A coating workshop point replenishment vehicle management and control method

Abstract

The present application belongs to the technical field of vehicle painting production, and particularly relates to a kind of painting workshop point repair vehicle management and control method;Point repair vehicle management and control system receives vehicle point repair signal and obtains vehicle body information, vehicle is painted according to traditional process in painting workshop, when vehicle enters inspection polishing process, point repair vehicle management and control system judges whether vehicle exists the risk of failing to paint according to plan, for risk vehicle, point repair vehicle management and control system controls it to walk according to AGV fast point repair path, for ordinary vehicle, then control vehicle to walk according to the path of traditional process, that is, enter point repair buffer area and wait;The present application painting point repair vehicle management and control method increases a fast AGV process path to point repair interval on the basis of existing, goes to point repair interval through AGV fast path after coming out of inspection polishing line, so that risk vehicle point repair time is reduced.

Description

Technical Field

[0001] This invention belongs to the field of vehicle painting production technology, specifically relating to a method for point-to-point vehicle maintenance and control in a painting workshop. Background Technology

[0002] The traditional spot-touch process in a painting workshop is as follows:

[0003] S1: Body pretreatment → S2: Electrophoresis → S3: Electrophoresis drying → S4: 3D warehouse 2 → S5: Electrophoresis sanding → S6: PVC → S7: Intermediate coat → S8: Intermediate coat drying → S9: 3D warehouse 3 → S10: Intermediate coat sanding → S11: Topcoat → S12: Clear coat → S13: Topcoat drying → S14: 3D warehouse 5 → S15: Inspection and polishing → S15.1: Spot patching buffer area → S15.2: Spot patching area → S16: Final inspection → S17: 3D warehouse 4 → S18: Waxing;

[0004] The traditional control method involves queuing in the replenishment buffer for replenishment. Vehicles wait for an available replenishment room in the S15.1: replenishment buffer area before entering the S15.2: replenishment room for replenishment. The replenishment buffer has a maximum storage capacity of 12 vehicles, with an average inventory occupancy rate of 82%, or 10 vehicles. There are 4 replenishment rooms in the replenishment area, and the average replenishment time in the 4 replenishment rooms is 2 hours. Under this situation, newly arrived vehicles need to wait 20 hours before they can leave the replenishment area. This method will seriously reduce the line cycle time of S16: final inspection. Summary of the Invention

[0005] To overcome the above problems, this invention provides a method for managing vehicle repairs at painting workshops. This method addresses the issue that when vehicles cannot be delivered to final assembly as planned during repairs at the painting manufacturing point, logistics cannot meet the final assembly requirements due to advance material allocation based on the production plan. This necessitates emergency material adjustments, resulting in assembly downtime and efficiency losses.

[0006] A method for controlling spot repairs in a painting workshop includes the following:

[0007] Step 1: The vehicle replenishment management system obtains the real-time location of the vehicle and interacts with the transport PLC and AGV in real time.

[0008] Step 2: The spot repair vehicle control system receives the spot repair signal from the vehicle and obtains the vehicle body information. The vehicle is painted in the painting workshop according to the traditional process. When the vehicle enters the S15: inspection and polishing process, the spot repair vehicle control system determines whether there is a risk that the vehicle will not be painted as planned, and assigns an attribute label to each vehicle according to the judgment result: risk vehicle or ordinary vehicle.

[0009] The risk that vehicles may fail to be painted as planned includes the following two situations:

[0010] 1. The actual total time of all the processes that the vehicle goes through during the traditional painting process, from S1: body pretreatment process to S14: automated warehouse process 5, exceeds the planned total time of the vehicle going through these processes by more than 2 hours.

[0011] 2. The vehicle's sales code in the vehicle information obtained by the vehicle replenishment management system is less than 5;

[0012] Step 3: For high-risk vehicles, the spot-repair vehicle management system controls them to travel along the AGV fast spot-repair path. That is, when they reach the S15: inspection and polishing process according to the traditional process, the spot-repair vehicle management system identifies the empty spot-repair room and assigns the high-risk vehicle to one of the empty spot-repair rooms, directly entering the S15.2: spot-repair process.

