A system for optimizing the tempo of an automobile production process

Abstract

The application belongs to the technical field of automobile manufacturing, and discloses a kind of automobile production process beat optimization system, and MES system produces according to product order, material resources and production capacity and determines the vehicle body number of vehicle, the numerical value of the vehicle body number of the vehicle with early production time is less than the vehicle body number of the vehicle with late production time, and production scheduling information enters AVI system, AVI system executes production activity according to plan, and AVI system is provided with automatic storage or withdrawal according to production plan in warehouse area;The warehouse area includes identification input area, a plurality of storage channels, sequencing channel, quick return channel, transfer machine and withdrawal deletion area;The above technical scheme is used, and the vehicles with close production sequence are stored in different storage channels, and the withdrawal is more smooth, even if the production is adjusted, the number of vehicles in the lane is limited, the adjustment is more rapid, and the production sequence of the vehicle not stored in the warehouse is also provided with quick return channel, so that the production is more rapid, and the production process is more smooth.

Description

Technical Field

[0001] This invention belongs to the field of automobile manufacturing technology, specifically, it relates to an automobile production process cycle optimization system. Background Technology

[0002] As competition intensifies in the automotive market, the variety of vehicles increases, and the pace of vehicle updates accelerates. Throughout the entire lifecycle of automobile production, in order to quickly meet market demands and rapidly capture market share, some automakers are maximizing the potential of their existing production lines, aiming to achieve maximum capacity with minimal cost and time. For assembly lines, cycle time is a crucial indicator of production capacity. Cycle time, also known as customer demand cycle or production interval, refers to the ratio of total effective production time to customer demand within a given timeframe; it represents the necessary market time for a customer to obtain a single product.

[0003] Researching ways to improve production line cycle time is crucial for reducing manufacturing costs and enhancing enterprise competitiveness. Among the four major processes in automobile manufacturing, the body production system is more rigid than the painting and final assembly systems. A body production line typically consists of welding sub-lines for the engine compartment, front body, side panels, floor, and roof, as well as the main welding assembly line. It involves complex manufacturing processes, numerous pieces of equipment, frequent model changes, and relatively low production efficiency. From the perspective of body manufacturing processes, the cycle time of a body production line is affected by several factors: production line design, equipment capacity, materials, and personnel operation.

[0004] Among these factors, reasonable production scheduling and smooth production according to plan have the greatest impact on cycle time. In particular, when measurements are stored in the warehouse area, the inability to quickly and effectively carry out outbound operations has a significant impact on the smoothness of production. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide an automobile production process cycle optimization system, which makes vehicle departure from the warehouse smoother by rationally arranging the vehicle layout in the warehouse area.

[0006] To solve the above-mentioned technical problems, the present invention provides the following technical solution: An automobile production process cycle optimization system includes an AVI system and a MES system. The MES system schedules vehicle production and determines the vehicle identification number (VIN) based on product orders, material resources, and production capacity. Vehicles with earlier production times have VINs with lower values ​​than those with later production times. The production scheduling information is entered into the AVI system, which executes production activities according to the plan. The AVI system has an automatic inbound / outbound program set up in the warehouse area according to the production plan. The warehouse area includes an identification and input area, several storage channels, a sequencing channel, a fast return channel, a transfer machine, and an outbound deletion area, and can perform the following operations: Separation: The identification and input area identifies the vehicle identification number of the vehicle entering the warehouse and inputs the vehicle information into the warehouse area. The vehicle identification number of the vehicle entering the warehouse is compared with the vehicle identification number of the next vehicle leaving the warehouse in the AVI system. If the vehicle identification number of the vehicle entering the warehouse is greater than the vehicle identification number of the vehicle leaving the warehouse, the vehicle entering the warehouse enters the storage lane; if the vehicle identification number of the vehicle entering the warehouse is less than or equal to the vehicle identification number of the vehicle leaving the warehouse, the vehicle entering the warehouse enters the fast return lane. Inbound: The AVI system calculates the vehicle number of the vehicle entering the storage lane by dividing it by the number of storage lanes, takes the remainder of the result and adds 1 to obtain the lane number of the storage lane the vehicle needs to enter, and the vehicle is moved into the storage lane by the transfer machine. Outbound: The AVI system queries the storage lane number of the vehicle to be outbound in the inbound record. The transfer machine moves to that lane and identifies the vehicle's vehicle number of the first vehicle closest to the transfer machine in the storage lane. If the vehicle's vehicle number is equal to that of the vehicle to be outbound, the vehicle is placed into the sequence lane by the transfer machine. If the vehicle's vehicle number is greater than or less than that of the vehicle to be outbound, the vehicle is placed into the fast return lane by the transfer machine. Vehicles in the sequence lane enter the outbound deletion area, and the AVI system deletes the vehicle's information from the storage area. Merging: The AVI system detects a vehicle entering the fast return lane and compares the vehicle number of the vehicle in the fast return lane with the vehicle number of the next vehicle to leave the warehouse. If the vehicle number of the vehicle in the fast return lane is less than the vehicle number of the vehicle leaving the warehouse, the vehicle in the fast return lane leaves the warehouse; if the vehicle number of the vehicle in the fast return lane is greater than the vehicle number of the vehicle leaving the warehouse, the vehicle leaving the warehouse continues to leave the warehouse.

