An intelligent production scheduling method for error-proofing control of assembly processes

Abstract

The present invention discloses an intelligent production scheduling method for error-proof control of an assembly process, which relates to process flow control optimization technology. The key points of the technical solution are as follows: the flow-type assembly stage includes: collecting materials, and classifying and grouping them in sequence according to the production batches of each accessory; processing the status of the remaining accessories at the assembly station, obtaining the assembly progress status of each section in the current assembly process, and detecting the corresponding accessory ratio status of each assembly station in each section. Based on the corresponding accessory ratio status of each assembly station, the assembly status of each section is monitored, and the assembly status includes abnormal status or normal status. The present invention divides the entire assembly line into several sections, which is convenient for following up on the assembly progress of each section. By monitoring the corresponding accessory ratio status at the assembly station, it is convenient for management personnel to understand the assembly status of each section, and when abnormal situations occur, they can make corrections in time.

Description

Technical Field

[0001] The present invention relates to a process flow control optimization technology, and more specifically, to an intelligent production scheduling method for error-proofing control of an assembly process. Background Art

[0002] The assembly line, also known as the assembly line, is a production method in industry, which means that each production unit only focuses on processing a certain segment of the work to improve work efficiency and output. The assembly line is highly scalable and can be designed according to demand in terms of conveying volume, conveying speed, assembly stations, auxiliary components (including quick connectors, fans, lights, sockets, process boards, storage tables, 24V power supplies, air batches, etc.), so it is widely welcomed by enterprises. The assembly line is an effective combination of man and machine, and it fully reflects the flexibility of the equipment. It organically combines the conveying system, accompanying fixtures and online special machines and testing equipment to meet the conveying requirements of multiple varieties of products. The transmission mode of the conveyor line can be synchronous transmission (mandatory) or asynchronous transmission (flexible). According to the configuration selection, the assembly and conveying requirements can be achieved. The conveyor line is indispensable in the batch production of the enterprise.

[0003] In contrast, traditional enterprises on the market adopt the assembly line production method, in which raw materials are gradually assembled, transferred and transported by manual labor and equipment. During the manual transportation and assembly process, some accessories with large quantities, high precision requirements and small size are prone to omissions and improper assembly. If the assembled finished products are only tested and inspected in the final quality inspection link, only defective products can be screened out, causing great economic losses, and it is difficult to control or improve the yield rate of the entire production process.

[0004] Therefore, a new solution needs to be proposed to solve this problem. Summary of the Invention

[0005] In view of the shortcomings of the existing technology, the purpose of the present invention is to provide an intelligent production scheduling method for error-proof control of assembly process.

[0006] The above technical objectives of the present invention are achieved through the following technical solutions: an intelligent production scheduling method for error-proofing control of assembly processes, comprising a material storage and inspection stage and a flow-type assembly stage, wherein the flow-type assembly stage comprises:

[0007] Receiving materials, classifying and grouping them according to the production batches of each component;

[0008] Batching: Process the received parts, dispatch the corresponding number of parts in sequence according to the assembly sequence, and record the production status of each batch of parts, including the production batch, production quantity, production assembly date, and remaining quantity of the parts;

[0009] Assembly: Each component is assembled in sequence according to the assembly sequence, and the status of the remaining components in each assembly station is obtained in real time;

[0010] The status of the remaining accessories at the assembly station is processed to obtain the assembly progress status of each section in the current assembly process, and the corresponding accessories ratio status of each assembly station in each section is detected. Based on the corresponding accessories ratio status of each assembly station, the assembly status of each section is monitored, and the assembly status includes an abnormal state or a normal state.

