Production system and production control method based on positioning system to simulate production process

Abstract

The invention relates to a digital model (30) of a production plant (12). The digital model (30) is designed to generate a simulation of a production process of the production plant (12). A control device (20) can use the simulation to optimally operate the production plant (12). The digital model (30) is designed to use data of a positioning system (22) to complete the simulation. The positioning system (22) monitors a carrier (18) for transporting components (16). The control device (20) can be designed to compare parameters of a simulation result with corresponding parameters of an earlier simulation result and / or actually obtained parameters of an earlier production process. The parameters of the earlier simulation result and / or the parameters actually obtained during production operation can be stored in a model library (32). The control device (20) can control the production plant (12) very effectively by means of the invention. In addition, the invention relates to a production control method that is performed accordingly.

Description

Technical Field

[0001] The invention relates to a production system and a production control method. Background Art

[0002] It is known, in particular in metal processing (preferably in sheet metal processing), to provide an optimized production system with a production plant for producing components, wherein the production plant comprises a plurality of production tools. The material (or the components) is transported between these production tools via movable carriers.

[0003] Due to the different processing times of these production tools and the changing transport routes of these carriers, it often happens that the production tools and / or carriers are not fully utilized. As a result, the production system works inefficiently.

[0004] Furthermore, it is known to create simulations of production processes. However, the creation of such simulations involves a high level of effort. This can take several months until the simulation is functional and answers the relevant questions. Summary of the invention

[0005] The object of the present invention is to provide an efficient production system or production control method.

[0006] According to the present invention, this object is achieved by a production system and a production control method. The embodiments of the present invention provide a preferred development solution.

[0007] Therefore, the object according to the invention is achieved by a production system having the following features:

[0008] a) A production plant having production tools for producing components. The production plant has carriers and / or transport aids for transporting components between the production tools. These carriers can be designed, for example, in the form of automatic (or self-propelled) and / or remote-controlled vehicles.

[0009] b) a control device, which controls the production equipment based on the production data;

[0010] c) A positioning system, which is designed to determine the position of a carrier, a transport aid, a production tool and / or a component. The positioning system is designed to:

[0011] i) determine the location of the mobile unit, and / or

[0012] ii) detecting identification information stored on the mobile unit,

[0013] and transmitting the position data of the carrier, the transport aid, the production tool and / or the component determined in this way to a control device;

[0014] d) A digital model of the production plant, which is used to simulate the production process. In this case, the simulation is based on data from the positioning system. This should mean that the simulation actively uses the data from the positioning system to create the digital model.

[0015] Production data refers, for example, to data that determine the production process of a component, for example in the following form: component A consists of a material (ST), has dimensions (x, y, z), and is cut to the desired contour on an LS-type laser cutting device and then bent on a TP-type bending machine according to the design drawing MP, etc.

[0016] The control device for controlling the production equipment is designed to use these production data in order to control the production of the components. In this case, the sequence of production steps can be set in the control device: transportation between production tools, possibly necessary intermediate storage, re-sorting, and more. Here, individual production steps can be performed fully automatically by the corresponding production tools. Therefore, the control device can be designed to provide the corresponding data to the corresponding machine tool (if necessary, sorted) for use. If necessary, the correspondingly equipped production tools can report the status and effectiveness of the production steps performed by them to the control device. For other production tools and work steps with a lower degree of automation, the operation of workers is necessary (for example, sorting, clamping, material supply or multiple bending processes). Here, the status and (if necessary) effectiveness of the production steps are frequently manually fed back. The advantages of the present invention are particularly evident in production equipment with such production tools, because the position data of the carrier and / or the component, the situation about the residence time, status, effectiveness and work steps can be tracked (tracked) by the positioning system.

[0017] It is also possible to combine a plurality of components into a component complex (Bauteilverbund). A component complex is a collection of a plurality of components that are connected to one another in an organized manner and that, for example, belong to a common production task or undergo a plurality of production steps together. It can be advantageous to determine position data of each component complex by means of a positioning system and to make these data available to the digital model.

[0018] These components (or component complexes) can be arranged on one or more transport aids or can be arranged in one or more transport aids. The transport aid can be, for example, a pallet (transport pallet) or a collection container (transport box, box, tank). These transport aids can be transported together with the carrier. A plurality of components and / or component complexes can be arranged for being transported on a transport aid. Additionally or alternatively, a mobile unit for positioning can be assigned to each transport aid. It can be advantageous to determine the position data of the transport aids respectively by means of a positioning system and provide these data to the digital model for use.

