A method and system for self-warning replacement of materials in a production line without stopping

Abstract

The present invention relates to a method for self-warning replacement of materials in a production line without stopping production, which includes the following steps: when the set time point arrives, the warehouse material management terminal prepares warning materials with a usage amount for a set duration on the material receiving mobile device; monitors the material usage situation on the production line, and when there is a material position where the remaining amount of the material is lower than a set value on the production line, determines whether a material receiving operation is required at this material position. If so, controls the material receiving mobile device loaded with warning materials to move to this material position, otherwise does not act, and automatically and / or manually replaces the corresponding material on the material receiving mobile device at the material position where a material receiving operation is required; by applying the method and means of the present invention, not only can high work efficiency be achieved, the labor intensity of operators can be reduced, but also error prevention and anti-fooling can be carried out, and the production line can operate without stopping production, and working hours are not wasted.

Description

Technical Field

[0001] The present invention relates to the technical field of material supply, and more specifically, to a method and system for self-warning replacement of materials on a non-stop production line. Background Art

[0002] In today's electronic manufacturing industry, the surface mount technology (SMT) is very commonly used. In the SMT production process, the connection of the roll-shaped (also known as disk-shaped) materials on the machine (production line) is a very frequent operation, and on average, it needs to be connected almost every few minutes.

[0003] Currently, the traditional on-line material connection operations are divided into two types: on-line (non-stop) connection and off-line (stop) connection. As Figure 1 shown, the basic operation steps of both are roughly this kind of operation method, and its disadvantages are: 1. Low work efficiency and too long material searching time; 2. It is easy to cause the production line to stop and wait for materials, wasting working hours; 3. Since there is no anti-fooling and anti-mistake measures, only one disk can be operated at a time. Summary of the Invention

[0004] The technical problem to be solved by the present invention is to provide a method for self-warning replacement of materials on a non-stop production line in view of the above-mentioned defects of the prior art, and also provide a system for self-warning replacement of materials on a non-stop production line.

[0005] The technical solution adopted by the present invention to solve its technical problems is:

[0006] Construct a method for self-warning replacement of materials on a non-stop production line, which includes the following steps:

[0007] The first step: When the set time point arrives, the warehouse material management terminal stocks the warning materials with the usage amount for the set duration to the material receiving mobile device;

[0008] The second step: Monitor the material usage situation on the production line, and when there is a material position on the production line where the remaining amount of the material is lower than a set value, judge whether the material position needs to perform a material receiving operation. If so, control the material receiving mobile device loaded with the warning materials to move to the material position, otherwise do not act;

[0009] The third step: Automatically and / or manually replace the corresponding materials on the material receiving mobile device at the material position that needs to perform a material receiving operation.

[0010] In the method for self-warning replacement of materials on a non-stop production line according to the present invention, in the third step, the method further includes:

[0011] The material receiving mobile device sets a reminder mark for the material to be received loaded thereon according to the material position information of the material position that needs to perform a material receiving operation, and cancels the reminder mark after the material receiving action is completed.

[0012] The method for self-warning replacement of materials in a non-stop production line according to the present invention further includes the following method:

[0013] During material receiving, perform a comparison of the codes on the material sweeping tray. If the comparison is incorrect, re-select the material. If the comparison is successful, perform material receiving, and after the material receiving is completed, send information feedback to the material receiving mobile device, and the material receiving mobile device cancels the reminder label according to this information feedback.

[0014] The method for self-warning replacement of materials in a non-stop production line according to the present invention, wherein when preparing materials in the first step, the following method is further included:

[0015] The material receiving mobile device scans the material barcode and sends a material details request to the warehouse material management terminal;

[0016] The material receiving mobile device receives the detailed material information returned by the warehouse material management terminal, binds the detailed material information to the corresponding storage location, and the warehouse material management terminal prepares the corresponding materials to the corresponding storage location;

[0017] The material receiving mobile device detects the change of materials on the storage location, conducts information verification of the materials and the storage location. If the verification is successful, it sends information to the warehouse material management terminal for posting processing and returns the result. If the verification fails, it feedbacks the information of incorrect material preparation.