[0011] By adopting the above technical solution, the parts are classified and grouped in accordance with the batches of their production, so that during the assembly process, the parts used in the assembled finished products can be kept in the same batch, which is convenient for subsequent quality tracking and reduces the yield rate of the overall finished product due to batch defects. In the process of mixing ingredients, the parts are grouped and arranged according to the assembly sequence, which can reduce the error rate in the assembly of fine parts. At the same time, the number of parts allocated to each assembly station is proportionally proportioned, so that the amount of parts used in the production process can be strictly controlled, which is convenient for subsequent accurate statistics of the depreciation rate and yield rate of the parts. In the assembly process, the entire assembly line is divided into several sections, which is convenient for following up the assembly progress of each section. By monitoring the proportion of the corresponding parts at the assembly station, it is convenient for management personnel to understand the assembly status of each section. When an abnormal situation occurs, it can be corrected in time, avoiding the lag in the traditional process that needs to be discovered only after the assembly is completed and quality inspection. At the same time, it also avoids the situation in which the full inspection of each finished product during the quality inspection process increases the labor intensity.

[0012] The present invention is further configured as follows: the synchronous and real-time acquisition of the status of the remaining accessories in each assembly station includes: the number of each accessory in at least one of the sections, the video monitoring data of at least one assembly station in the section, and the total weight of the accessories in at least one assembly station in the section.

[0013] By adopting the above technical solution, the number of each accessory in at least one section is monitored, thereby realizing monitoring of accessory depreciation, while avoiding the situation of missing or over-installation of accessories. The assembly station is monitored by video, and the total weight of the accessories on the assembly station is detected, thereby realizing multi-channel and multi-mode monitoring of the assembly status through the consumption of accessories, which can intuitively reflect the assembly status.

[0014] The present invention is further configured as follows: monitoring the assembly status of each section based on the proportion of corresponding accessories at each assembly station includes:

[0015] Obtain the remaining quantity of parts of at least two adjacent assembly stations in the i-th section, where i is a positive integer;

[0016] Based on the remaining quantities of the parts at the at least two assembly stations, determining the change trend information of the remaining quantity of the parts in the i-th section within a preset time;

[0017] Based on the change trend information, it is determined whether the assembly state of the i-th section is an abnormal state.

[0018] By adopting the above technical solution, the assembly remainder between two adjacent assembly stations is specifically detected, and the change trend information of the accessories on the two adjacent assembly stations during the normal assembly stage can be obtained. When the change in the number of accessories is abnormal, the difference in the change trend information can be clearly perceived, and corrections can be made in the first time, thereby improving the accuracy of the assembly process. It is also applicable to most current assembly lines and has strong applicability.

[0019] The present invention is further configured as follows: the obtaining of the remaining amount of accessories of at least two adjacent assembly stations of the i-th section includes: obtaining the remaining amount of accessories of an assembly station of the i-th section at a first moment and the remaining amount of accessories of an adjacent assembly station at a second moment based on a counting module, the first moment and the second moment are separated by a predetermined time length, and the predetermined time length is set according to the time required to complete a standard assembly of a specified process.

[0020] By adopting the above technical solution, during monitoring, the number of accessories at the first moment and the second moment are monitored respectively, and the time interval between the first time and the second time is used to realize the time agreement of one assembly step or N assembly steps, thereby improving the tracking of the use and consumption of accessories in each assembly step, and can intuitively provide feedback on the progress of assembly, and is conducive to the statistics of production.

[0021] The present invention is further configured as follows: the obtaining of the remaining amount of accessories at at least two adjacent assembly stations of the i-th section includes: obtaining the total weight of accessories at the corresponding assembly stations of the i-th section at a first moment and the total weight of accessories at the corresponding assembly stations at a second moment based on a weighing module, the first moment and the second moment are separated by a predetermined time length, and the predetermined time length is set as a multiple according to the time required to complete n standard assemblies of a specified process.

[0022] By adopting the above technical solution, the total weight of the accessories is weighed and the changing status of the accessories on two adjacent assembly stations is monitored in a manner of quantity and weight. When there is an abnormality in one of the assembly processes, intuitive feedback can be given. At the same time, by observing the next process, the faulty workpiece can be tracked, and rework can be carried out in time to reduce the defective rate and reduce the labor intensity of subsequent rework.

