A method for testing and commissioning a production line by modular intelligent testing and commissioning

Abstract

The application provides a module intelligent test and adjustment method for a test and adjustment production line, belongs to the technical field of flexible simulation module test and adjustment, and solves the limitation problem caused by the traditional technology taking the whole test and adjustment content of a module as an object; a plurality of product modules are sequentially passed through a plurality of test and adjustment areas, and corresponding test and adjustment content is completed in each test and adjustment area; if there is no corresponding test and adjustment requirement, the product module does not enter the test and adjustment area; the test and adjustment area includes a debugging preparation area, a normal temperature debugging area, an environment debugging area, a vibration debugging area and a laboratory debugging area; each test and adjustment area includes a plurality of test and adjustment stations with same or different test instruments and tools; the product module is tested and adjusted on the idle test and adjustment station according to the test and adjustment requirement of the product module in the current test and adjustment area; and the product module enters the next test and adjustment area after the test and adjustment process is completed; the application can meet the sudden large-quantity module product test and adjustment task requirement in a short period by taking a signal and function construction workstation production line.

Description

Technical Field

[0001] This invention belongs to the field of flexible simulation module debugging and testing technology, and is applied to the production testing process of electronic product modules. Specifically, it is a debugging and production method for intelligent module debugging and production line. Background Technology

[0002] With the development of information technology, the types and functions of electronic product modules are becoming increasingly complex, and their integration level is increasing. Therefore, the debugging and testing process has become a key part of the production process for these products. At the same time, due to the increasing production volume of electronic product modules year by year, the existing debugging and testing methods are no longer able to meet the capacity demand, resulting in an inefficient debugging and testing sub-production process.

[0003] In existing technologies, due to the large variety of electronic product modules, each with its unique debugging and testing requirements and associated testing instruments, significant inconvenience arises in the management and efficiency of the debugging process. The lack of universal process methods prevents the parallel debugging and production of various types of electronic product modules under a single, complete testing resource, and also hinders the simultaneous debugging of multiple quantities of the same type of electronic product module. When faced with sudden surges in production and debugging tasks within a short period, existing methods fail to respond to and meet the demands, severely impacting the production and delivery efficiency of electronic product modules.

[0004] Changing the commissioning and production allocation method by simply piling up resources and building production line environments would incur high costs. Therefore, it is necessary to fully explore and rationally utilize existing commissioning resources, and replace them with new, flexible, and digital commissioning and production allocation methods to increase production line capacity and meet the ever-growing task demands. Thus, designing efficient commissioning and production allocation methods that can adapt to the commissioning of multiple types and large quantities of modules has become a key research focus for those skilled in the art. Summary of the Invention

[0005] This invention changes the concept of commissioning and testing production separation method, changing from the approach of establishing separate production lines for each module product to a production line construction approach using signals and functions as workstations. This brings about a brand-new intelligent commissioning and testing production separation method for modules. This method can enable parallel production and commissioning of the same type of module products, as well as simultaneous production and commissioning of multiple types of module products. Therefore, it can meet the demand for large-volume production and commissioning of module products in a short period of time, and enable the production line to have the excellent characteristics of automation, informatization and reduced manpower.

[0006] The present invention employs the following technical solutions to achieve its objective:

[0007] A module intelligent debugging and production line debugging and distribution method involves passing multiple product modules waiting to be debugged through multiple debugging areas in sequence, completing the corresponding debugging content in each debugging area, and not allowing product modules without corresponding debugging needs to enter the corresponding debugging area.

[0008] The testing area includes a testing preparation area, a normal temperature testing area, an environmental testing area, a vibration testing area, and a laboratory testing area. Each testing area includes multiple testing stations, and different testing stations have the same or different testing instruments and tools.

[0009] The intelligent commissioning and testing production control area is responsible for managing and monitoring the commissioning process of each product module in different areas, enabling multiple product modules to enter the same or different commissioning areas at the same time. When a product module enters a commissioning area, it performs the commissioning process at an idle commissioning station equipped with the corresponding testing instruments and tools, based on its own commissioning needs in the current commissioning area. After the commissioning process is completed, it leaves the current commissioning area and enters the next commissioning area. The above process is repeated until all commissioning content of the corresponding product module is completed, and the commissioning process ends.