[0019] Additionally or alternatively, a mobile unit for positioning can be assigned to each carrier. It can be advantageous to determine position data of the carriers in each case with the aid of a positioning system and to provide these data for use in the digital model.

[0020] In many production plants, movable tools are also used, for example hand-operated tools, such as drilling machines, deburring tools, hand saws, bending machines, movable machines such as punching, welding or induction heating units, etc. It can be advantageous to determine the position data of the movable tools by means of a positioning system and to make these data available to the digital model. For this purpose, a movable unit can also be assigned to the movable tool and the movable unit can be fastened to the tool in particular.

[0021] The mobile unit can be assigned to a carrier, a transport aid, a component and / or a component complex and in particular also to a movable tool. This should mean that:

[0022] a) such a mobile unit is arranged in the vicinity of a tool, a carrier, a transport aid, a component and / or a component assembly, and

[0023] b) This mobile unit is also assigned in a data-related manner to the tool, carrier, transport aid, component and / or component assembly, ie, for example, to the production data of the control device and / or to a digital model for the simulation.

[0024] The mobile unit can be designed as a transceiver unit, which is designed to receive and send electromagnetic signals. The propagation time of these signals can be determined by the positioning system, and the instantaneous position in the production system can be determined from this. In this way, positioning with an accuracy of 1 m or less, in particular 30 cm or less, can be achieved. The positioning of these units can be detected several times per minute, in particular several times per second, particularly preferably several times per 1 / 10 second.

[0025] In the context of the present invention, it has proven advantageous to obtain relevant input data for the generation and parameterization of simulations. These input data can be obtained by means of a positioning system which is introduced into a plurality of production plants with an increasing degree of digitization. The position data thus determined of supports, transport aids, components and / or component assemblies can be used to continuously further improve the digital model for the simulation. The accuracy of the position determination process described above is particularly suitable for making the digital model suitable for the simulation.

[0026] The production system according to the invention therefore comprises a digital model of a production plant which can simulate processes in the production plant. The data of the carrier and its movement patterns are stored in the digital model. In addition, the digital model can be designed to take into account the working process of the production tool. As a result, the digital model can generate suggestions for particularly efficient production processes, which take into account the movement of the carrier, the transport aids, the components and / or the component complex and possibly also the tools. It has been shown that the consideration of the data of the positioning system in the simulation of the production process has led to a surprisingly efficient production process.

[0027] Such a simulation is preferably stored in the form of a material flow simulation. This means that the position changes of the components over time (material flow) are stored in a simulated form.

[0028] Preferably, at least one production tool is designed in the form of a metal working tool, in particular a sheet metal working tool, in particular a punching machine and / or a laser cutting machine. At least one component (or workpiece) can be designed in the form of a sheet metal part.

[0029] Preferably, the control device of the production system is configured to: perform control of the production equipment based on the simulation, thereby enabling automated optimization of the production equipment.

[0030] This control is carried out based on the production data of the production equipment. As described above, these production data include at least the data of the positioning system of the carrier. In a preferred embodiment of the present invention, the production data also include: the above-mentioned working process of the production tool, the arrangement of the production tool, the characteristic parameters of the production tool and / or the component data. The characteristic parameters of the production tool can be, for example: laser beam intensity, laser beam focus, bending tool used, through speed, feed speed, pulse ratio in pulsed operation, power, energy, etc., all of which are particularly related to the corresponding working steps. The characteristic parameters of the component data can be, for example: material, contour, size, deformation (Verformungen), thickness, etc.

[0031] In a particularly preferred embodiment of the invention, the production system has a model library with simulated and / or actually executed production processes. In this case, the control device can be designed to compare the production process simulated in the digital model with the production process of the model library. The control device can then decide or allow the user to decide whether to use a newly simulated production process or to adopt a production process stored in the model library.

[0032] It is further preferred that the simulation, digital model and / or model library are constructed based on the cloud. This makes it possible to use the actual and / or simulated production processes of multiple production plants and at the same time realize the very effective optimization possibilities of the production plants described previously. Here, the cloud refers to a data processing device (especially a storage device) that is particularly remote in location (preferably anonymized). The data of more than one (advantageously hundreds or thousands) different users can be stored in the data processing device. Thus, various simulations or models can help optimize the method regardless of the production location. It has been recognized that if hundreds (especially thousands) of simulations have been read out, the described method can be significantly improved. This amount of data is usually not achievable within a year for a single production facility.