[0007] The following are further optimizations of the above technical solution by the present invention: The storage area includes six storage channels. The sequencing channel, storage channel, and fast return channel are all arranged horizontally from left to right. The order of the channels in the storage area is sequencing channel, first storage channel, second storage channel, third storage channel, fast return channel, fourth storage channel, fifth storage channel, and sixth storage channel.

[0008] Further optimization: The identification and input area is located on the right side of the warehouse area, and an inbound transfer machine is set on the left side of the identification and input area to move vehicles in the identification and input area into the storage lane or the fast return lane; an outbound transfer machine is set on the left side of the warehouse area to move vehicles out of the storage lane or the fast return lane, and the outbound transfer machine is equipped with a vehicle body number recognition device.

[0009] Further optimization: The identification and input area can accommodate two vehicles entering at the same time. Two inbound transfer machines are set on the left side of the identification and input area, and two outbound transfer machines are set on the left side of the warehouse area. A pause area is set on the left side of the warehouse area. Vehicles on the outbound transfer machines can be moved into the pause area. A sequence transfer machine is set on the left side of the pause area. The sequence transfer machine can move vehicles in the pause area into the sequence lane.

[0010] Further optimization: The AVI system is an automatic identification system that can record and monitor vehicle production information and complete automatic production tasks based on the collected information.

[0011] Further optimization: The MES system is a production execution system that contains product orders, process routes, operations, material resources, and capacity information. The system can automatically sort vehicle production based on its internal information.

[0012] The present invention adopts the above-mentioned technical solution to store vehicles with similar production sequences in different storage lanes, making the outbound process smoother. Even if production is adjusted, the number of vehicles stuck in the lane is limited, and the adjustment is faster. For vehicles whose production sequence has been adjusted but have not yet entered the warehouse, a fast return lane is also set up to allow them to enter production more quickly. In conjunction with the AVI system and MES system, the production cycle is improved, making the production process smoother.

[0013] The present invention will be further described below with reference to the accompanying drawings and embodiments. Attached Figure Description

[0014] Figure 1 This is a schematic diagram of the structure of the library area in a specific embodiment of the present invention; Figure 2 This is a flowchart illustrating the production scheduling process in a specific embodiment of the present invention; Figure 3 This is a flowchart illustrating the process of vehicle entry into the storage area according to a specific embodiment of the present invention; Figure 4 This is a flowchart illustrating the vehicle entry process into the warehouse area according to a specific embodiment of the present invention. Figure 5 This is a flowchart illustrating the vehicle exit process according to a specific embodiment of the present invention.

[0015] In the diagram: 1- Warehouse area; 2- Identification and input area; 3- Inbound transfer machine; 4- Sequencing channel; 41- Sequencing transfer machine; 51- First storage channel; 52- Second storage channel; 53- Third storage channel; 54- Fourth storage channel; 55- Fifth storage channel; 56- Sixth storage channel; 6- Quick return channel; 7- Outbound transfer machine; 8- Outbound deletion area; 9- Pause area. Detailed Implementation