[0010] Furthermore, before the product modules are commissioned and distributed for production, they are stored in the material warehouse. When the commissioning process begins, the production control area sends the production commissioning task to the input / output terminal of the commissioning preparation area, and at the same time submits a material transportation request to the logistics scheduling system. After receiving the material transportation request, the logistics scheduling system sends the AGV to the material warehouse, loads the multiple product modules waiting for commissioning, and then transports them to the commissioning preparation area, where they are installed with commissioning fixtures and clamped to begin the subsequent commissioning process.

[0011] Specifically, once all the debugging and testing of a product module is completed, the product module leaves the current debugging and testing area and re-enters the debugging preparation area to disassemble and clamp the debugging fixtures; the AGV carts of the logistics scheduling system will load multiple product modules that have completed the debugging and testing process and transport them to the finished product warehouse.

[0012] Furthermore, the debugging preparation area includes multiple preparation stations where product modules awaiting debugging undergo module checks and clamping processes. After this process is completed, the product modules are transported by AGV vehicles to the ambient temperature debugging area for debugging.

[0013] Furthermore, the ambient temperature testing area includes multiple linearly arranged test stations, and is equipped with a line-side warehouse and a circulating conveyor belt. AGVs transport product modules that have completed preparation in the testing preparation area and temporarily store them in the line-side warehouse. The reciprocating direction of the circulating conveyor belt is the same as the linear arrangement direction of the test stations. The circulating conveyor belt transports product modules from the line-side warehouse to each test station, where an automatic clamping and fitting station completes the loading and unloading of the product modules. Product modules that have completed ambient temperature testing are transported back to the line-side warehouse via the circulating conveyor belt, and then transported out of the ambient temperature testing area by AGVs to perform the remaining testing in other areas.

[0014] Furthermore, after the product module passes the room temperature test at the test station in the room temperature debugging area, it is transported by AGV to the temporary storage rack in the environmental debugging area. The environmental debugging area has multiple environmental testing / aging stations and is equipped with multiple temperature chambers. After the product module is taken out of the temporary storage rack, it undergoes high and low temperature baseline testing and temperature cycling testing through the temperature chambers. After the high and low temperature baseline testing and temperature cycling testing are completed, the product module continues to enter the vibration debugging area and the laboratory debugging area to complete the remaining debugging and testing.

[0015] Furthermore, if the product module fails to meet the testing requirements in the ambient temperature testing area, vibration testing area, or laboratory testing area, the AGV cart of the logistics scheduling system will transport the product module to the testing preparation area. At the testing station in the testing preparation area, the adapter of the product module will be disassembled and reassembled, and then it will flow into the troubleshooting station in the testing preparation area for troubleshooting.

[0016] Preferably, the product modules are used in different areas and the flow and operation of content within these areas are as follows: multiple testing stations in the testing preparation area are operated manually, and the corresponding logistics method is intelligent production line logistics, which is achieved by AGV cart transportation controlled by the logistics scheduling system; the working mode of the ambient temperature testing area is automatic, and the logistics method is also intelligent production line logistics.

[0017] Specifically, the working modes of the environmental testing area, vibration testing area, laboratory testing area, material warehouse, and finished product warehouse are all manual; the logistics method of the vibration testing area and laboratory testing area is manual transportation, while the logistics method of the material warehouse and finished product warehouse is intelligent production line logistics; the logistics method of the environmental testing area is a combination of manual transportation and intelligent production line logistics.

[0018] Furthermore, the test chamber debugging area includes multiple environmental testing stations and is equipped with multiple temperature chambers. High and low temperature operation debugging tests are conducted on the product modules at the environmental testing stations in the test chamber debugging area. The vibration debugging area has multiple vibration stations, each of which is equipped with a vibration table. Stress screening vibration debugging tests are conducted on the product modules on the vibration tables of the vibration stations.