[0033] The positioning system can be configured as an ultra-wideband system (Ultra Wideband, UWB) so that high positioning accuracy can be achieved. For example, in DE 10 2017 120 378 A1 or in the application PCT / FR2019 / 000057 with the title "Ultra-Wideband Location Systems and Methods" which has not been published until the filing date, such a system is described as an indoor positioning system. As described herein, such a system can be integrated in production equipment that has not yet been digitally networked, and helps to promote digital networking without excessive investment. At the same time, data about the production process that can be obtained from this can be detected not only in space but also in time. In this way, data for simulation of the production process can be obtained without further investment in hardware. The contents of DE 102017 120 378 A1 and PCT / FR2019 / 000057 are fully incorporated into the present invention by reference.

[0034] Particularly preferably, the positioning system is designed to detect the position of the mobile unit, the carrier, the transport aid, the component and / or the component complex and possibly also the tool with an accuracy of 1 m or less, preferably less than 0.3 m. This further increases the optimization possibilities of the production plant. The positioning system can further be designed to detect the position three-dimensionally. Thus, not only position data in the plane of the production plant but also position data in height can be detected and input into the simulation.

[0035] The digital model can have a map of a part of the production facility or of the entire production facility. The map can have information about production tools and / or components and in particular their position and orientation.

[0036] The supports can have image acquisition modules, in particular respectively a laser scanner and / or a camera, in order to detect the surroundings of the supports, in particular in order to update a map.

[0037] The carrier and / or the transport aid may have at least one further sensor. In particular, the carrier may have an inertial measurement unit (“inertial measurement, IMU”), which in particular has a combination of a plurality of inertial sensors, such as acceleration sensors and rotational speed sensors.

[0038] The carrier and / or the transport aid can have a transmitter-receiver system for automatically and contactlessly identifying and locating the carrier, for example based on radio-frequency identification (RFID).

[0039] The control device can have an interface in order to process log files of the production tool.

[0040] In one embodiment of the invention, at least one production tool may have a loading and unloading area for loading and unloading carriers. In this case, the production system may have an image capture unit, which is configured to detect image information in the loading and unloading area. In addition, the positioning system may have an image analysis unit, which is configured to determine the position and / or state of a carrier (in particular the loading condition of the carrier) using image information. These image capture units can be expanded with the help of virtual reality (VR) systems or augmented reality (AR) systems.

[0041] Furthermore, the object according to the invention is achieved by a production control method for a production system, in particular the production system described here, wherein the production control method has at least the following steps:

[0042] A) reading in the position and / or identification information of the carrier, the transport aid, the production tool and / or the component, wherein the reading in is performed by a positioning system;

[0043] B) simulating the production process, wherein the simulation is based on data from the positioning system;

[0044] D) Controlling the production equipment. Preferably, this control is performed based on a simulation of the production process according to step B).

[0045] The production control method preferably has the following steps between steps B) and D):

[0046] C) Comparing the simulated production process with previously simulated and / or actually executed production processes stored in a model library.

[0047] The production control method described here can thereby be optimized particularly effectively.

[0048] In order to obtain a model library that is as extensive as possible, a simulated production sequence is preferably saved in any case, regardless of whether the production process is actually carried out with this simulated production sequence or with a previously stored production sequence.

[0049] Further advantages of the invention can be derived from the description and the drawings. Likewise, the above-mentioned features and those further described can also be used individually or in multiples in any combination according to the invention. The embodiments shown and described are not to be understood as a definitive enumeration, but rather have an exemplary character for the description of the invention.

[0050] This simulation can provide its results to another virtual reality (VR) system or augmented reality (AR) system for use in production planning. This simulation can utilize the data of this other virtual reality (VR) system or augmented reality (AR) system in order to carry out production planning.

[0051] Furthermore, the object according to the invention is achieved by using and / or utilizing the data of the positioning system described here, in particular position data, in the previously described production control method and / or production system. These position data are in particular position data of carriers and / or components and / or transport aids and / or tools, which are detected during operation of the production system in order to track the components (or workpieces). BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 A schematic diagram showing a production system according to the present invention or a production control method according to the present invention. DETAILED DESCRIPTION

[0053] Figure 1 A production system 10 is shown having a production device 12, which includes a plurality of production tools 14. These production tools 14 are used to produce components 16. Preferably, at least one production tool 14 is designed in the form of a metalworking tool or a sheet metal working tool, in particular a punching machine and / or a laser cutting machine. At least one component 16 can be designed in the form of a sheet metal part.