[0018] The method for self-warning replacement of materials in a non-stop production line according to the present invention, wherein in the second step, the method for monitoring the material usage situation on the production line is as follows:

[0019] The material receiving mobile device sends a material query request to the production line at a set time node and receives the machine tool material inventory information at different time points returned;

[0020] Calculate the material consumption speed and the remaining available time of the materials based on the machine tool material inventory information at different time points.

[0021] A non-stop production line material self-warning replacement system, which includes a warehouse material management terminal, a material receiving mobile device, and a production line terminal;

[0022] The warehouse material management terminal includes a loading module and a main controller that controls it to prepare and load the materials for a set duration at a set time point to the material receiving mobile device;

[0023] The production line terminal includes a monitoring module for monitoring the material usage situation and a control host for determining the material shortage status and the material receiving requirement according to the data of the monitoring module;

[0024] The material receiving mobile device includes a material storage area, a moving module, and an industrial control computer;

[0025] The industrial control computer is wirelessly communicatively connected to both the main controller and the control host.

[0026] In the non-stop production line material self-warning replacement system of the present invention, one or more material storage positions are provided in the material storage area, and reminder signs corresponding to the material storage positions are provided, and the reminder signs are controlled by the industrial control computer.

[0027] In the non-stop production line material self-warning replacement system of the present invention, the material receiving and moving device further includes a code scanning and comparison unit for comparing the tray codes during material receiving, and the industrial control computer controls the closing of the reminder sign according to the feedback information of the code scanning and comparison unit.

[0028] In the non-stop production line material self-warning replacement system of the present invention, the material receiving and moving device further includes an information binding module for binding material information with the material storage position and a stock preparation verification module for verifying the materials on the material storage position; the warehouse material management terminal includes a posting processing module, and the posting processing module performs posting processing after receiving the verification correct information of the stock preparation verification module.

[0029] In the non-stop production line material self-warning replacement system of the present invention, the material receiving and moving device includes a material query module, and the material query module sends a material query request to the production line end at a set time node, receives the machine tool material inventory information at different time points returned, and calculates the material consumption speed and the remaining available time of the material according to the machine tool material inventory information at different time points.

[0030] The beneficial effects of the present invention are as follows: By applying the methods and ways of the present invention, not only can a high working efficiency be achieved, the labor intensity of operators can be reduced, but also error prevention and anti-fooling can be carried out, and the production line can operate without stopping, and working hours are not wasted. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] In order to more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the following will further illustrate the present invention in conjunction with the drawings and embodiments. The drawings in the following description are only partial embodiments of the present invention. For those of ordinary skill in the art, other drawings can be obtained according to these drawings without creative efforts:

[0032] Figure 1 is the existing method of replacing materials during downtime;

[0033] Figure 2 is the flowchart of the non-stop production line material self-warning replacement method of the preferred embodiment of the present invention;

[0034] Figure 3 is the logical schematic diagram of the non-stop production line material self-warning replacement method of the preferred embodiment of the present invention;

[0035] Figure 4It is a principle block diagram of the non-stop production line material self-warning replacement system according to a preferred embodiment of the present invention. Specific embodiments

[0036] In order to make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below. Obviously, the described embodiments are part of the embodiments of the present invention, rather than all the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0037] The non-stop production line material self-warning replacement method according to a preferred embodiment of the present invention, as Figure 2 shown, and also referring to Figure 3 , includes the following steps:

[0038] S01: When the set time point arrives, the warehouse material management terminal stocks the warning materials for the usage amount of the set duration to the material receiving mobile device;

[0039] S02: Monitor the material usage situation on the production line, and when there is a material position where the remaining amount of the material is lower than a set value on the production line, determine whether a material receiving operation is required at this material position. If so, control the material receiving mobile device loaded with the warning materials to move to this material position, otherwise do not act;

[0040] S03: Automatically and / or manually replace the corresponding materials on the material receiving mobile device at the material position that requires a material receiving operation;

[0041] Applying the methods and ways of the present invention can not only have a high working efficiency, reduce the labor intensity of operators, but also prevent errors and mistakes, and the production line can operate without stopping, without wasting working hours.