[0019] In summary, due to the adoption of this technical solution, the beneficial effects of this invention are as follows:

[0020] The method of this invention can adapt to the current situation of diverse production models, small batches, and significant differences in external interfaces between products when debugging product modules. It also fully utilizes existing human and instrument resources and production environment conditions, changing the process of building production lines for individual products to a model of building production lines based on signals / functions as workstations and different testing areas. Therefore, this invention can achieve parallel production of multiple sets of the same type of product, as well as simultaneous production of multiple types of products, meeting the needs of sudden large-volume tasks in a short period, enabling rapid response to emergency tasks, and equipping production lines with automation, intelligence, and reduced manpower capabilities. Moreover, when a new product with similar signals / functions is transferred to mass production, only simple adapter racks and product-specific testing instruments need to be added, and the product can be quickly integrated into the flexible production line for production, reducing the investment in the testing environment and greatly alleviating the management and personnel cost pressures brought about by increased production volume. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the process flow for the commissioning and production process of the method of the present invention;

[0022] Figure 2 A schematic diagram of the process flow for the product module;

[0023] Figure 3 This is a schematic diagram showing the specific process information for the product module. Detailed Implementation

[0024] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations.

[0025] Therefore, the following detailed description of the embodiments of the invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the invention without inventive effort are within the scope of protection of the invention.

[0026] Please also refer to Figure 1The process flow diagram illustrates that this embodiment provides a module intelligent debugging and production line debugging and distribution method. The core idea of ​​the method is to sequentially pass multiple product modules waiting for debugging through multiple debugging areas, complete the corresponding debugging content in each debugging area, and if there is no corresponding debugging requirement for a product module, it will not enter the corresponding debugging area.

[0027] The testing area includes a testing preparation area, a normal temperature testing area, an environmental testing area, a vibration testing area, and a laboratory testing area. Each testing area includes multiple testing stations, with the same or different testing instruments and tools at different testing stations.

[0028] The intelligent commissioning and testing production control area is responsible for managing and monitoring the commissioning process of each product module in different areas, enabling multiple product modules to enter the same or different commissioning areas at the same time. When a product module enters a commissioning area, it performs the commissioning process at an idle commissioning station equipped with the corresponding testing instruments and tools, based on its own commissioning needs in the current commissioning area. After the commissioning process is completed, it leaves the current commissioning area and enters the next commissioning area. The above process is repeated until all commissioning content of the corresponding product module is completed, and the commissioning process ends.

[0029] In this embodiment, as Figure 1 As shown, after the input / output terminal in the debugging preparation area receives the production task issued by the production control area of ​​the intelligent debugging sub-production line, it will first apply to the logistics scheduling system for AGV carts for material transportation. After receiving the command from the logistics scheduling system, the AGV carts will go directly to the material warehouse to transport materials. After the AGV carts arrive at the material warehouse and the material handler completes the loading, the control terminal at the warehouse will request the AGV carts to transport the product modules to the debugging preparation area.

[0030] After the product modules are shipped from the material warehouse, they first enter the debugging preparation area to perform module inspection and clamping processes. After completion, they flow into the ambient temperature debugging area. Each batch of product modules passes through three test stations in the ambient temperature debugging area in sequence to complete the debugging content. Finally, they are loaded into AGV carts and transported to the environmental debugging area, vibration debugging area and laboratory debugging area for subsequent debugging processes.

[0031] In this embodiment, the ambient temperature testing area includes multiple linearly arranged test stations, along with a line-side warehouse and a circulating conveyor belt. AGVs transport product modules that have completed preparation in the testing preparation area and temporarily store them in the line-side warehouse. The circulating conveyor belt travels in the same direction as the linear arrangement of the test stations, transporting product modules from the line-side warehouse to each test station. The automatic clamping and fitting station at the corresponding test station handles the loading and unloading of the product modules. Product modules that have completed ambient temperature testing are transported back to the line-side warehouse via the circulating conveyor belt and then transported away from the ambient temperature testing area by AGVs for further testing in other areas.

[0032] AGVs are the main transport vehicles for moving product modules between various testing areas. Figure 1 As illustrated, the ambient temperature debugging area in this embodiment can be configured with two AGV carts. One AGV cart is used to ensure the normal loading of materials to the three test stations corresponding to the line-side warehouse; the other AGV cart is used for the unloading process from the line-side warehouse after the product module test is completed. Regardless of whether the product module test in the ambient temperature debugging area is qualified, the AGV cart responsible for unloading will send it to the next area it should go to.

