cylinder, sphere) can be quickly adjusted through key data assignment; and for unconventional parts that cannot be characterized by parameter expression, a local reconstruction mechanism is introduced, so as to balance the modeling efficiency and accuracy.

[0050] The structure variant mainly changes the specific attribute value in the attribute packaging, such as the length, width, height, cycle, and other attributes of the product.

[0051] The key data parameterization assignment and the assignment of the key parameter attribute in the foregoing packaging quickly complete the change of the equipment mechanism position, the conventional graphic structure (cuboid, cylinder, sphere, etc.), and realize the partial variant of the equipment.

[0052] If the geometric size or cycle of the assigned key parameter exceeds the range constrained when the equipment model is packaged, the equipment model is considered as a non-reusable existing resource. In addition, unconventional graphic parts are redesigned. There are a certain number of unconventional shape parts in the production line, such as various castings. The mechanism of such parts cannot be characterized by key parameter attribute expression when the key parameter changes, and for such parts, they need to be redesigned.

[0053] When the cycle parameter is assigned, the processing speed variant can be determined by changing the value of the speed / cycle parameter in the packaging function (this embodiment is uniformly set by the task scheduler), the processing action cycle value is determined by analyzing the processing time requirement, and the value is assigned.

[0054] When adjusting the control program, the action execution sequence in the control program can be modified by analyzing the machining process, and the position of the already packaged signal in the control program can be changed, so that the equipment can meet the machining requirements of the new product.

[0055] Further, in step S7, judging whether the expected dimensions include any one or any combination of the following dimensions: Judging dimension one, performing collision detection on the motion trajectory of the equipment model and the action range of the tooling fixture, verifying whether the station spacing, motion parameters, and safety distance meet the design requirements; if the detection result exists interference or unreasonable parameters, it is judged as not expected.

[0056] Judging dimension two, verifying the correctness of the process sequence, interlocking logic, and assembly path; if there is a process logic error or assembly conflict, it is judged as not expected.

[0057] Judging dimension three, analyzing the operation time of each station and the overall production rhythm, identifying the bottleneck station, and evaluating whether the production line capacity meets the demand of the new product; if the capacity is insufficient or the rhythm is unbalanced, it is judged as not expected.

[0058] Judging dimension four, constructing a material flow model, simulating the material supply, transportation, and buffering process, verifying the timeliness of material supply, the smoothness of logistics channel, and the rationality of buffer zone and buffering strategy; if there is material backlog, insufficient supply, or congestion, it is judged as not expected.

[0059] Judging dimension five, calculating the energy consumption of the production line according to the running state and power parameters of the equipment model, combining the equipment modification cost and operation and maintenance cost, evaluating the economy of the changeover scheme; if the energy consumption is too high or the cost exceeds the expectation, it is judged as not expected.

[0060] Further, the task scheduler of the embodiment integrates the MES system function module to trace and control the state of at least part of the equipment model; and compares the expected changeover production line after changeover with the current production line to generate a changeover report to assist the user to implement the changeover operation step by step.

[0061] Embodiment 2 The embodiment discloses a data processing system in a virtual changeover process of a production line, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, and the processor implements the method of embodiment 1 when executing the computer program.

[0062] In summary, the data processing method and system in the virtual changeover process of the production line disclosed in the above two embodiments of the application have at least the following beneficial effects: 1. Through the simulation of the current production line, the reliability of the retained equipment model and process during the changeover process can be ensured.

[0063] 2. When the equipment model is packaged, the function relationship of the structural parameters of the increased packaging part changing with the geometric parameters of the machining object is changed; and in the subsequent adjustment of the task scheduler according to the actual changeover task, the structural parameters of the part of the retained equipment model in the generated initial changeover production line are automatically changed according to the function relationship of the packaging; while improving the efficiency, the comprehensiveness of the adaptive adjustment is also ensured.

[0064] 3. In the program packaged in each equipment model, the function relationship of the driving parameters of the action part changing with the overall beat of the production line is set to adaptively adjust, and during the simulation, the adaptive action driving control can be performed according to the adjustment beat of the task scheduler; the user can verify the correctness of the virtual changeover and realize the optimization processing of the beat by comparing multiple changeover beats.

[0065] 4. During the automatic generation of the initial changeover production line based on the changeover task, the task scheduler can adjust the process based on the verified segmented relationship of the current production line, so as to match the flexible changeover requirements of the user, and assist the user in checking and optimizing the changeover process.

[0066] In summary, the present application can construct a multi-dimensional, high-fidelity digital twin production line scene integrating geometric attributes, physical attributes, behavior rules and business logic, and can automatically generate an initial changeover production line in a virtual scene, and then accurately evaluate the existing resources for reuse and new resources to be introduced according to the simulation results. Further, the effect of virtual changeover can be evaluated through simulation, and if the effect does not meet the expectation, the scheme needs to be adjusted again and the changeover effect needs to be re-evaluated, and so on until the actual landing changeover scheme is finally determined to guide the actual changeover implementation; by predicting the changeover effect in advance, the cost loss caused by repeated adjustment of the equipment and process of the actual production line can be effectively avoided, and the changeover cycle of the production line can be significantly shortened.

