A Control Method and System for a Dynamic Island Chain Production Mode

Abstract

The present invention discloses a control method for a dynamic island chain production mode, which includes: after receiving a production instruction, the system automatically confirms the required production workstations according to the vehicle model BOP and manufacturing process; after confirming the production workstations, the scheduling management system determines the workstations that must be passed through in sequence according to the production process, and makes real-time adjustments and changes to the remaining workstations according to the production busyness degree of the workstations; based on the adjustment result, the system judges whether the currently produced vehicle model has been completed. If it is judged that the production is not completed, the system queries the current production progress from the factory cloud; if it is judged that the production has been completed, the relevant workstations start to perform equipment and program switching, and at the same time the main control host computer starts the production process of the next vehicle model. The dynamic island chain system of the present invention effectively reduces redundancy and control costs and solves the solidification problem through distributed management and control, flexible scheduling of mobile tooling, real-time planning of mobile routes without manual intervention, and strong fault handling capabilities.

Description

Technical Field

[0001] The present invention relates to the technical field of intelligent manufacturing, and in particular to a control method and system for a flexible island chain production mode. Background Art

[0002] Currently, the manufacturing process of the white body production line is still fixed, resulting in the production line being unable to intelligently plan and execute the production route according to different products, which has caused a series of problems. First, the production line corresponds to each fixed product one by one, which means that before introducing a new product, the production line must be adapted. Second, as the number of introduced vehicle models increases, the hardware requirements of the control system and the identification system also continuously accumulate. In addition, as the number of introduced vehicle models increases, the control system software also needs to be adjusted and updated repeatedly. Finally, when a completely new product is introduced, there may be a mismatch between the control system and the production process, resulting in the inability to adapt to the production of the new product. This limits the introduction of new vehicle models, and it may be necessary to either establish a new production line or conduct a compatibility analysis on all production lines that may introduce new vehicle models, which will bring huge human resource requirements and time consumption, and there is also uncertainty in the accuracy of the preliminary evaluation. Summary of the Invention

[0003] The purpose of this part is to outline some aspects of the embodiments of the present invention and briefly introduce some preferred embodiments. Some simplifications or omissions may be made in this part, as well as in the abstract and title of the present application, to avoid obscuring the purpose of this part, the abstract, and the title, and such simplifications or omissions shall not be used to limit the scope of the present invention.

[0004] In view of the existing problem that the manufacturing process of the current white body production line is still fixed, the present invention is proposed.

[0005] Therefore, the problem to be solved by the present invention is how to solve the problem of the fixed manufacturing process of the current white body production line, and achieve distributed management and control, reducing the centralized control redundancy on the entire production line.

[0006] To solve the above technical problems, the present invention provides the following technical solutions:

[0007] In a first aspect, an embodiment of the present invention provides a control method for a dynamic island chain production mode, which includes the master host computer of the current production line performing production scheduling by receiving the vehicle model BOP and production progress information in the production instruction; after receiving the production instruction, the system automatically confirms the required production workstations according to the vehicle model BOP and manufacturing process; after confirming the production workstations, the system transfers the workstation information and workstation content to the AGV scheduling management system, and the scheduling management system determines the workstations that must be passed through in sequence according to the production process, and makes real-time adjustments and changes to the remaining workstations according to the production busyness degree of the workstations; the system determines whether the currently produced vehicle model has been produced, and if it is determined that the production is not completed, it queries the current production progress from the factory cloud;

[0008] If a produced vehicle model on the AGV tooling in the "dynamic island" is marked as produced by the electric control signal in the system, the workstations associated with this "dynamic island" start to perform equipment and program switching, and at the same time, the master host computer starts the production process of the next vehicle model under this "function island".

[0009] As a preferred solution of the control method for the dynamic island chain production mode of the present invention, the production scheduling includes the following steps: corresponding the product with the corresponding process by using the computing power of the cloud, calling the "islands" with the same function in real time during the production process to meet the production, reducing production waiting, and distributing them to each island for execution, and at the same time connecting these manufacturing islands according to the production process to form a complete island chain system; the cloud uses wireless transmission technology to guide the mobile tooling to move between different dynamic islands in real time and monitor its travel route and working status; the cloud analyzes the process requirements of the product to be produced in real time according to the production instruction and plans an island chain suitable for producing this product; after the island chain is generated, the master host computer of the current production line performs production scheduling by receiving the vehicle model BOP and production progress information in the production instruction.

