A production line design method suitable for digital assembly of small turbofan engines

Abstract

The application discloses a production line design method suitable for digital assembly of small turbofan engines and belongs to the technical field of digital manufacturing. The design method comprises the following steps: step one, dividing an assembly process; step two, designing an overall business process based on the divided assembly process and in combination with business management regulations; step three, designing overall system functions and a network integration architecture based on the overall business process; step four, carrying out production line layout according to the overall system functions and the network integration architecture in step three; and step five, designing key equipment of the production line according to the assembly process in step one and the production line layout in step four. The application can realize digital assembly of multi-variety, small-batch small turbofan engines, improve engine assembly quality and efficiency, reduce assembly error rate, shorten assembly cycle and improve resource utilization.

Description

TECHNICAL FIELD

[0001] The application belongs to the technical field of digital manufacturing, and particularly relates to a production line design method suitable for digital assembly of small turbofan engines. BACKGROUND

[0002] Small turbofan engine products are mostly discrete production modes with multiple varieties and small batches, and the production mode has characteristics such as multiple varieties of parallel production, limited resources, and uncertain production cycle; the assembly process adopts a pure manual assembly mode, and there are many problems such as high labor intensity of workers and serious dependence of quality control on personnel quality. As the last link in the engine manufacturing process, assembly plays a key role in the formation of product characteristics, therefore, how to improve the assembly quality and efficiency of the engine, reduce the assembly error rate, shorten the assembly cycle, and improve the resource utilization rate has become a bottleneck problem that needs to be solved urgently in engine assembly. SUMMARY

[0003] Therefore, the application provides a production line design method suitable for digital assembly of small turbofan engines, which can realize digital assembly of small turbofan engines with multiple varieties and small batches, improve the assembly quality and efficiency of the engine, reduce the assembly error rate, shorten the assembly cycle, and improve the resource utilization rate.

[0004] A production line design method suitable for digital assembly of small turbofan engines, the design method comprising the following steps:

[0005] Step one: dividing the assembly process flow;

[0006] Step two: based on the divided assembly process flow, combining business management regulations, designing the overall business process;

[0007] Step three: based on the overall business process, designing the overall system function and network integration architecture;

[0008] Step four: according to the overall system function and network integration architecture of step three, performing production line layout;

[0009] Step five: designing the key equipment of the production line according to the assembly process flow of step one and the production line layout of step four.

[0010] Further, the assembly process flow of step one comprises: assembly action decomposition, work step time statistics, process station division, and work station time calculation, according to the work station time calculation result, taking the work time of the bottleneck station as the production line beat, and according to the given annual average working time and production line start-up rate index, the theoretical annual production capacity of the assembly production line can be obtained.

[0011] Further, the overall business process of step two includes order planning, structured production line process programming, task assignment, production preparation, material flow, assembly execution, data collection and monitoring, completion reporting, abnormal problem handling business and its process design, realizing integrated control of production line business.

[0012] Further, the overall system function and network integration architecture of step three includes ERP system, PLM system, MES system, AMS system and logistics system related to the overall business, realizing top-down instruction transmission and bottom-up transmission of product and production environment information in the assembly process of turbofan engine.

[0013] Further, the ERP system is an enterprise resource management system, and its functions and integration include generating group batch plan, generating batch product order and managing supporting component batch, number, inventory information, and two-way integration with MES system, issuing batch product order to MES system to complete enterprise-level production plan issuance; receiving product supporting component delivery application from MES system, issuing product supporting information to MES system in single supporting manner; at the same time, receiving order completion information feedback from MES system.

[0014] Further, the PLM system is a product lifecycle management system, and its functions and integration include PBOM programming and signing based on unified product BOM, structured production line process design and signing, PBOM and structured production line process issuance, and one-way integration with MES system, issuing PBOM and structured production line process to MES system.

[0015] Further, the MES system is a manufacturing execution system, and its functions and integration include batch product order receiving and analysis, structured production line process receiving and analysis, process and order binding, plan scheduling, work order issuance, production preparation, assembly execution, equipment task issuance, abnormal problem handling, completion reporting and product production process display, assembly execution including work order start, material receiving, material confirmation, work step operation guidance, this system and AMS system are two-way integrated, issuing equipment task to AMS system in the form of process data package, and receiving process result data package returned by AMS system, when the equipment state is abnormal, abnormal information returned by AMS system needs to be received, and abnormal problem handling process is initiated.