[0054] At least one component 16 (in particular, a plurality of components 16, in particular, a plurality of components 16 assembled into a component complex) is transported between production tools 14 by a carrier 18. The carrier 18 is controlled by a control device 20 and tracked (tracked) or monitored by a positioning system 22. The positioning system 22 may have a plurality of transceiver units in order to determine the position of the carrier 18 in the production device 12 by calculating the signal propagation time between the transmitter and the carrier 18. These transceiver units may be configured to receive and send electromagnetic signals. Here, the propagation time of these signals may be determined by the positioning system 22, and the instantaneous position in the production device 12 may be determined therefrom. A plurality of these transceiver units may be fixedly mounted units, the positions of which are known to the positioning system 22. Here, the identification of the carrier 18 in the positioning system 22 is performed by means of mobile units 24, which are respectively arranged or configured indirectly or directly on the carrier 18. Alternatively or additionally, other mobile units may be assigned to the transport aid, the component and / or the component complex and possibly also to the tool. Thus, the positions of these units may also be tracked.

[0055] These mobile units 24 themselves can be designed as transceiver units, which are designed to receive and send electromagnetic signals (indicated by dashed lines 17). The propagation time of these signals can be determined by the positioning system 22, and the instantaneous position in the production device 12 can be determined therefrom. In this way, positioning with an accuracy of 1 m or less, in particular 30 cm or less, can be achieved.

[0056] These mobile units 24 can be assigned to carriers 18, transport aids 19 and / or individual components 16 and / or component complexes as well as tools 23. An assignment between the data of the positioning system 22 and the tasks of the production control can then take place.

[0057] The unloading and loading of the carrier 18 can be carried out in a monitored manner in the loading and unloading area 28 of the production tool 14 (in particular by an image recording unit 26, for example a camera). In this case, the control device 20 can be designed to use the data of the image recording unit 26 for optimizing the production device 12. Such a system is described, for example, in the document DE 10 2016 120 131 A1. The content of DE 10 2016 120 131 A1 is fully incorporated by reference.

[0058] The control device 20 uses a digital model 30 of the production facility 12. A simulation of the production process of the production facility 12 can be performed in the digital model 30. This simulation is based on the data of the positioning system 22. This makes the simulation more precise.

[0059] Before the data of the positioning system 22 are fed to the control device 20, the data of the positioning system 22 can be processed in the data processing and analysis unit 21. The data processing and analysis unit 21 can organize the position data, that is, for example, associate them with production tools, assign the data to specific work steps, such as: transport AB, production step on machine C, production step on machine D, sorting and storage on transport aids E, transport to bending machine G with the help of carrier F, etc.

[0060] Additionally or alternatively, however, the data of the positioning system 22 can also be fed directly to the control device 20. The control device 20 can then improve the simulation and update the digital model 30 during ongoing production, ie during a production run.

[0061] In addition or as an alternative, however, the data of the positioning system 22 can also be fed directly to the digital model 30. The digital model 30 can then also improve the simulation more quickly and update the digital model 30 during ongoing production.

[0062] Additionally or alternatively, the data of the positioning system 22 can be processed by the data processing and analysis unit 21 before they are fed to the digital model 30 .

[0063] In addition to the data of positioning system 22 , data of production tool 14 and / or image recording unit 26 can be taken into account in the simulation.

[0064] The simulation (i.e., the simulation result) can be provided to the control device 20 for use. In addition, the control device 20 can be configured to access a model library 32 with a plurality of simulations (or simulation results). The control device 20 can be configured to: automatically and / or in accordance with user instructions, in a selected manner, control the production device 12 using the parameters used in the simulation or using parameters from the model library 32.

[0065] Additionally or alternatively, the digital model 30 may be configured to access a model library 32 having a plurality of simulations (or simulation results). The digital model 30 may be configured to use parameters set for simulation or parameters from the model library 32 automatically and / or in response to user instructions.

[0066] The digital model 30 and / or model library 32 may be constructed in the cloud to enable multiple users to utilize large data sets.

[0067] In conjunction with the accompanying drawings, the present invention generally relates to a digital model 30 of a production facility 12. The digital model 30 is configured to generate a simulation of a production process of the production facility 12. The control device 20 can use this simulation in order to optimally operate the production facility 12. The digital model 30 is configured to use data from a positioning system 22 to establish this simulation. The positioning system 22 monitors, in particular, a carrier 18 for transporting components 16. The control device 20 can be configured to compare parameters of a simulation result with corresponding parameters of an earlier simulation result and / or actually obtained parameters of an earlier production process. These parameters of an earlier simulation result and / or actually obtained parameters can be stored in a model library 32. The control device 20 can control the production facility 12 very effectively through the present invention. In addition, the present invention also relates to a production control method that is executed accordingly.