[0023] The present invention is further configured as follows: determining whether the assembly state of the i-th section is an abnormal state based on the change trend information includes:

[0024] If it is determined that the difference in the remaining accessories between the first moment and the second moment is less than or greater than the preset quantity difference threshold: if so, it is determined that there is improper assembly or omission in the assembly of the i-th section, and the i-th section is determined to be in an abnormal state.

[0025] If it is determined that the difference in the total amount of accessories between the first moment and the second moment is less than or greater than the preset weight difference threshold: if so, it is determined that there is improper assembly or omission in the assembly of the i-th section, and the i-th section is determined to be in an abnormal condition.

[0026] By adopting the above technical solution, the difference in the total amount of accessories at two moments is compared with the changing trend of normal assembly. If there is a difference greater than or less than the preset weight difference threshold, it is judged that there is improper assembly or omission in the assembly of this section. It has high real-time performance and can help management personnel track abnormal workstations in time and make corrections.

[0027] The present invention is further configured as follows: the counting module and the weighing module are connected to a central control operation module, which receives the remaining accessories or the total weight of the accessories from the counting module or the weighing module at the first moment or the second moment, and outputs a warning signal in response to the difference in the remaining accessories or the total weight of the accessories between the first moment and the second moment being less than or greater than a preset quantity difference threshold or a preset weight difference threshold.

[0028] By adopting the above technical solution, combined with the counting module and the weighing module, the central control operation module performs difference calculation on the quantity and weight, so as to efficiently know the assembly progress of the accessories in the organization process. At the same time, the central control operation module can compare and monitor the quantity and weight, and through the output warning signal, it can remind the management personnel and assembly workers, so as to facilitate the timely rework of defective parts.

[0029] The present invention is further configured to include: a reminder component connected to the central control operation module and a display unit based on local area network communication, wherein the reminder component includes a plurality of light-emitting tube groups electrically connected to the central control operation module, which light up in response to the warning signal.

[0030] By adopting the above technical solution, through the reminder component, when the central control operation module outputs a warning signal, the light-emitting tube group lights up to remind the assemblers in the section, so that the semi-finished products with abnormalities can be sorted out.

[0031] The present invention is further configured as follows: the display unit is connected to a number of monitoring probes located in each section or assembly station, the monitoring probes are used to obtain video images of each section or assembly station, and the display unit responds to the warning signal to display the video image of the specified section or assembly station.

[0032] By adopting the above technical solution, the monitoring probe can monitor the status of the sections and assembly stations in real time. Through the acquired video images, the defects in the assembly process can be actually understood, which is conducive to the improvement of the subsequent process. When the warning signal occurs, the section or assembly station where the unit shows an abnormal status is displayed, which makes it easier for management personnel to understand the assembly status.

[0033] The present invention is further configured as follows: the weighing module includes a weighing platform for placing accessories, the weighing platform is separated into an assembly area and a fault reporting area, and the fault reporting area is used to temporarily store defective accessories.

[0034] By adopting the above technical solution, an assembly area and a fault reporting area are set up on the weighing platform, so that if the assemblers find any defects in the accessories during the assembly process, they can sort them to the fault reporting area and sort the faulty accessories without affecting the normal assembly.

[0035] In summary, the present invention has the following beneficial effects:

[0036] The parts are classified and grouped according to the batches of their production, so that during the assembly process, the parts used in the assembled finished products can be kept in the same batch, which is convenient for subsequent quality tracking and reduces the yield rate of the overall finished product due to batch defects. In the process of mixing ingredients, they are grouped and arranged according to the assembly sequence, which can reduce the error rate in the assembly of fine parts. At the same time, the number of parts allocated to each assembly station is proportional, so that the amount of parts used in the production process can be strictly controlled, which is convenient for the subsequent accurate statistics of the depreciation rate and yield rate of parts. In the assembly process, the entire assembly line is divided into several sections, which is convenient for following up the assembly progress of each section. By monitoring the corresponding parts ratio status at the assembly station, it is convenient for management personnel to understand the assembly status of each section. When an abnormal situation occurs, it can be corrected in time, avoiding the lag in traditional processes that need to be discovered only after quality inspection after assembly is completed. It also avoids the situation in which full inspection of each finished product during quality inspection increases labor intensity. DETAILED DESCRIPTION

[0037] The present invention is described in detail below with reference to the embodiments.