[0013] For ordinary vehicles, the vehicle is controlled to travel along the traditional procedure path, i.e., enter S15.1: fill the buffer area and wait.

[0014] In step two, when the vehicle proceeds to step S9: automated warehouse 3 according to the traditional process, the point replenishment vehicle control system controls the order of vehicles leaving the automated warehouse 3 for the next step S10: intermediate grinding. The vehicle order is either to first leave dark-colored vehicles one by one, and then leave light-colored vehicles one by one after all dark-colored vehicles have left the warehouse, or to first leave light-colored vehicles one by one, and then leave dark-colored vehicles one by one after all light-colored vehicles have left the warehouse.

[0015] The vehicle information in step two includes: vehicle model, color, and sales code.

[0016] The traditional process for painting the vehicle is as follows:

[0017] S1: Body pretreatment → S2: Electrophoresis → S3: Electrophoresis drying → S4: 3D warehouse 2 → S5: Electrophoresis sanding → S6: PVC → S7: Intermediate coat → S8: Intermediate coat drying → S9: 3D warehouse 3 → S10: Intermediate coat sanding → S11: Topcoat → S12: Clear coat → S13: Topcoat drying → S14: 3D warehouse 5 → S15: Inspection and polishing → S15.1: Spot patching buffer area → S15.2: Spot patching area → S16: Final inspection → S17: 3D warehouse 4 → S18: Waxing.

[0018] The steps for AGV rapid path completion in step three are as follows:

[0019] S1: Body pretreatment → S2: Electrophoresis → S3: Electrophoresis drying → S4: 3D warehouse 2 → S5: Electrophoresis sanding → S6: PVC → S7: Intermediate coat → S8: Intermediate coat drying → S9: 3D warehouse 3 → S10: Intermediate coat sanding → S11: Topcoat → S12: Clear coat → S13: Topcoat drying → S14: 3D warehouse 5 → S15: Inspection and polishing → S15.2: Spot touch-up → S16: Final inspection → S17: 3D warehouse 4 → S18: Waxing.

[0020] The beneficial effects of this invention are:

[0021] This invention's painting spot repair vehicle management method adds a fast AGV process path to the spot repair room, based on existing methods. After exiting the inspection and polishing line, the vehicle travels via the AGV fast path to the S15.2: spot repair room. This new management method reduces the spot repair time for high-risk vehicles, offering the following advantages over existing management methods:

[0022] 1. This invention adds a fast point-filling path, improving the flexibility of point-filling areas;

[0023] 2. This invention maximizes the improvement of vehicle replenishment time by intelligently allocating fast replenishment routes for special vehicles. The traditional replenishment storage area has a maximum storage capacity of 12 vehicles, with an average inventory occupancy rate of 82%, or 10 vehicles. The replenishment area has 4 replenishment rooms, with an average replenishment time of 2 hours for each room. In this case, newly arrived vehicles need to wait 20 hours to leave the replenishment area. The newly added replenishment route takes an average of 10 minutes from vehicle pickup to delivery to the destination. In addition, the replenishment room takes an average of 2 hours, and the overall time is close to 2 hours. Compared with the traditional method, vehicles can save 10 hours, thus minimizing the vehicle replenishment time.

[0024] 3. This invention intelligently allocates the fast-track remediation path for such vehicles, shortening the time vehicles spend in the remediation area from an average of 10 hours to 2 hours. This minimizes the risk of vehicles not being able to be repainted as planned, allowing the overall repainting time of special vehicles to return to normal and improving the overall repainting fulfillment rate of vehicles.

[0025] 4. This invention reduces energy consumption for vehicles entering the replenishment area; it transforms the average 18 process roller beds that each replenishment vehicle needs to travel into a system where some vehicles only need to travel 8 roller bed paths with the help of AGVs, greatly saving vehicle travel distance and thus saving energy and reducing costs. Attached Figure Description

[0026] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments of the present invention will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the content of the embodiments of the present invention and these drawings without creative effort.