[0042] Preferably, in S03, the method further includes:

[0043] The material receiving mobile device sets a reminder mark for the material to be received loaded thereon according to the material position information of the material position that requires a material receiving operation, and cancels this reminder mark after the material receiving action is completed;

[0044] Applying the reminder mark can more accurately identify and remind the material to be received; a preferred reminder mark is to use an indicator light, and rely on the on and off of the indicator light for reminder. Of course, there can also be other reminder methods, and the conventional transformations based on this principle all fall within the protection scope of this application;

[0045] Preferably, the method further includes:

[0046] During material receiving, a comparison is made between the material tray codes. If the comparison is incorrect, the material is selected again. If the comparison is successful, the material is received, and after the receiving is completed, information feedback is sent to the material receiving mobile device, which cancels the reminder identifier based on this information feedback. When receiving materials, it is ensured that the received materials are correct by scanning and comparing the identification codes on the new and old material trays.

[0047] Preferably, when preparing goods in the first step, the method also includes:

[0048] The material receiving mobile device scans the material barcode and sends a material details request to the warehouse material management terminal.

[0049] The material receiving mobile device receives the detailed material information returned by the warehouse material management terminal, binds the detailed material information to the corresponding storage location, and the warehouse material management terminal stocks the materials to the corresponding storage location.

[0050] The material receiving mobile device detects changes in the materials at the storage location, conducts information verification between the materials and the storage location. If the verification is successful, it sends information to the warehouse material management terminal for posting processing and returns the result. If the verification fails, it feeds back the information of incorrect goods preparation.

[0051] When preparing warning materials, the information of the materials is bound to the storage location, and relying on this binding correspondence relationship can ensure the accuracy of feeding, and can preferably avoid the problem of incorrect feeding from the feeding stage.

[0052] Preferably, in the second step, the method for monitoring the material usage situation on the production line is as follows:

[0053] The material receiving mobile device sends a material query request to the production line at a set time node and receives the machine material stock information at different time points returned.

[0054] Calculate the material consumption speed and the remaining available time of the materials based on the machine material stock information at different time points.

[0055] Relying on the active inquiry of the material receiving mobile device and relying on the comparison and statistics of multiple time points to obtain the remaining available time of the materials. This method is completely triggered and calculated by the material receiving mobile device. The monitoring method is very flexible, and only data feedback is required on the production line without any additional actions, so it can preferably be applied to almost all existing production lines.

[0056] A non-stop production line material self-warning replacement system, as Figure 4 shown, includes a warehouse material management terminal 1, a material receiving mobile device 2, and a production line terminal 3;

[0057] The warehouse material management terminal 1 includes a feeding module 10 and a main controller 11 that controls it to stock and feed the materials in the set duration at the set time point to the material receiving mobile device.

[0058] The production line end 3 includes a monitoring module 30 for monitoring the usage of materials and a control host 31 for determining the material shortage status and the material receiving requirement based on the data of the monitoring module;

[0059] The material receiving mobile device 2 includes a material storage area 20, a moving module 21, and an industrial control computer 22;

[0060] The industrial control computer 22 is wirelessly communicatively connected to both the main controller 11 and the control host 31.

[0061] Preferably, the material storage area 20 is provided with one or more material storage positions 200 and reminder signs 201 corresponding to the material storage positions, and the reminder signs 201 are controlled by the industrial control computer 22.

[0062] Preferably, the material receiving mobile device 2 further includes a code scanning and comparison unit 23 for comparing the material tray codes during material receiving, and the industrial control computer 22 controls the closing of the reminder signs 201 according to the feedback information of the code scanning and comparison unit 23.

[0063] Preferably, the material receiving mobile device 2 further includes an information binding module 24 for binding the material information with the material storage position and a stock preparation verification module 25 for verifying the materials on the material storage position; the warehouse material management end 1 includes a posting processing module 12, and the posting processing module 12 performs posting processing after receiving the verification passed information from the stock preparation verification module 25;

[0064] When preparing the warning materials, bind the information of the materials with the storage positions, and rely on this binding correspondence to ensure the accuracy of material feeding, which can better avoid the problem of material feeding errors from the material feeding stage.

[0065] Preferably, the material receiving mobile device 2 includes a material query module 26. The material query module 26 sends a material query request to the production line end 3 at a set time node, receives the machine material inventory information at different time points returned, and calculates the material consumption speed and the remaining available time of the materials based on the machine material inventory information at different time points;

[0066] Rely on the active inquiry of the material receiving mobile device and rely on the comparison and statistics of multiple time points to obtain the remaining available time of the materials. This method is completely triggered and calculated by the material receiving mobile device. The monitoring method is very flexible, and only data feedback is required on the production line without any additional actions, so it can be well applied to almost all existing production lines;

[0067] It should be noted that the above-mentioned modules, modules, and units of the non-stop production line material self-warning replacement system of the present application can all be directly implemented by using existing devices, and the simple replacement of components based on this combination principle belongs to the protection scope of the present application.