[0038] An intelligent production scheduling method for error-proofing control of assembly processes includes a material storage and inspection stage and a flow-type assembly stage. The flow-type assembly stage includes:

[0039] Receiving materials, classifying and grouping them according to the production batches of each component;

[0040] Batching: Process the received parts and dispatch the corresponding number of parts in sequence according to the assembly sequence. Record the production status of each batch of parts, including the production batch, production quantity, assembly date, and remaining quantity.

[0041] Assembly: Each component is assembled in sequence according to the assembly sequence, and the status of the remaining components in each assembly station is obtained in real time;

[0042] The status of the remaining parts in the assembly station is processed to obtain the assembly progress status of each section in the current assembly process, and the corresponding parts ratio status of each assembly station in each section is detected. Based on the corresponding parts ratio status of each assembly station, the assembly status of each section is monitored, and the assembly status includes abnormal status or normal status. The status of the remaining parts in each assembly station is obtained synchronously and in real time, including: the number of each part in at least one section, video monitoring data of at least one assembly station in the section, and the total weight of the parts in at least one assembly station in the section. Based on the corresponding parts ratio status of each assembly station, the assembly status of each section is monitored, including:

[0043] S1, obtaining the remaining quantity of parts of at least two adjacent assembly stations in the i-th section, where i is a positive integer;

[0044] S2. Based on the remaining quantities of parts at at least two assembly stations, determining the change trend information of the remaining quantities of parts in the i-th section within a preset time, wherein obtaining the remaining quantities of parts at at least two adjacent assembly stations in the i-th section includes: obtaining, based on a counting module, the remaining quantity of parts at an assembly station in the i-th section at a first moment and the remaining quantity of parts at an adjacent assembly station at a second moment, with a predetermined time interval between the first moment and the second moment, and the predetermined time interval being set according to the time required for a specified process to complete one standard assembly; or, based on a weighing module, obtaining, based on a weighing module, the total weight of parts at corresponding assembly stations in the i-th section at a first moment and the total weight of parts at corresponding assembly stations at a second moment, with a predetermined time interval between the first moment and the second moment, and the predetermined time interval being set as a multiple of the time required for a specified process to complete n standard assemblies;

[0045] S3: Determine whether the assembly state of the i-th section is abnormal based on the change trend information. Specifically, determining whether the assembly state of the i-th section is abnormal based on the change trend information includes:

[0046] If it is determined that the difference in the remaining quantity of accessories between the first moment and the second moment is less than or greater than the preset quantity difference threshold: if so, it is determined that there is improper assembly or omission in the assembly of the i-th section, and the i-th section is determined to be in an abnormal state.

[0047] If it is determined that the difference in the total amount of accessories between the first moment and the second moment is less than or greater than the preset weight difference threshold: if so, it is determined that there is improper assembly or omission in the assembly of the i-th section, and the i-th section is determined to be in an abnormal condition.

[0048] In this embodiment, the counting module and the weighing module are connected to a central control operation module. The weighing module includes a weighing platform for placing accessories. The weighing platform is separated into an assembly area and a fault reporting area. The fault reporting area is used to temporarily store defective accessories. The remaining accessories or the total weight of the accessories at the first moment or the second moment are received by the counting module or the weighing module through the central control operation module. In response to the difference in the remaining accessories or the total weight of the accessories between the first moment and the second moment being less than or greater than a preset quantity difference threshold or a preset weight difference threshold, an alarm signal is output. A reminder component and a display unit based on LAN communication are communicated with the central control operation module. The reminder component includes a plurality of light-emitting tube groups electrically connected to the central control operation module, which light up in response to the alarm signal.