[0027] Figure 1 This is a schematic diagram of the process path of the present invention. Detailed Implementation

[0028] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and not intended to limit it. Furthermore, it should be noted that, for ease of description, the accompanying drawings show only the parts relevant to the present invention, and not all of the structures.

[0029] In the description of this invention, unless otherwise explicitly specified and limited, the terms "connected," "linked," and "fixed" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0030] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can include direct contact between the first and second features, or contact between the first and second features through another feature between them. Furthermore, "above," "over," and "on top" of the second feature includes the first feature directly above or diagonally above the second feature, or simply indicates that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature includes the first feature directly below or diagonally below the second feature, or simply indicates that the first feature is at a lower horizontal level than the second feature.

[0031] In the description of this embodiment, the terms "upper," "lower," "left," and "right," etc., refer to the orientation or positional relationship shown in the accompanying drawings. They are used only for ease of description and simplification of operation, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the present invention. In addition, the terms "first" and "second" are used only for distinction in description and have no special meaning.

[0032] A method for controlling spot repairs in a painting workshop includes the following:

[0033] Step 1: The vehicle replenishment management system obtains the real-time location of the vehicle and interacts with the transport PLC and AGV in real time.

[0034] Step 2: The spot-replenishment vehicle control system receives the manually input vehicle spot-replenishment signal and obtains the vehicle body information. It then controls the vehicle to be painted in the painting workshop according to the traditional process through the mechanical transport PLC and AGV. When the vehicle enters the S15: inspection and polishing process, the spot-replenishment vehicle control system determines whether the vehicle is at risk of failing to be painted as planned, and assigns an attribute label to each vehicle according to the judgment result: risk vehicle or ordinary vehicle.

[0035] The risk that vehicles may fail to be painted as planned includes the following two situations:

[0036] 1. The actual total time of all the processes that the vehicle goes through during the traditional painting process, from S1: body pretreatment process to S14: automated warehouse process 5, exceeds the planned total time of the vehicle going through these processes by more than 2 hours.

[0037] 2. The vehicle's sales code in the vehicle body information obtained by the point-to-point vehicle management system is less than 5; the color of a vehicle with a sales code less than 5 is considered to be a color with a high probability of return for repair, thus posing a risk.

[0038] Step 3: For high-risk vehicles, the spot-repair vehicle management system controls them to travel along the AGV fast spot-repair path. That is, when they reach the S15: inspection and polishing process according to the traditional process, the spot-repair vehicle management system identifies the empty spot-repair room and assigns the high-risk vehicle to one of the empty spot-repair rooms, directly entering the S15.2: spot-repair process.

[0039] For regular vehicles, the system controls them to follow the traditional process path, i.e., entering S15.1: the spot-painting buffer area to wait. This makes vehicle allocation in the spot-painting area more flexible, ensures that high-risk vehicles are painted according to plan, and improves the overall efficiency of painting and dispatching vehicles.

[0040] In step two, when the vehicle proceeds to step S9: automated warehouse 3 according to the traditional process, the point replenishment vehicle control system controls the order of vehicles leaving the automated warehouse 3 for the next step S10: intermediate grinding. The vehicle order is either to first leave dark-colored vehicles one by one, and then leave light-colored vehicles one by one after all dark-colored vehicles have left the warehouse, or to first leave light-colored vehicles one by one, and then leave dark-colored vehicles one by one after all light-colored vehicles have left the warehouse.

[0041] The vehicle information in step two includes: vehicle model, color, and sales code.

[0042] like Figure 1 As shown, the traditional process for painting the vehicle is as follows:

[0043] S1: Body pretreatment → S2: Electrophoresis → S3: Electrophoresis drying → S4: 3D warehouse 2 → S5: Electrophoresis sanding → S6: PVC → S7: Intermediate coat → S8: Intermediate coat drying → S9: 3D warehouse 3 → S10: Intermediate coat sanding → S11: Topcoat → S12: Clear coat → S13: Topcoat drying → S14: 3D warehouse 5 → S15: Inspection and polishing → S15.1: Spot patching buffer area → S15.2: Spot patching area → S16: Final inspection → S17: 3D warehouse 4 → S18: Waxing.