[0016] like Figure 1-5As shown, an automobile production process cycle optimization system includes an AVI system and a MES system. The MES system schedules vehicle production based on product orders, material resources, and production capacity, determining the vehicle identification number (VIN). Vehicles with earlier production times have VINs with lower values ​​than those with later production times. The production scheduling information is entered into the AVI system, which executes production activities according to the plan. The AVI system has an automatic inbound / outbound program in the warehouse area, based on the production plan. The warehouse area includes an identification and input area, several storage channels, a sequencing channel, a fast return channel, a transfer machine, and an outbound deletion area, and can perform the following operations: Separation: The identification and input area identifies the vehicle identification number of the vehicle entering the warehouse and inputs the vehicle information into the warehouse area. The vehicle identification number of the vehicle entering the warehouse is compared with the vehicle identification number of the next vehicle leaving the warehouse in the AVI system. If the vehicle identification number of the vehicle entering the warehouse is greater than the vehicle identification number of the vehicle leaving the warehouse, the vehicle entering the warehouse enters the storage lane; if the vehicle identification number of the vehicle entering the warehouse is less than or equal to the vehicle identification number of the vehicle leaving the warehouse, the vehicle entering the warehouse enters the fast return lane. Inbound: The AVI system calculates the vehicle number of the vehicle entering the storage lane by dividing it by the number of storage lanes, takes the remainder of the result and adds 1 to obtain the lane number of the storage lane the vehicle needs to enter, and the vehicle is moved into the storage lane by the transfer machine. Outbound: The AVI system queries the storage lane number of the vehicle to be outbound in the inbound record. The transfer machine moves to that lane and identifies the vehicle's vehicle number of the first vehicle closest to the transfer machine in the storage lane. If the vehicle's vehicle number is equal to that of the vehicle to be outbound, the vehicle is placed into the sequence lane by the transfer machine. If the vehicle's vehicle number is greater than or less than that of the vehicle to be outbound, the vehicle is placed into the fast return lane by the transfer machine. Vehicles in the sequence lane enter the outbound deletion area, and the AVI system deletes the vehicle's information from the storage area. Merging: The AVI system detects a vehicle entering the fast return lane and compares the vehicle number of the vehicle in the fast return lane with the vehicle number of the next vehicle to leave the warehouse. If the vehicle number of the vehicle in the fast return lane is less than the vehicle number of the vehicle leaving the warehouse, the vehicle in the fast return lane leaves the warehouse; if the vehicle number of the vehicle in the fast return lane is greater than the vehicle number of the vehicle leaving the warehouse, the vehicle leaving the warehouse continues to leave the warehouse.

[0017] The storage area includes six storage channels. The sequencing channel, storage channel, and fast return channel are all arranged horizontally from left to right. The order of the channels in the storage area is sequencing channel, first storage channel, second storage channel, third storage channel, fast return channel, fourth storage channel, fifth storage channel, and sixth storage channel.

[0018] When there are six storage lanes, the vehicle number is divided by six. If the remainder is 0, the vehicle enters the first storage lane; if the remainder is 1, the vehicle enters the second storage lane, and so on.

[0019] The identification and input area is located on the right side of the warehouse area. On the left side of the identification and input area, there is an inbound transfer machine that can move vehicles in the identification and input area into the storage lane or the fast return lane. On the left side of the warehouse area, there is an outbound transfer machine that can move vehicles out of the storage lane or the fast return lane. The outbound transfer machine is equipped with a vehicle number recognition device.

[0020] After the vehicle identification number is read by the outbound transfer machine, the information is transmitted to the AVI system for comparison to determine whether the vehicle has left the warehouse.

[0021] The identification and input area can accommodate two vehicles entering at the same time. Two inbound transfer machines are set on the left side of the identification and input area, and two outbound transfer machines are set on the left side of the warehouse area. A pause area is set on the left side of the warehouse area. Vehicles on the outbound transfer machines can be moved into the pause area. A sequence transfer machine is set on the left side of the pause area. The sequence transfer machine can move vehicles in the pause area into the sequence lane.

[0022] The AVI system is an automatic identification system that can record and monitor vehicle production information and complete automatic production tasks based on the collected information.

[0023] The MES system is a production execution system. It contains product orders, process routes, operations, material resources, and capacity information. The system can automatically sort vehicle production based on its internal information.

[0024] This optimization system is a tool for short-term prioritization of production plans. It plans production based on completion time, process flow, order quantity, and bill of materials, and is also affected by production line data, personnel attendance, and equipment status. The bill of materials not only includes inventory status but also needs to be adjusted according to raw material procurement and delivery dates. Changes in any of the above data will affect the production plan. When changes occur, the optimization system can adjust the production plan in real time, optimize the production sequence, and improve production efficiency.