[0010] As a preferred solution of the control method for the dynamic island chain production mode of the present invention, the following steps are included: The system automatically confirms the required production workstations according to the vehicle model BOP and manufacturing process: The main control host computer analyzes the vehicle model information in the production instruction, and determines the types and quantities of all components required to form this vehicle model according to the preset BOM list of vehicle model production equipment; The main control host computer queries the preset manufacturing process route database according to the component types, and determines the processing procedures and processes of each component; By summarizing the process information of all components, the main control host computer plans the complete manufacturing process flow of this vehicle model, and determines which production workstations need to be enabled to complete this process route; For the workstations that require important production equipment in the process route, the main control host computer schedules in advance to ensure that the equipment is ready when reaching this process; During the production process, the main control host computer schedules the subsequent workstations that need to be enabled in a timely manner according to the real-time production progress information to ensure smooth operation between processes; If the process route needs to adjust the process sequence or add processes, the main control host computer updates the production line scheduling plan by re-analyzing the optimized process route.

[0011] As a preferred solution of the control method for the dynamic island chain production mode of the present invention, the following steps are included: The main control host computer schedules in advance by controlling the robot in the island to dock with the vision servo positioning device through the PLC, and the specific formula is as follows:

[0012]

[0013] Among them, b is the distance from the upper plane of the conical table to the laser rangefinder emission point, and x, y, z are the coordinates of the center of the bottom surface of the conical table.

[0014]

[0015] Among them, A' x 、A' y 、A' z 、B' x 、B' y 、B' z 、C' x 、C' y 、C' z respectively represent the x, y, z coordinates of points A', B', C', and t A 、t B 、t C are respectively the distances from the laser rangefinder to the conical table, and T is a constant.

[0016]

[0017] Among them, α A is the tilt angle of the laser angle at point A', and β Ais the azimuth angle of the laser angle at point A', x, y, and z are the coordinates of the center of the bottom surface of the frustum of a cone, and x A , y A , z A are the coordinates of the points where the laser emitter A irradiates on the frustum of a cone respectively, and Δx, Δy, and Δz are the offsets.

[0018] As a preferred solution of the control method for the flexible island chain production mode described in the present invention, wherein: the master upper computer performing scheduling in advance further includes using the Kriging algorithm to improve the measurement accuracy of the vision system installed at the end of the robot. The specific formula is as follows:

[0019]

[0020] where r ij is the semi-variance, is the Kriging error, σ 2 is the variance, ω i , ω j are the weight coefficients, and n is the observed value.

[0021] As a preferred solution of the control method for the flexible island chain production mode described in the present invention, wherein: the master upper computer performing scheduling in advance further includes achieving real-time detection and correction of the positioning accuracy of loading parts through vision devices and algorithms. The specific formula is as follows:

[0022]

[0023] where M k,i is the i-th point among the three points selected from the P and Q standard feature plates for the k-th time, k = 1, 2,.., K, and M' k,i is the point corresponding to M k,i selected from the moved P and Q standard feature plates for the k-th time, and R' wk , T′ wk is the translation matrix for the k-th time.

[0024] As a preferred solution of the control method for the dynamic island chain production mode of the present invention, it includes the following steps: The scheduling management system determines the workstations that must be passed through in sequence according to the production process. After confirming the production workstations, it transmits the workstation information and workstation content to the AGV scheduling management system. The AGV scheduling management system analyzes the key workstations that must be strictly passed through in sequence according to the production process, and considers the real-time production status of each workstation, and dynamically adjusts and changes the non-key workstations to achieve optimized scheduling. The scheduling management system sends an instruction to the AGV scheduling management system of the switching island, instructing it to switch to the tooling that matches the product to be produced to ensure precise operation. After receiving the product, the AGV scheduling management system moves the product to different process islands for corresponding operations according to the predetermined sequence of the process island chain. Determine the workstations that must be passed through in sequence according to the production process, and make real-time adjustments and changes to the remaining workstations according to the production busyness of the workstations.