[0044] The steps for AGV rapid path completion in step three are as follows:

[0045] S1: Body pretreatment → S2: Electrophoresis → S3: Electrophoresis drying → S4: 3D warehouse 2 → S5: Electrophoresis sanding → S6: PVC → S7: Intermediate coat → S8: Intermediate coat drying → S9: 3D warehouse 3 → S10: Intermediate coat sanding → S11: Topcoat → S12: Clear coat → S13: Topcoat drying → S14: 3D warehouse 5 → S15: Inspection and polishing → S15.2: Spot touch-up → S16: Final inspection → S17: 3D warehouse 4 → S18: Waxing.

[0046] Example 1

[0047] Point-to-point vehicle dispatch architecture:

[0048] The architecture based on rapid return and scheduling of replenishment vehicles: The replenishment vehicle management system interacts in real time with the transport PLC and AGV to obtain the real-time location of the vehicles. The replenishment vehicle management system identifies whether there is a risk of vehicles falling behind, and then allocates the path that the replenishment vehicle needs to travel and sends it to the execution layer for execution.

[0049] Point-to-point vehicle dispatching logic:

[0050] This method adds a fast AGV replenishment path while retaining the original replenishment path in the workshop. The original replenishment path has an average replenishment time of 5 hours, while the new AGV fast replenishment path has an average replenishment time of 2 hours. Combined with the newly added replenishment vehicle queuing algorithm, the system intelligently determines whether a vehicle has the risk of failing to be painted as scheduled, and assigns an attribute flag to each vehicle to determine whether it is a risk vehicle or a normal vehicle. Risk vehicles are assigned to the AGV fast replenishment channel, while normal vehicles travel along the original replenishment path. This makes vehicle allocation in the replenishment area more flexible, ensures that risk vehicles are painted as scheduled, and improves the overall efficiency of painting and dispatching vehicles. Detailed implementation method:

[0051] 1. Point-to-point vehicle scheduling algorithm:

[0052] 1.1 Historical Data Analysis:

[0053] By analyzing historical data of vehicles requiring on-site repair, the probability and duration of on-site repair for different vehicle colors were summarized. The influence of the order of color on the occurrence of on-site repair was analyzed by combining the relationship between the data. The conclusions are shown in Table 1 below, based on the data analysis of August and September 2022.

[0054] Table 1 shows the probability of rework and average repair time for different colors.

[0055]

[0056] 1.2 Correlation Analysis:

[0057] There is a correlation between the order in which vehicles are painted and the timing of their replacement, often exhibiting a causal relationship. These phenomena can be quantified as variables: the color of the vehicle painted first is the independent variable, denoted by x, which is the cause of subsequent replacements of adjacent vehicles of different colors and is controllable; the color of the vehicle painted later is the dependent variable, denoted by y, which is the result of the influence of adjacent x and is an uncertain value; under linear correlation conditions, the statistical indicator reflecting the degree of linear correlation between the two variables x and y is denoted by r; the relationship between r and x and y is as follows:

[0058]

[0059] Where: x i It is the i-th value of the color x of the vehicle currently being painted, y i : is the i-th value of the color y of the vehicle to be painted later, and n is the number of analyses in the variables x and y;

[0060]

[0061]

[0062]

[0063] The result of r can reflect the correlation between x and y. Generally, |r|>0.95 indicates a significant correlation; 0.8≤|r|<0.95 indicates a high correlation; 0.5≤|r|<0.8 indicates a moderate correlation; 0.3≤|r|<0.5 indicates a low correlation; |r|<0.3 indicates a very weak relationship, considered uncorrelated; r=0 indicates no linear correlation.

[0064] The results of the analysis of the order of colors are shown in Table 2 below:

[0065] Table 2. Correlation between the order of colors of adjacent vehicles

[0066]

[0067]

[0068] Data shows that painting dark-colored cars first and then light-colored cars has a significantly higher correlation, indicating that painting vehicles so close together is more likely to cause painting problems and require rework.

[0069] 1.3 Guidance and Suggestions

[0070] Based on data analysis, the following suggestions are made:

[0071] Using AGV routes to transport vehicles with long repair times can save on repair waiting time.