[0033] In this embodiment, if the product module fails to meet the testing requirements in any area, the AGV vehicle of the logistics scheduling system will transport the product module to the debugging preparation area. The adapter of the product module will be disassembled and reassembled at the debugging station in the debugging preparation area, and then flow into the troubleshooting station in the debugging preparation area for troubleshooting.

[0034] In this embodiment, after the testing in the ambient temperature testing area is deemed satisfactory, the product module will be transported to the environmental testing area by an AGV. There, at the environmental testing / aging station, a series of testing tasks will be completed, including high and low temperature baseline testing, temperature cycling testing, and electrical aging. After the testing is completed, the product module will continue to operate according to... Figure 1 The process numbering indicates that the process flows and is tested between different areas until all testing tasks are completed and the product enters the finished goods warehouse.

[0035] In this embodiment, the intelligent workstation test station in the ambient temperature debugging area performs procedures such as ambient temperature debugging, self-testing, and military inspection. The environmental debugging area's environmental testing / aging station performs procedures such as aging, continuous operation, and high and low temperature testing. The laboratory debugging area also has an environmental testing station equipped with a corresponding temperature chamber for performing temperature operation tests.

[0036] Table 1 below shows the working modes and corresponding logistics methods of each area in the testing area used in this embodiment.

[0037] Table 1: Correspondence between working modes and logistics methods for different areas of the production line

[0038] Serial Number Work area Work mode Logistics methods 1 Debugging preparation area Manual mode Intelligent logistics on production lines 2 room temperature test area Automatic mode Intelligent logistics on production lines 3 Environmental testing area Manual mode Combining intelligent logistics and manual transportation on the production line 4 Vibration test area Manual mode manual transport 5 Laboratory debugging area Manual mode manual transport 6 Material warehouse, finished goods warehouse Manual mode Intelligent logistics on production lines

[0039] Taking the receiver module XXX-2 of a certain type of electronic device as an example, after optimizing its debugging process using the method of this embodiment, the optimal quantity is 20 units. The flowchart of its process steps is as follows. Figure 2 As shown.

[0040] Figure 2 In the figure, the buildings where the production lines are located involve different testing areas in the method of this embodiment. Building No. 37 in the location column is the building where the testing preparation area, the ambient temperature testing area and the environmental testing area are located, Building No. 24 is the building where the vibration testing area is located, and Building No. 32 is the building where the laboratory testing area is located.

[0041] Figure 3 This provides detailed schematic diagrams of the method in this embodiment at each process step, which can be synchronously applied. Figure 1 and Figure 2 See below for a detailed explanation of the working mode and time consumption of the method in this embodiment at each process step.

[0042] When the method of this embodiment is adopted, the concept of product module commissioning will be greatly different from the original concept. The original commissioning process involved receiving a product module and completing all testing tasks at a single workstation using various testing instruments and tools, i.e., establishing a multi-workstation production line based on the product module. In contrast, this embodiment changes to a production line model that uses signals / functions as workstations and different commissioning areas to build the production line. Therefore, this embodiment enables parallel production of multiple sets of the same type of product, and also allows for the simultaneous production of multiple types of products. It can meet the demand for large-volume tasks in a short period of time, achieve rapid response to emergency tasks, and enable the production line to be automated, intelligent, and have reduced manpower capabilities. It also provides greater convenience and higher efficiency in the standardization and management of the commissioning process, avoiding the chaos and disorder of the original commissioning method.