[0049] The display unit is connected to a number of monitoring probes located in various sections or assembly stations. The monitoring probes are used to obtain video images of various sections or assembly stations. The display unit responds to the warning signal to display the video image of the specified section or assembly station. In this embodiment, the display unit is composed of a number of display screen modules, and the display screen modules are connected to the computer serving as the central control computing module via a serial port line.

[0050] Working principle: Classify and group the parts according to the batches of their production, so that during the assembly process, the parts used in the assembled finished products can maintain a unified batch, which is convenient for subsequent quality tracking and reduces the yield rate of the overall finished product affected by batch defects. In the process of mixing ingredients, they are grouped and arranged according to the assembly sequence, which can reduce the error rate in the assembly of fine parts. At the same time, the number of parts allocated to each assembly station is proportional, so that the amount of parts used in the production process can be strictly controlled, which is convenient for the subsequent accurate statistics of the depreciation rate and yield rate of parts. In the assembly process, the entire assembly line is divided into several sections, which is convenient for following up the assembly progress of each section. Specifically, the number of each part in at least one section is monitored, so as to realize the monitoring of the depreciation of parts and avoid the situation of missing or over-installation of parts. The assembly station is video monitored and the total weight of the parts on the assembly station is detected, so as to realize multi-channel and multi-mode monitoring of the assembly status. The consumption of parts can intuitively reflect the assembly status. By monitoring the proportion of corresponding accessories on the assembly station, it is convenient for management personnel to understand the assembly status of each section. When an abnormal situation occurs, it can be corrected in time, avoiding the lag in traditional processes that require quality inspection after assembly is completed. It also avoids the situation where full inspection of each finished product during the quality inspection process increases labor intensity. Specifically, the remaining assembly quantity between two adjacent assembly stations is detected, and the changing trend information of accessories on two adjacent assembly stations in the normal assembly stage can be obtained. When the change in the number of accessories is abnormal, the warning signal output by the central control operation module triggers the light-emitting tube group at the corresponding assembly station, and reminds the assembler visually. It can also be combined with a buzzer to remind in an auditory way. I will not go into details here. At the same time, the video images obtained by the monitoring probe are output to the display module through the video decoder, so that management personnel in the office can understand the assembly status in time, and then make corrections in the first time, thereby improving the accuracy of the assembly process. It is suitable for most current assembly lines and has strong applicability.

[0051] During monitoring, the number of accessories and the total weight of accessories at the first moment and the second moment are monitored respectively, and the time interval between the first time and the second time is used to realize the time agreement of one assembly step or N assembly steps, so as to improve the tracking of the use and consumption of accessories in each assembly step, and provide intuitive feedback on the progress of assembly. It is also beneficial to the statistics of output, and the change status of accessories on two adjacent assembly stations is monitored in the form of quantity and weight. When there is an abnormality in one assembly process, intuitive feedback can be given. At the same time, by observing the next process, the workpiece with fault defects can be tracked, and rework can be carried out in time to reduce the defective rate and reduce the labor intensity of subsequent rework.

[0052] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiment. All technical solutions based on the concept of the present invention are within the scope of protection of the present invention. It should be noted that for those skilled in the art, various improvements and modifications that do not depart from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. An intelligent production scheduling method for error-proofing control of assembly processes, characterized by: It includes the material storage and inspection stage and the flow-type assembly stage, and the flow-type assembly stage includes: Receiving materials, classifying and grouping them according to the production batches of each component; Batching: Process the received parts, dispatch the corresponding number of parts in sequence according to the assembly sequence, and record the production status of each batch of parts, including the production batch, production quantity, production assembly date, and remaining quantity of the parts; Assembly: Each component is assembled in sequence according to the assembly sequence, and the status of the remaining components in each assembly station is obtained in real time; Processing the status of remaining parts at the assembly stations, obtaining the assembly progress status of each section in the current assembly process, detecting the proportion of corresponding parts at each assembly station in each section, and monitoring the assembly status of each section based on the proportion of corresponding parts at each assembly station, wherein the assembly status may include an abnormal state or a normal state; The monitoring of the assembly status of each section based on the corresponding parts ratio of each assembly station includes: Obtain the remaining quantity of parts of at least two adjacent assembly stations in the i-th section, where i is a positive integer; Determining, based on the remaining quantities of the parts at the at least two assembly stations, change trend information of the remaining quantities of the parts in the i-th section within a preset time; Based on the change trend information, it is determined whether the assembly state of the i-th section is an abnormal state.