[0025] In a second aspect, an embodiment of the present invention provides a control system for a dynamic island chain production mode, which includes a production scheduling module for performing production scheduling by receiving the vehicle model BOP and production progress information in the production instruction; a production workstation confirmation module for automatically confirming the required production workstations according to the vehicle model BOP and manufacturing process after receiving the production instruction; a real-time adjustment module for transmitting the workstation information and workstation content to the AGV scheduling management system after confirming the production workstations. The scheduling management system determines the workstations that must be passed through in sequence according to the production process, and makes real-time adjustments and changes to the remaining workstations according to the production busyness of the workstations; a system judgment module for judging whether the currently produced vehicle model is completed through the adjustment result and performing corresponding operations.

[0026] In a third aspect, an embodiment of the present invention provides a computer device, including a memory and a processor, where the memory stores a computer program, and: when the computer program instructions are executed by the processor, the steps of the control method for the dynamic island chain production mode as described in the first aspect of the present invention are implemented.

[0027] In a fourth aspect, an embodiment of the present invention provides a computer-readable storage medium, on which a computer program is stored, and: when the computer program instructions are executed by the processor, the steps of the control method for the dynamic island chain production mode as described in the first aspect of the present invention are implemented.

[0028] The beneficial effects of the present invention are as follows: In the present invention, the execution actions in each flexible island are managed and controlled in a distributed manner, reducing the centralized control redundancy on the entire production line; according to the island chain plan given by the cloud, the mobile tooling is flexibly scheduled to complete the operations of each flexible island; the system can real-time plan the waiting and routes between the mobile tooling and the flexible islands, enabling the equipment in each island to be fully utilized and exerting their maximum production capacity; the present invention is applicable to the control in a dark factory without manual intervention; when a certain flexible island fails, the system can call or switch the current task and the mobile tooling to make it complete the operations of the current island in other flexible islands; through flexible control, the present invention solves the problems of production process and control solidification, and improves the flexibility and adaptability of manufacturing. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] In order to more clearly illustrate the technical solutions of the embodiments of the present invention, the following will briefly introduce the drawings required for the description of the embodiments. Obviously, the following drawings are only some embodiments of the present invention. For those of ordinary skill in the art, without creative efforts, other drawings can be obtained based on these drawings. Among them:

[0030] Figure 1 It is a flowchart of the control method for the flexible island chain production mode.

[0031] Figure 2 It is an explanatory diagram of the control system for the flexible island chain production mode. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0032] In order to make the above objects, features and advantages of the present invention more obvious and understandable, the following will make a detailed description of the specific embodiments of the present invention in conjunction with the drawings of the specification.

[0033] In the following description, many specific details are set forth in order to fully understand the present invention. However, the present invention can also be implemented in other ways different from those described herein. Those skilled in the art can make similar promotions without departing from the connotation of the present invention. Therefore, the present invention is not limited by the specific embodiments disclosed below.

[0034] Secondly, the so-called "one embodiment" or "embodiment" herein refers to a specific feature, structure or characteristic that can be included in at least one implementation manner of the present invention. The "in one embodiment" appearing in different places in this specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment that mutually excludes other embodiments.

[0035] Embodiment 1

[0036] Refer to Figures 1 to 2, which is the first embodiment of the present invention. This embodiment provides a control method for the dynamic island chain production mode, including:

[0037] S1: The main control host computer of the current production line performs production scheduling by receiving the vehicle model BOP and production progress information in the production instruction.

[0038] Specifically, by utilizing the computing power of the cloud, the product is corresponded with the corresponding process. During the production process, the "islands" with the same function are called in real time to meet the production needs, reducing production waiting time, and distributed to each island for execution. At the same time, these manufacturing islands are connected according to the process flow to form a complete island chain system; the cloud uses wireless transmission technology to guide the mobile tooling to move between different dynamic islands in real time, and monitors its travel route and working status; the cloud analyzes the process requirements of the product to be produced in real time according to the production instruction, and plans an island chain suitable for producing this product; after the island chain is generated, the main control host computer of the current production line performs production scheduling by receiving the vehicle model BOP and production progress information in the production instruction.

[0039] S2: After receiving the production instruction, the system automatically confirms the required production stations according to the vehicle model BOP and manufacturing process.