[0072] For vehicles with a high probability of needing repairs at designated repair points, a priority lane can be set up in the repair waiting area to prioritize repairs, which can reduce the waiting time for other vehicles.

[0073] Guidance and suggestions: Based on correlation analysis, the following guidance and suggestions are provided:

[0074] It is recommended to separate light and dark colored vehicles when they leave the warehouse, and try to avoid sending light-colored vehicles out of the warehouse after black vehicles.

[0075] This method identifies high-risk vehicles and assigns them fast-track repainting routes, reducing the risk of vehicles being unable to complete painting in repainting areas. This improves the overall painting completion rate and significantly reduces final assembly logistics costs.

[0076] The original point-filling storage path required each vehicle to pass through an average of 18 roller beds to reach the point-filling room. The newly added AGV fast point-filling path reduces the average travel distance to 8 roller beds. The design length of a single roller bed is 6m, and the overall travel distance of a single vehicle is shortened by 60m. In terms of annual efficiency, this greatly saves vehicle travel energy consumption and reduces workshop energy consumption costs.

[0077] Example 2

[0078] Research on point-to-point replenishment control is an important way to achieve rapid vehicle return to the queue. Through joint research with the workshop production department, and discussions based on the specific physical location of the workshop and process path planning, it was finally decided to add AGV process paths at the physical level to meet the needs of vehicles that need to jump the queue for point-to-point replenishment. At the control method level, a joint control algorithm for point-to-point replenishment and vehicle return was added to achieve rapid vehicle return to the queue. This fundamentally solves the problem of the overall workshop cycle time being affected by the waiting time of point-to-point replenishment vehicles, as well as the problem of low plan fulfillment rate and overall workshop cost caused by path issues.

[0079] This embodiment uses vehicle TPS number 10065281. When entering the painting workshop, the system identifies the vehicle as having a single attribute and no color with the same configuration for replacement. The system defines this vehicle as a high-risk vehicle. After inspecting the polishing production line, the staff identifies that this vehicle needs spot repair. To avoid affecting the vehicle's painting schedule, the system assigns the vehicle to perform spot repair using the AGV fast path.

[0080] Review Conclusion: Due to its single configuration attribute and the absence of a vehicle with the same configuration for replacement, this vehicle was identified as a high-risk vehicle by the system and assigned an AGV rapid spot repair path. The time from the inspection and polishing line to the spot repair room was 10 minutes, the spot repair itself took 100 minutes, and the time from the spot repair room to the final inspection line was 1 minute, for a total time of 111 minutes. Compared with the traditional spot repair inventory waiting method, this saved 309 minutes. This vehicle significantly reduced the risk of not being able to leave the painting workshop as planned, and the overall process met the original design intention.

[0081] Example 3

[0082] This embodiment uses vehicle PS number 10032532. When entering the painting workshop, the system identifies the vehicle as having multiple attributes and configurations. In case of anomalies, the system can use the same configuration replacement rule to ensure that painting proceeds as planned. Therefore, the system defines this vehicle as a regular vehicle. After inspecting the polishing production line, the staff identifies that this vehicle needs spot repair. The system assigns this vehicle to follow the regular spot repair path.

[0083] Review Conclusion: Because this vehicle has a non-single configuration and there are multiple vehicles with the same configuration in the finished product garage area, and the replacement rules can be executed to meet the painting schedule, the system determined that this vehicle should be assigned the traditional spot-painting path. From the inspection and polishing line to the spot-painting, it took 15 minutes, waiting time was 300 minutes, spot-painting time was 120 minutes, and time from the spot-painting area to the final inspection line was 1 minute, for a total time of 436 minutes. During the entire spot-painting period, the vehicle painting was executed according to the same configuration replacement rules, which met the painting schedule and was consistent with the original design intent.

[0084] The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings. However, the scope of protection of the present invention is not limited to the specific details in the above embodiments. Within the scope of the technical concept of the present invention, any person skilled in the art can make equivalent substitutions or changes based on the technical solution and inventive concept of the present invention within the scope of the technology disclosed in the present invention. These simple modifications are all within the scope of protection of the present invention.