Claims

1. A method for adjusting and distributing production on a modular intelligent adjustment and distribution production line, characterized in that: Multiple product modules awaiting testing will be passed through multiple testing areas in sequence, and the corresponding testing content will be completed in each testing area. If a product module does not have a corresponding testing requirement, it will not enter the corresponding testing area. The testing area includes a testing preparation area, a normal temperature testing area, an environmental testing area, a vibration testing area, and a laboratory testing area. Each testing area includes multiple testing stations, and different testing stations have the same or different testing instruments and tools. The intelligent commissioning and testing production control area is responsible for the management and monitoring of the commissioning process of each product module in different areas, enabling multiple product modules to enter the same or different commissioning areas at the same time. When a product module enters a commissioning area, it performs the commissioning process at an idle commissioning station equipped with the corresponding testing instruments and tools, based on its own commissioning needs in the current commissioning area. After the commissioning process is completed, it leaves the current commissioning area and enters the next commissioning area. The above process is repeated until all the commissioning content of the corresponding product module is completed, and the commissioning process ends. Before the product modules are debugged and distributed for production, they are stored in the material warehouse. When the debugging process begins, the production control area sends the production debugging task to the input / output terminal of the debugging preparation area, and at the same time submits a material transportation request to the logistics scheduling system. After receiving the material transportation request, the logistics scheduling system sends the AGV to the material warehouse, loads the multiple product modules waiting for debugging, and then transports them to the debugging preparation area, where the debugging fixtures are installed and clamped to begin the subsequent debugging process. The ambient temperature testing area includes multiple linearly arranged test stations, and is equipped with a line-side warehouse and a circulating conveyor belt. AGVs transport product modules that have completed preparation in the testing preparation area and temporarily store them in the line-side warehouse. The circulating conveyor belt travels in the same direction as the linear arrangement of the test stations, transporting product modules from the line-side warehouse to each test station. The automatic clamping and fitting station at the corresponding test station handles the loading and unloading of the product modules. Product modules that have completed ambient temperature testing are transported back to the line-side warehouse via the circulating conveyor belt, and then transported out of the ambient temperature testing area by AGVs to perform the remaining testing in other areas. The product modules and their flow and operation between different areas are as follows: In the debugging preparation area, multiple debugging stations are operated manually, and the corresponding logistics method is intelligent production line logistics, which is achieved by AGV cart transportation controlled by the logistics scheduling system; The working mode of the ambient temperature debugging area is automatic, and the logistics method is also intelligent production line logistics. The environmental testing area, vibration testing area, laboratory testing area, material warehouse, and finished product warehouse all operate in a manual mode. The logistics in the vibration testing area and laboratory testing area are manually transported, while the logistics in the material warehouse and finished product warehouse are intelligent production line logistics. The logistics in the environmental testing area is a combination of manual transport and intelligent production line logistics.

2. The method for adjusting and distributing production on a modular intelligent adjustment and distribution production line according to claim 1, characterized in that: Once all the debugging and testing of a product module is completed, the product module leaves its current debugging area and re-enters the debugging preparation area to disassemble and clamp the debugging fixtures. The AGV carts of the logistics scheduling system will load multiple product modules that have completed the debugging and testing process and transport them to the finished product warehouse.

3. The method for adjusting and distributing production on a modular intelligent adjustment and distribution production line according to claim 1, characterized in that: The debugging preparation area includes multiple preparation stations. Product modules awaiting debugging undergo module inspection and clamping processes at these stations. After this process is completed, the product modules are transported by AGV vehicles to the ambient temperature debugging area for debugging.

4. The method for adjusting and distributing production on a modular intelligent adjustment and distribution production line according to claim 1, characterized in that: After the product module passes the room temperature test at the test station in the room temperature debugging area, it is transported by AGV to the temporary storage rack in the environmental debugging area. The environmental debugging area has multiple environmental testing / aging stations and multiple temperature chambers. After the product module is taken out of the temporary storage rack, it undergoes high and low temperature baseline testing and temperature cycling testing in the temperature chamber. After the high and low temperature baseline testing and temperature cycling testing are completed, the product module continues to enter the vibration debugging area and the laboratory debugging area to complete the remaining debugging and testing.

5. The method for adjusting and distributing production on a modular intelligent adjustment and distribution production line according to claim 4, characterized in that: If the product module fails to meet the testing requirements in the ambient temperature testing area, vibration testing area, or laboratory testing area, the AGV cart of the logistics scheduling system will transport the product module to the testing preparation area. At the testing station in the testing preparation area, the adapter of the product module will be disassembled and reassembled, and then it will flow into the troubleshooting station in the testing preparation area for troubleshooting.

6. The method for adjusting and distributing production on a modular intelligent adjustment and distribution production line according to claim 1, characterized in that: The laboratory debugging area includes multiple environmental testing stations and is equipped with multiple temperature chambers. High and low temperature operation debugging tests are conducted on the product modules at the environmental testing stations in the laboratory debugging area. The vibration debugging area has multiple vibration stations, each with a corresponding vibration table. Stress screening vibration debugging tests are conducted on the product modules on the vibration tables at the vibration stations.

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