2. The intelligent production scheduling method for assembly process error prevention control according to claim 1, characterized in that: The synchronous and real-time acquisition of the status of the remaining accessories in each assembly station includes: the number of each accessory in at least one of the sections, the video monitoring data of at least one assembly station in the section, and the total weight of the accessories in at least one assembly station in the section.

3. The intelligent production scheduling method for assembly process error prevention control according to claim 1, characterized in that: The method of obtaining the remaining amount of accessories of at least two adjacent assembly stations in the i-th section includes: obtaining the remaining amount of accessories of an assembly station in the i-th section at a first moment and the remaining amount of accessories of an adjacent assembly station at a second moment based on a counting module, and the first moment and the second moment are separated by a predetermined time length, and the predetermined time length is set according to the time required to complete a standard assembly of a specified process.

4. The intelligent production scheduling method for assembly process error prevention control according to claim 3, characterized in that: The method of obtaining the remaining amount of accessories at at least two adjacent assembly stations of the i-th section includes: obtaining the total weight of accessories at the corresponding assembly stations of the i-th section at a first moment and the total weight of accessories at the corresponding assembly stations at a second moment based on a weighing module, the first moment and the second moment are separated by a predetermined time length, and the predetermined time length is set as a multiple according to the time required to complete n standard assemblies of a specified process.

5. The intelligent production scheduling method for assembly process error prevention control according to claim 4 is characterized by: The determining, based on the change trend information, whether the assembly state of the i-th section is an abnormal state includes: If it is determined that the difference in the remaining quantity of the accessories between the first moment and the second moment is less than or greater than a preset quantity difference threshold: if so, it is determined that there is improper assembly or omission in the assembly of the i-th section, and the i-th section is determined to be in an abnormal state; If it is determined that the difference in accessory weight between the first moment and the second moment is less than or greater than a preset weight difference threshold: if so, it is determined that there is improper assembly or omission in the assembly of the i-th section, and the i-th section is determined to be in an abnormal condition.

6. The intelligent production scheduling method for assembly process error prevention control according to claim 5, characterized in that: The counting module or the weighing module is connected to a central control computing module, which receives the remaining accessories or the total weight of accessories from the counting module or the weighing module at the first moment or the second moment, and outputs a warning signal in response to the difference in the remaining accessories or the total weight of accessories between the first moment and the second moment being less than or greater than a preset quantity difference threshold or a preset weight difference threshold.

7. The intelligent production scheduling method for assembly process error prevention control according to claim 6, characterized in that: It also includes a reminder component connected to the central control operation module and a display unit based on local area network communication. The reminder component includes several light-emitting tube groups electrically connected to the central control operation module, which light up in response to the warning signal.

8. The intelligent production scheduling method for assembly process error prevention control according to claim 7, characterized in that: The display unit is connected to a number of monitoring probes located in various sections or assembly stations. The monitoring probes are used to obtain video images of various sections or assembly stations. The display unit responds to the warning signal to display the video image of the specified section or assembly station.

9. The intelligent production scheduling method for assembly process error prevention control according to claim 7, characterized in that: The weighing module includes a weighing platform for placing accessories, and the weighing platform is divided into an assembly area and a fault reporting area. The fault reporting area is used to temporarily store defective accessories.