[0085] It should also be noted that the various specific technical features described in the above specific embodiments can be combined in any suitable manner without contradiction. In order to avoid unnecessary repetition, the present invention will not describe the various possible combinations separately.

[0086] Furthermore, various different embodiments of the present invention can be combined in any way, as long as they do not violate the spirit of the present invention, they should also be regarded as the content disclosed by the present invention.

Claims

1. A method for controlling spot repairs in a painting workshop, characterized in that... Includes the following: Step 1: The vehicle replenishment management system obtains the real-time location of the vehicle and interacts with the transport PLC and AGV in real time. Step 2: The spot repair vehicle control system receives the spot repair signal from the vehicle and obtains the vehicle body information. The vehicle is painted in the painting workshop according to the traditional process. When the vehicle enters the S15: inspection and polishing process, the spot repair vehicle control system determines whether there is a risk that the vehicle will not be painted as planned, and assigns an attribute label to each vehicle according to the judgment result: risk vehicle or ordinary vehicle. The risk that vehicles may fail to be painted as planned includes the following two situations:

1. The actual total time of all the processes that the vehicle goes through during the traditional painting process, from S1: body pretreatment process to S14: automated warehouse process 5, exceeds the planned total time of the vehicle going through these processes by more than 2 hours.

2. The vehicle's sales code in the vehicle information obtained by the point-to-point vehicle management system is less than 5; Step 3: For high-risk vehicles, the spot-repair vehicle management system controls them to travel along the AGV fast spot-repair path. That is, when they reach the S15: inspection and polishing process according to the traditional process, the spot-repair vehicle management system identifies the empty spot-repair room and assigns the high-risk vehicle to one of the empty spot-repair rooms, directly entering the S15.2: spot-repair process. For ordinary vehicles, the vehicle is controlled to travel along the traditional process path, that is, to enter S15.1: waiting in the buffer area.

2. The method for controlling spot repairs in a painting workshop according to claim 1, characterized in that... In step two, when the vehicle proceeds to step S9: automated warehouse 3 according to the traditional process, the point replenishment vehicle control system controls the order of vehicles leaving the automated warehouse 3 for the next step S10: intermediate grinding. The vehicle order is either to first leave dark-colored vehicles one by one, and then leave light-colored vehicles one by one after all dark-colored vehicles have left the warehouse, or to first leave light-colored vehicles one by one, and then leave dark-colored vehicles one by one after all light-colored vehicles have left the warehouse.

3. The method for controlling spot repairs in a painting workshop according to claim 1, characterized in that... The vehicle information in step two includes: vehicle model, color, and sales code.

4. The method for controlling spot repairs in a painting workshop according to claim 1, characterized in that... The traditional process for painting the vehicle is as follows: S1: Body Pretreatment → S2: Electrophoresis → S3: Electrophoresis Drying → S4: 3D Grinding 2 → S5: Electrophoresis Sanding → S6: PVC → S7: Intermediate Coat → S8: Intermediate Coat Drying → S9: 3D Grinding 3 → S10: Intermediate Coat Sanding → S11: Topcoat → S12: Topcoat application → S13: Topcoat drying → S14: 3D storage 5 → S15: Inspection and polishing → S15.1: Spot patching buffer area → S15.2: Spot patching area → S16: Final inspection → S17: 3D storage 4 → S18: Waxing.

5. The method for controlling spot repairs in a painting workshop according to claim 1, characterized in that... The steps for AGV rapid path completion in step three are as follows: S1: Body Pretreatment → S2: Electrophoresis → S3: Electrophoresis Drying → S4: 3D Grinding 2 → S5: Electrophoresis Sanding → S6: PVC → S7: Intermediate Coat → S8: Intermediate Coat Drying → S9: 3D Grinding 3 → S10: Intermediate Coat Sanding → S11: Topcoat → S12: Topcoat application → S13: Topcoat drying → S14: 3D warehouse 5 → S15: Inspection and polishing → S15.2: Spot repair → S16: Final inspection → S17: 3D warehouse 4 → S18: Waxing.

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