[0068] It should be understood that those of ordinary skill in the art can make improvements or modifications based on the above description, and all such improvements and modifications shall fall within the protection scope of the appended claims of the present invention.

Claims

1. A method for self-warning replacement of materials in a non-stop production line, characterized in that, it includes the following steps: The first step: When the set time point arrives, the warehouse material management terminal stocks the warning materials with the usage amount for the set duration to the material receiving mobile device; When stocking, it also includes: The material receiving mobile device scans the material barcode and sends a material details request to the warehouse material management terminal; The material receiving mobile device receives the detailed material information returned by the warehouse material management terminal, binds the detailed material information to the corresponding storage location, and the warehouse material management terminal stocks the materials corresponding to the corresponding storage location; The material receiving mobile device detects the change of materials on the storage location, conducts information verification of the materials and the storage location. If the verification is successful, it sends information to the warehouse material management terminal for posting processing and returns the result. If the verification fails, it feedbacks the stocking error information; The second step: Monitor the material usage situation on the production line, and when there is a material position on the production line where the remaining amount of materials is lower than a set value, judge whether the material position needs to perform a material receiving operation. If so, control the material receiving mobile device loaded with the warning materials to move to the material position, otherwise do not act; The method for realizing monitoring the material usage situation on the production line is as follows: The material receiving mobile device sends a material query request to the production line at the set time node and receives the machine tool material stock information at different time points returned; Calculate the material consumption speed and the available remaining time of the materials based on the machine tool material stock information at different time points; The third step: Automatically and / or manually replace the corresponding materials on the material receiving mobile device at the material position that needs to perform a material receiving operation; The material receiving mobile device sets a reminder mark for the materials to be received loaded on it according to the material position information that needs to perform a material receiving operation, and cancels the reminder mark after the material receiving action is completed; When receiving materials, conduct a comparison of the material tray codes. If the comparison is incorrect, reselect the materials. If the comparison is successful, receive the materials, and after receiving the materials, give information feedback to the material receiving mobile device. The material receiving mobile device cancels the reminder mark according to this information feedback.

2. A non-stop production line material self-warning replacement system for realizing the non-stop production line material self-warning replacement method as described in claim 1, characterized in that, it includes a warehouse material management terminal, a material receiving mobile device and a production line terminal; The warehouse material management terminal includes a feeding module and a main controller that controls it to stock and feed the materials with the usage amount for the set duration to the material receiving mobile device when the set time point arrives; The production line terminal includes a monitoring module for monitoring the material usage situation and a control host for judging the material shortage state and the material receiving requirement according to the data of the monitoring module; The material receiving mobile device includes a material storage area, a moving module and an industrial control computer; The industrial control computer is wirelessly communicatively connected to both the main controller and the control host.

3. The non-stop production line material self-warning replacement system according to claim 2, characterized in that, The material storage area is provided with one or more material storage locations and a reminder mark corresponding to the material storage location, and the reminder mark is controlled by the industrial control computer.

4. The non-stop production line material self-warning replacement system according to claim 3, characterized in that, The material receiving and moving device further includes a code scanning and comparison unit for scanning and comparing the material tray codes during material receiving, and the industrial control computer controls the closing of the reminder identifier according to the feedback information of the code scanning and comparison unit.

5. The non-stop production line material self-warning replacement system according to claim 3 or 4, characterized in that the material receiving and moving device further includes an information binding module for binding the material information with the material storage location and a stock preparation verification module for verifying the materials on the material storage location; the warehouse material management terminal includes a posting processing module, and the posting processing module performs posting processing after receiving the verification correct information from the stock preparation verification module.

6. The non-stop production line material self-warning replacement system according to any one of claims 2-4, characterized in that the material receiving and moving device includes a material query module, and the material query module sends a material query request to the production line end at a set time node, receives the machine material inventory information at different time points returned, and calculates the material consumption speed and the remaining available time of the material according to the machine material inventory information at different time points.

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