[0016] Further, the AMS system is an assembly line management system, and functions and integration thereof include device task receiving, motion control, data acquisition, production line monitoring, abnormal alarm and production line state display, receiving process data packets issued by the MES system, issuing motion control and data acquisition instructions to the production line equipment after analysis, collecting process and result data returned by the equipment, monitoring the running state of the equipment, summarizing production line abnormal information and reasons thereof, and dynamically displaying the production line state in a graphical form.

[0017] Further, the logistics system comprises an AGV vehicle and scheduling software thereof, and the system independently operates and receives the distribution starting position, distribution material information and distribution end position information from the MES system through a two-dimensional code transfer mode, so that the precise distribution of materials in the turbofan engine assembly process is realized.

[0018] Further, the production line layout comprises one production preparation area, one component assembly area and one final assembly unit, the total land area of the production line is 75m*7.5m, the production preparation area comprises a line-side warehouse, a material vehicle, a production line display screen, an AGV and two production preparation workstations, the material distribution of the turbofan engine is realized, the component assembly area comprises one component assembly workstation, a press-fitting device and a heating box, the component assembly of the turbofan engine is realized, and the final assembly unit comprises three final assembly workstations, one all-purpose workstation, a mechanical arm auxiliary overturning transfer device and an auxiliary lifting device, the pulsating assembly of the turbofan engine body is realized, the all-purpose workstation is used for product abnormal problem processing, buffering and single-product full-process assembly, and is suitable for inline assembly production of multi-variety and small-batch products.

[0019] Further, the key equipment of the production line in step five comprises a digital bearing press-fitting device, a digital assembly workstation and a mechanical arm auxiliary overturning transfer device, the digital press-fitting device can meet the requirements of various press-fitting strategy control, process curve generation, result data automatic acquisition and uploading, the digital assembly workstation serves as a main part of the final assembly workstation and the all-purpose workstation, and can meet the requirements of semi-automatic rotation and lifting in the assembly process of various small turbofan engines, the mechanical arm auxiliary overturning transfer device comprises one industrial mechanical arm and one mechanical arm external shaft, cooperates with the digital assembly workstation, and can realize automatic overturning of products and automatic transfer between final assembly workstations, and each assembly workstation of the production line is provided with an industrial camera, which is used for quality recording and quality tracing in the engine assembly process.

[0020] Beneficial effects:

[0021] 1. A unified BOM data source is constructed based on the PLM system, the top-down instruction transmission and the transmission of product and production environment information in the turbofan engine assembly process from bottom to top are realized, and the complete recording and unified tracing of product full-life cycle data are realized.

[0022] 2、The present application makes the process flow more clear, improves the readability of the on-site process, reduces the operation and quality control difficulty of manual work, and realizes a substantial reduction in personnel training period by splitting the assembly process, structuring the process line design, and designing the operation guide.

[0023] 3、The present application realizes online business, data and quality of the small turbofan engine assembly process through the supplementary construction and integration of ERP, PLM, MES and AMS systems, improves the transparency of production process management, and effectively improves the digital control ability of production process.

[0024] 4、The present application saves more than 8 hours of production preparation time, saves more than 5 auxiliary operators, reduces the labor intensity of operators, improves the digitalization and automation of small turbofan engine assembly process, and for the first time completes the exploration and application of human-machine collaborative operation in the field of small turbofan engine assembly.

[0025] 5、The present application improves the assembly efficiency, reduces the error rate, and improves the assembly quality and efficiency by using information system and two-dimensional code to replace manual process material confirmation; the use of mechanical arm, AGV and other automatic equipment to replace manual product turnover and transfer reduces the manual operation time and the number of personnel engaged in this work, shortens the product production preparation cycle and personnel carrying cycle; the application of the method for the construction of production line greatly improves the utilization rate of site resources under the same capacity after construction. BRIEF DESCRIPTION OF DRAWINGS

[0026] Figure 1 The step flow chart of the production line design method of the present application.

[0027] Figure 2 The turbofan engine assembly process time chart of the present application.

[0028] Figure 3 The assembly line station time chart of the present application.

[0029] Figure 4 The overall business process and system function chart of the present application.

[0030] Figure 5 The overall network integration architecture chart of the present application.

[0031] Figure 6 The digital assembly production line layout chart of the present application.

[0032] In the figure: 1- production preparation station, 2- subassembly station, 3- digitized press-fitting equipment, 4- general assembly station 1, 5- general assembly station 2, 6- buffer area, 7- general assembly station 3, 8- all-purpose station, 9- off-line station, 10- mechanical arm-assisted turnover transfer device, 11- line-side warehouse, 12- material distribution vehicle, 13- on-site display screen, 14- AGV vehicle. DETAILED DESCRIPTION

[0033] The present application will be described in detail below with reference to the accompanying drawings and examples.