[0025] The so-called production cycle, also known as customer demand cycle or production interval time, refers to the ratio of the total effective production time to the quantity of customer demand within a certain time period. It is the market-necessary time for a customer to demand a product.

[0026] This optimization system has a production scheduling function. By acquiring basic data such as product orders, material resources, and capacity, as well as constraints such as planning strategies from the MES system, it prioritizes the production of vehicles with complete materials in the production order. Order plans and resource load status, including materials, logistics, workshop energy, and personnel, can be queried via computer or mobile phone, and manual adjustment of plans is supported.

[0027] When the production line operates smoothly, equipment is fault-free, and product parts are complete, the production line reaches the predetermined cycle time, and the plan does not need to be adjusted. When situations affecting production occur, such as equipment failure or staff absence, the optimization system obtains the downtime, calculates the cycle time for the remaining working time based on the day's plan and current production quantity, and thus achieves flexible cycle time production requirements. When there are problems with parts resources, such as a shortage of parts for a production vehicle, the vehicle with the shortage is automatically moved to the shortage group, and subsequent vehicles are put into production ahead of schedule. Once the parts arrive, the vehicle with the shortage will be produced first.

[0028] This optimization system includes an AVI system, which tracks and records vehicles entering the workshop, providing basic vehicle data for operators and conveying equipment within the workshop. This enables the automated production process to complete smoothly, assists the workshop in managing the production process, and transmits vehicle information in real time to the AVI monitoring computer system in the central control room, allowing production managers to monitor and schedule production status at any time.

[0029] During vehicle production, the system provides body information and production process monitoring: querying body information for welding, painting, and final assembly; real-time monitoring of the AVI system, graphically displaying the system's configuration and operation; storing body point information for a certain period in the AVI system server; communicating with workshop robots and transportation systems to provide them with body and routing data, enabling automatic body routing selection. Areas requiring routing calculation include, but are not limited to: the WBS area in the welding workshop, the electrophoresis drying and storage area, adhesive drying and storage area, topcoat drying and storage area, minor repair storage area, delivery buffer area, and the PBS area in the final assembly workshop; the entrance to the WBS area in the welding workshop must have the function of allowing vehicles to enter according to the production plan, and the exit must have the function of allowing vehicles to leave according to the production plan; the painting workshop must have an accuracy adjustment function; and the exit of the PBS area in the final assembly workshop must have the function of allowing vehicles to leave according to the production plan.

[0030] The AVI system can also monitor the condition of the vehicle body and carrier in the workshop, perform statistics and queries on production information reports, control the priority and restrictions of storage lines, and provide accurate and real-time vehicle information for multiple systems on the production line.

[0031] During the production process, setting up 6 storage lanes helps to disperse vehicles with similar production times. Under normal circumstances, vehicles need to enter the storage lanes, and two inbound transfer machines are responsible for the storage lanes on both sides of the fast return lane, which improves the efficiency of inbound work.

[0032] There are two scenarios for the fast return lane. One scenario is that the production sequence of vehicles that have not yet entered the warehouse is advanced. In this case, after identification in the identification and recording area, the vehicle directly enters the fast return lane, and the next time it leaves the warehouse, the vehicle directly enters the next production process. The other scenario is that the first vehicle on the left side of the storage lane where the vehicle to be left is identified after vehicle identification as not being the vehicle to be left. This vehicle is temporarily placed in the fast return lane, and the search continues to look for the vehicle to be left in the storage lane. Because vehicles with similar production times are dispersed, generally, the second vehicle is the vehicle to be left. Of course, if it is not, it can continue to be temporarily stored in the fast return lane.

[0033] When a vehicle leaves the warehouse, its vehicle number is read by the vehicle identification device on the outbound transfer machine to confirm that it is an outbound vehicle. The vehicle is then moved into the designated lane. Vehicles that are not outbound enter the fast return lane. The information of vehicles leaving the warehouse through the designated lane is deleted from the warehouse area to avoid information confusion.

[0034] For those skilled in the art, any changes, modifications, substitutions, and variations made to the embodiments without departing from the principles and spirit of the present invention, based on the teachings of the present invention, still fall within the protection scope of the present invention.