[0068] Reference numerals list

[0069] 10Production System

[0070] 12Production Equipment

[0071] 14Production Tools

[0072] 16 components

[0073] 17 Electromagnetic Signal

[0074] 18 Carrier

[0075] 19 Transportation Aids

[0076] 20 Control device

[0077] 21Data processing and analysis unit

[0078] 22 Positioning system

[0079] 23 Tools

[0080] 24 mobile units

[0081] 26 Image capture unit

[0082] 28 Loading and unloading area

[0083] 30Digital models of production equipment

[0084] 32 Model Library

Claims

1. A production system (10), wherein: The production system (10) has the following features: a) Production equipment (12) having: i) a plurality of production tools (14) for producing components (16), and ii) a plurality of carriers (18) and / or a plurality of transport aids (19) for transporting the component (16) between the production tools (14); b) a control device (20) for controlling the production equipment (12) based on the production data; c) a positioning system (22) for positioning a plurality of mobile units (24) arranged or constructed on a plurality of carriers (18) or a plurality of transport aids (19), wherein the positioning system (22) is configured to: i) determining the position of the mobile unit (24), and ii) detecting identification information stored on said mobile unit (24), Furthermore, the position data of the carrier (18) or the transport auxiliary device (19) obtained based on the position of the mobile unit and the identification information is transmitted to the control device (20); d) a digital model (30) of the production plant (12) for simulating a production process, wherein the simulation is based at least on position data of the positioning system (22), It is characterized in that The production data includes at least one of the following items: characteristic parameters of component data, a production process of the production tool (14), an arrangement of the production tool (14), and characteristic parameters of the production tool (14), The characteristic parameter of the production tool (14) is at least one of the following: laser beam intensity, laser beam focus, bending tool used, flow rate, feed rate, pulse ratio in pulsed operation, power, energy, The characteristic parameter of the component data is at least one of the following items: material, profile, size, deformation, thickness, The control device (20) is configured to control the production facility (12) based on a result of the simulation. 2 . The production system according to claim 1 , in which the carrier ( 18 ) and / or the transport aid ( 19 ) has at least one further sensor.

3. The production system according to claim 1 or 2, wherein the production system (10) has a model library (32), the model library having simulated and / or actually executed production processes, wherein: The control device (20) is designed to compare a production process simulated in the digital model (30) with a production process in the model library (32). 4 . The production system according to claim 3 , in which the simulation and / or the model library is constructed in a cloud-based manner.

5. The production system according to claim 1 or 2, wherein the positioning system (22) is configured as an ultra-wideband system.

6. The production system according to claim 1 or 2, in which the positioning system (22) is configured to detect the position of the carrier (18) with an accuracy of less than 1 m.

7. The production system according to claim 1 or 2, in which the positioning system (22) is configured to detect the position of the carrier (18) with an accuracy of less than 0.3 m.

8. The production system according to claim 1 or 2, wherein at least one production tool (14) has a loading and unloading area (28) for loading and unloading carriers (18), in, The production system (10) has an image capturing unit (26) configured to: detect image information in the loading and unloading area (28); and The positioning system (22) has an image analysis unit which is configured to determine a position and / or a state of a carrier (18) using the image information.

9. The production system according to claim 1 or 2, wherein the simulation is stored in the form of a logistics simulation.

10. The production system according to claim 1 or 2, wherein: At least one production tool is designed as a metalworking tool.

11. The production system according to claim 1 or 2, wherein: At least one production tool is designed as a sheet metal processing tool.

12. The production system according to claim 1 or 2, wherein: At least one production tool is designed as a punching machine and / or a laser cutting machine.

13. The production system according to claim 1 or 2, wherein: At least one component is designed as a sheet metal part.

14. The production system according to claim 1 or 2, wherein: The digital model (30) has a map of a part of the production facility (12) or of the entire production facility (12).

15. The production system according to claim 14, wherein: The map contains information about the production tool and / or the component.

16. The production system according to claim 15, wherein: The map contains information about the position and orientation of the production tool and / or component.

17. A production control method for a production system (10), the production system being a production system according to any one of claims 1 to 16, the production control method comprising the following steps: A) detecting the position and identification information of the carrier (18) or the transport aid (19) by means of the positioning system (22) and transmitting the position data of the carrier (18) or the transport aid (19) determined based on the position of the mobile unit and the identification information to the control device (20); B) simulating a production process, wherein the simulation is based at least on position data detected by the positioning system (22); D) The production plant (12) is controlled by the control device (20), wherein the control is performed based on the results of the simulation with the aid of a digital model (30) of the production plant (12).

18. The production control method according to claim 17, comprising the following steps: C) comparing the simulated production process with the simulated and / or actually performed production processes stored in the model library (32).

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