[0034] The present application provides a production line design method suitable for digital assembly of small turbofan engines, as shown in the accompanying drawings Figure 1 , including the following five steps:

[0035] Step one: dividing the assembly process flow;

[0036] Step two: based on the divided assembly process flow, combining business management regulations, designing the overall business process;

[0037] Step three: based on the overall business process, designing the overall system function and network integration architecture;

[0038] Step four: according to the overall system function and network integration architecture of step three, carrying out the production line layout;

[0039] Step five: according to the assembly process flow of step one and the production line layout of step four, designing the key equipment of the production line.

[0040] Among them, the assembly process flow is divided by decomposing the assembly action and the statistical time of the working step, analyzing the assembly rhythm of the engine, the time of each process is as shown in Figure 2 , and the working time of the integrated station is as shown in Figure 3 .

[0041] As shown in the accompanying drawings Figure 4As shown in the figure, the overall business process and system function design of the application is divided into management layer, business layer, execution layer and field layer; the overall business process includes order issuing, process issuing, plan scheduling, assembly execution, equipment control and equipment monitoring; the order issuing business belongs to the ERP system; the process preparation and process issuing business belongs to the PLM system; the plan scheduling and assembly execution business belongs to the MES system, wherein the plan scheduling function includes plan receiving, process binding, detailed scheduling, work order issuing and task issuing, and the assembly execution function includes production preparation, work order starting, material receiving, material confirmation, operation guidance, abnormality processing, completion reporting and production state display; the equipment control and equipment monitoring business belongs to the AMS system, wherein the equipment control function includes task receiving, program issuing, material distribution, motion control, data acquisition and abnormality processing, and the equipment monitoring function includes production line monitoring, abnormality monitoring and state display.

[0042] The overall network integration architecture design of the application is as shown in the figure Figure 5 As shown in the figure, the ERP system and the MES system are bidirectionally integrated, the batch product order is issued to the MES system, the enterprise-level production plan is issued, the product matching component delivery application is received from the MES system, the product matching information is issued to the MES system in the form of single matching, the order completion information is received from the MES system; the PLM system and the MES system are unidirectionally integrated, the PBOM and the structured production line process are issued to the MES system; the MES system and the AMS system are bidirectionally integrated, the equipment task is issued to the AMS system in the form of process data packet, the process result data packet is received from the AMS system, when the equipment state is abnormal, the abnormal information is received from the AMS system, and the abnormality problem processing process is initiated.

[0043] According to the application of the above scheme, the production line layout is as shown in the figure Figure 6As shown, the production line layout includes 1 production preparation area, 1 subassembly area and 1 final assembly unit, and the total land area of the production line is 75m*7.5m; the production preparation area includes a line side warehouse 11, a material car 12, a production line display screen 13, an AGV 14 and 2 production preparation workstations 1, realizes the size selection of the turbofan engine, the material sorting and loading, and the material distribution; the subassembly area includes 1 component assembly workstation 2, a press-fitting device 3 and a heating box 15, realizes the component assembly of the turbofan engine; the final assembly unit includes a final assembly workstation a4, a final assembly workstation b5, a final assembly workstation c7, an all-purpose workstation 8, a mechanical arm auxiliary overturning transfer device 10 and an auxiliary lifting device 16, realizes the pulsating assembly of the turbofan engine body; the buffer area 6 can be used for temporarily buffering the products completed by the previous workstation when the next workstation is occupied, and the all-purpose workstation 8 can be used for product abnormal problem processing, buffering and single product whole-process assembly, and is suitable for inline assembly production of multi-variety and small-batch products. The materials required for production are automatically distributed from the production preparation workstation 1 to other workstations by the AGV car 14, and the precise distribution of the materials in the turbofan engine assembly process is realized.