Claims

1. A cycle time optimization system for automobile production, comprising an AVI system and a MES system, characterized in that: The MES system schedules vehicle production and determines the vehicle body number based on product orders, material resources, and production capacity. The vehicle body number of a vehicle with an earlier production time is less than that of a vehicle with a later production time. The production scheduling information is entered into the AVI system, which executes production activities according to the plan. The AVI system has an automatic inbound or outbound program set up in the warehouse area (1) according to the production plan. The warehouse area (1) includes an identification and input area (2), several storage channels, a sequencing channel (4), a fast return channel (6), a transfer machine, and an outbound deletion area (8), and can perform the following operations: Separate lanes: Identification and input area (2) Identify the vehicle body number of the vehicle entering the warehouse and input the vehicle information into the warehouse area (1). The vehicle body number of the vehicle entering the warehouse is compared with the vehicle body number of the next vehicle leaving the warehouse in the AVI system. If the vehicle body number of the vehicle entering the warehouse is greater than the vehicle body number of the vehicle leaving the warehouse, the vehicle entering the warehouse enters the storage lane; if the vehicle body number of the vehicle entering the warehouse is less than or equal to the vehicle body number of the vehicle leaving the warehouse, the vehicle entering the warehouse enters the fast return lane (6). Inbound: The AVI system calculates the vehicle number of the vehicle entering the storage lane by dividing it by the number of storage lanes, takes the remainder of the result and adds 1 to obtain the lane number of the storage lane the vehicle needs to enter, and the vehicle is moved into the storage lane by the transfer machine. Outbound: The AVI system queries the storage lane number of the vehicle body number of the vehicle to be outbound in the inbound record. The transfer machine moves to that lane and identifies the body number of the first vehicle closest to the transfer machine in the storage lane. If the body number of the first vehicle is equal to the body number of the vehicle to be outbound, the vehicle is placed into the sequence lane (4) by the transfer machine. If the body number of the first vehicle is greater than or less than the body number of the vehicle to be outbound, the vehicle is placed into the fast return lane (6) by the transfer machine. The vehicle in the sequence lane (4) enters the outbound deletion area (8), and the AVI system deletes the information of the vehicle in the storage area (1). Convergence: The AVI system detects that a vehicle has entered the fast return lane (6). It compares the vehicle number of the vehicle in the fast return lane (6) with the vehicle number of the next vehicle to leave the warehouse. If the vehicle number of the vehicle in the fast return lane (6) is less than the vehicle number of the vehicle leaving the warehouse, the vehicle in the fast return lane (6) leaves the warehouse. If the vehicle number of the vehicle in the fast return lane (6) is greater than the vehicle number of the vehicle leaving the warehouse, the vehicle leaving the warehouse continues to leave the warehouse.

2. The automobile production process cycle optimization system according to claim 1, characterized in that: The storage area (1) includes six storage channels. The sequencing channel (4), storage channel and fast return channel (6) are arranged horizontally from left to right. The order of the channels in the storage area (1) is sequencing channel (4), first storage channel (51), second storage channel (52), third storage channel (53), fast return channel (6), fourth storage channel (54), fifth storage channel (55) and sixth storage channel (56).

3. The automobile production process cycle optimization system according to claim 2, characterized in that: The identification and input area (2) is located on the right side of the storage area (1). On the left side of the identification and input area (2), there is an inbound transfer machine (3) that can move vehicles in the identification and input area (2) into the storage lane or the fast return lane (6). On the left side of the storage area (1), there is an outbound transfer machine (7) that can move vehicles out of the storage lane or the fast return lane (6). The outbound transfer machine (7) is equipped with a vehicle body number recognition device.

4. The automobile production process cycle optimization system according to claim 3, characterized in that: The identification and input area (2) can accommodate two vehicles entering at the same time. Two inbound transfer machines (3) are set on the left side of the identification and input area (2), two outbound transfer machines (7) are set on the left side of the warehouse area (1), and a pause area (9) is set on the left side of the warehouse area (1). Vehicles on the outbound transfer machine (7) can be moved into the pause area (9). A sequence transfer machine (41) is set on the left side of the pause area (9). The sequence transfer machine (41) can move vehicles in the pause area (9) into the sequence lane (4).

5. The automobile production process cycle optimization system according to claim 1, characterized in that: The AVI system is an automatic identification system that can record and monitor vehicle production information and complete automatic production tasks based on the collected information.

6. The automobile production process cycle optimization system according to claim 5, characterized in that: The MES system is a production execution system. It contains product orders, process routes, operations, material resources, and capacity information. The system can automatically sort vehicle production based on its internal information.

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