[0067] The above only describes the preferred embodiments of the present application and is not used to limit the present application. For those skilled in the art, the present application can have various changes and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principles of the present application shall be included in the protection scope of the present application.

Claims

1. A data processing method in a virtual changeover process of a production line, characterized by, Comprise: Step S1, the digital twin simulation system software saves the 1:1 three-dimensional model of the user to the three-dimensional model library for encapsulation; wherein, in the process of encapsulating at least part of the device model, the control program and the control signal, the function relationship between the structure parameters of the encapsulated part and the geometric parameters of the processing object is changed; and in the encapsulated program, the function relationship between the driving parameters of the action part and the overall beat of the production line is set to adaptively adjust; Step S2, the digital twin simulation system software obtains the first operation of the user, the first operation includes: arranging the encapsulated device model according to the layout of the current production line, then segmenting the current production line according to the process, and then creating a task scheduler, the task scheduler is used to listen to and receive the device model end signal, and according to the preset current production line process logic, judge the next device model triggered, and send a start signal to the next device model when the trigger time arrives, wherein, the preset current production line process logic is used to assign the overall beat of the production line, the buffer strategy and the geometric parameters of the processing object corresponding to each device model, and adjust the process order in response to the user's changeover demand; Step S3, the digital twin simulation system software simulates the current production line, so that the user can judge whether it is consistent with the actual situation according to the simulation result, if it is consistent, go to the next step; if it is not consistent, prompt the user to return to step S1 to adjust the modeling, encapsulation, position arrangement of the device model and / or the task scheduler; Step S4, the digital twin simulation system software obtains the second operation of the user, the second operation is to modify the overall beat of the production line, the geometric parameters of the processing object corresponding to each device model and / or the process order in the task scheduler according to the actual changeover task on the copy of the current production line; Step S5, the digital twin simulation system software automatically generates an initial changeover production line according to the modification of the task scheduler, and simulates the initial changeover production line, and then outputs the simulation result for the user to determine the existing resources to be reused and the new resources to be introduced; wherein, the part of the device model retained in the changeover production line automatically changes the structure parameters according to the function relationship between the encapsulated function relationship and the geometric parameters of the processing object, and the part of the device model corresponding to the deleted process segment is deleted.

2. The data processing method in a virtual changeover process of a production line according to claim 1, characterized in that, Also include: Step S6, after the user performs the same three-dimensional modeling, encapsulation and saving to the three-dimensional model library of the digital twin simulation system software on the new resources to be introduced, the digital twin simulation system software obtains the third operation of the user, the third operation is to arrange the device model corresponding to the new resource according to the changeover task, and reconstruct the task scheduler based on the device model corresponding to the new resource and the deleted process; Step S7, the digital twin simulation system software simulates the production line and according to the simulation results, then outputs the simulation results for the user to model the related equipment model, package, position arrangement and / or iterative adjustment of the task scheduler until the expected result is achieved.

3. The method according to claim 2, characterized in that, The dimensions for judging the expected result include any one or any combination of the following dimensions: Dimension one, collision detection is performed on the motion trajectory of the equipment model and the action range of the tooling fixture to verify whether the station spacing, motion parameters and safety distance meet the design requirements; if the detection result shows interference or unreasonable parameters, it is judged as not meeting the expectation; Dimension two, the correctness of the process sequence, interlocking logic and assembly path is verified; if there is a process logic error or assembly conflict, it is judged as not meeting the expectation; Dimension three, the operation time of each station and the overall production rhythm are analyzed to identify the bottleneck station and assess whether the production line capacity meets the demand of the new product; if the capacity is insufficient or the rhythm is unbalanced, it is judged as not meeting the expectation; Dimension four, a material flow model is constructed to simulate the material supply, transportation and buffering process to verify the timeliness of material supply, the smoothness of logistics channel, the rationality of buffer zone and buffering strategy; if there is material backlog, insufficient supply or congestion, it is judged as not meeting the expectation; Dimension five, according to the equipment model running state and power parameters, the energy consumption of the production line is calculated, and combined with the equipment modification cost and operation and maintenance cost, the economy of the change production scheme is evaluated; if the energy consumption is too high or the cost exceeds the expectation, it is judged as not meeting the expectation.

4. The data processing method in a virtual changeover process of a production line according to claim 2, characterized in that, The task scheduler integrates the MES system function module to trace and control the state of at least part of the equipment model.

5. The data processing method in a virtual changeover process of a production line according to claim 2, characterized in that, Further comprising: Comparing the change production line after meeting the expectation with the current production line to generate a change production report.

6. A data processing system in a virtual changeover process of a production line, comprising a memory, a processor, and a computer program stored on the memory and executable on the processor, characterized in that, The processor executes the computer program to realize the method of any one of claims 1 to 5.

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