[0044] To sum up, the above is only a preferred embodiment of the present application, and is not used to limit the protection scope of the present application. Any modification, equivalent replacement, improvement, etc. within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A production line design method suitable for the digital assembly of small turbofan engines, characterized in that, This design method includes the following steps: Step 1: Divide the assembly process flow; Step 2: Based on the divided assembly process flow and in conjunction with business management regulations, design the overall business process; Step 3: Based on the overall business process, design the overall system functions and network integration architecture; Step 4: Lay out the production line based on the overall system functions and network integration architecture from Step 3; Step 5: Design the key equipment for the production line based on the assembly process flow in Step 1 and the production line layout in Step 4. The assembly process in step one includes: decomposition of assembly actions, statistics of work steps and working hours, division of work stations and calculation of work station working hours. Based on the work station working hour calculation results, the working hours of the bottleneck work station are used as the production line cycle time. According to the given annual average working time and production line uptime index, the theoretical annual capacity of the assembly production line can be obtained. The production line layout includes one production preparation area, one sub-assembly area, and one final assembly unit; the total area of ​​the production line is 75m × 7.5m; the production preparation area includes a line-side warehouse, material carts, a production line display screen, AGVs, and two production preparation workstations, realizing turbofan engine size selection, material sorting and loading, and material distribution; the sub-assembly area includes one component assembly workstation, pressing equipment, and a heating box, realizing turbofan engine component assembly; the final assembly unit includes three final assembly workstations, one all-purpose workstation, a robotic arm-assisted flipping and transfer device, and an auxiliary lifting device, realizing the pulsed assembly of the turbofan engine body; the all-purpose workstation is used for handling product abnormalities, buffering, and single-piece full-process assembly, suitable for multi-variety, small-batch product co-line assembly production; The key equipment in step five of the production line includes a digital bearing press-fitting device, a digital assembly operating table, and a robotic arm-assisted flipping and transfer device. The digital press-fitting device can meet the requirements of various press-fitting strategy control, process curve generation, and automatic acquisition and uploading of result data. The digital assembly operating table, as the main part of the final assembly station and the all-around station, can meet the semi-automatic rotation and lifting requirements in the assembly process of various small turbofan engines. The robotic arm-assisted flipping and transfer device includes an industrial robotic arm and an external axis of the robotic arm. In conjunction with the digital assembly operating table, it can realize automatic product flipping and automatic transfer between final assembly stations. Each assembly station on the production line is equipped with an industrial camera for quality recording and quality traceability during the engine assembly process.

2. The production line design method for digital assembly of small turbofan engines as described in claim 1, characterized in that, The overall business process in step two includes order planning, structured production line process development, task assignment, production preparation, material flow, assembly execution, data acquisition and monitoring, completion reporting, and handling of abnormal issues, as well as the design of related processes, to achieve integrated management and control of production line operations.

3. The production line design method for digital assembly of small turbofan engines as described in claim 2, characterized in that, The overall system functions and network integration architecture in step three include ERP system, PLM system, MES system, AMS system and logistics system related to the overall business, to realize top-down instruction transmission and bottom-up transmission of product and production environment information during the turbofan engine assembly process. The ERP system is an Enterprise Resource Management System. Its functions and integrations include generating batch plans, generating batch product orders, and managing batch, number, and inventory information of supporting components. It is bidirectionally integrated with the MES system, sending batch product orders to the MES system to complete the issuance of enterprise-level production plans; receiving product supporting component outbound requests from the MES system and sending product supporting information to the MES system in a single-unit supporting manner; and receiving order completion information from the MES system. The PLM system is a product lifecycle management system. Its functions and integrations include the compilation and approval of PBOM based on a unified product BOM, the design and approval of structured production line processes, the distribution of PBOM and structured production line processes, and one-way integration with the MES system, distributing PBOM and structured production line processes to the MES system. The MES system is a Manufacturing Execution System. Its functions and integrations include receiving and parsing batch product orders, receiving and parsing structured production line processes, binding processes with orders, production planning and scheduling, issuing work orders, production preparation, assembly execution, issuing equipment tasks, handling abnormal issues, completion reporting, and displaying the product production process. Assembly execution includes work order initiation, material receipt, material confirmation, and work step guidance. This system is bidirectionally integrated with the AMS system, issuing equipment tasks to the AMS system in the form of process data packets and receiving process result data packets returned by the AMS system. When equipment malfunctions, it needs to receive abnormal information returned by the AMS system and initiate an abnormal issue handling process. The AMS system is an assembly line management system. Its functions and integrations include equipment task reception, motion control, data acquisition, production line monitoring, abnormal alarm, and production line status display. It receives process data packets sent by the MES system, parses them, and sends motion control and data acquisition instructions to the production line equipment. It collects process and result data returned by the equipment, monitors the equipment operating status, summarizes abnormal information of the production line and its causes, and dynamically displays the production line status in a graphical form. The logistics system includes AGV vehicles and their scheduling software. The system operates independently and communicates with the MES system via QR code transfer to receive delivery start location, delivery material information, and delivery end location information, thus achieving precise delivery of materials during the turbofan engine assembly process.

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