[0040] Preferably, the main control host computer analyzes the vehicle model information in the production instruction, and determines the types and quantities of all components required to form this vehicle model according to the preset BOM list of vehicle model production equipment; the main control host computer queries the preset manufacturing process route database according to the component types, and determines the processing procedures and processes of each component; by summarizing the process information of all components, the main control host computer plans the complete manufacturing process flow of this vehicle model, and determines which production stations need to be enabled to complete this process route; for the stations that require important production equipment in the process route (such as welding stations, painting stations, assembly stations, etc.), the main control host computer will schedule in advance to ensure that the equipment is ready when reaching this process; during the production process, the main control host computer schedules the stations that need to be enabled subsequently according to the real-time production progress information to ensure smooth operation between each process; if the process route needs to adjust the process sequence or add processes, the main control host computer updates the production line scheduling plan by re-analyzing the optimized process route.

[0041] Furthermore, as Figure 2 shown, A, B, and C are three different vehicle models respectively. Since these three models are A0-class, A00-class, and smaller vehicles respectively, their production processes and flows are different.

[0042] Specifically, Figure 2In the BOP, it is the production process: First, according to the operation diagram (taking Model A as an example), after the AGV with the vision servo positioning device brings Model A to the "switching island", the robot in the switching island is controlled by the PLC to dock with the vision servo positioning device, so that the vision servo positioning device can reach the appropriate position to pick up Model A and transport it to the "repair welding island 1" (to complete the welding of the front part of the vehicle body), then send it to the "repair welding island 2" to complete (to complete the welding of the rear part of the lower vehicle body), and then to the "repair welding island 3" (to complete the welding of the lower vehicle body); then it is sent to the "loading island 1" (to complete the loading and positioning welding of the front side panels of the vehicle body); then to the "loading island 2" (to complete the loading and positioning welding of the sill panels of the vehicle body), and then to the "loading island 3" (to complete the loading and positioning welding of the triangular panels of the vehicle body); then it is sent to the "repair welding island 21" (to complete the repair welding of the front side panel part of the vehicle body), then sent to the "repair welding island 22" to complete (to complete the repair welding of the sill panel part of the vehicle body), and then to the "repair welding island 23" (to complete the repair welding of the triangular panel part of the vehicle body);

[0043] Then it is sent to the "composite assembly island 1" (to complete the loading and positioning welding of the side body and the roof of the vehicle body). The subsequent "composite assembly islands 2 and 3" workstations are parallel workstations for standby or for improving the production rhythm; then it is sent to the "repair welding island 31" (to complete the repair welding of the side body + roof part in the composite assembly island 1), and then sent to the "repair welding island 32" as needed or sent out of this production line to the adjustment line of the next production link.

[0044] Specifically, when the robot docks, the three-point deviation correction algorithm formula group used is as follows:

[0045]

[0046] Among them, b is the distance from the upper plane of the conical table to the laser rangefinder emission point, and x, y, z are the coordinates of the center of the bottom surface of the conical table.

[0047]

[0048] Among them, A' x 、A' y 、A' z 、B' x 、B' y 、B' z 、C' x 、C' y 、C' z respectively represent the x, y, z coordinates of points A', B', C', and t A 、t B 、t C are the distances from the laser rangefinder to the round table respectively, and T is tan30°.

[0049]

[0050] Among them, α A is the tilt angle of the laser angle at point A', and β A is the azimuth angle of the laser angle at point A'. x, y, and z are the coordinates of the center of the bottom surface of the frustum of a cone. x A , y A , and z A are respectively the point coordinates where the laser emitter A irradiates on the frustum of a cone, and Δx, Δy, and Δz are the offsets.

[0051] Preferably, the positioning accuracy of the loaded parts is detected and corrected in real time through a vision device and an algorithm, expanding the welding channel of the welding robot in the workstation and improving the production rhythm due to the lack of docking interference in the robot trajectory. The specific formula is as follows:

[0052] [u c , u c , 1] T = A·[R, t]·[x w , y w , z w , 1] T

[0053] Among them, A is the camera internal parameter matrix, R is the spatial rotation matrix, t is the 3×1 spatial translation matrix, and (u c , v c ) is the pixel coordinate system, and (x w , y w , z w ) is the robot coordinate system.

[0054]

[0055] Among them, R w , T w are respectively the 3×3 rotation matrix and the 3×1 translation matrix describing the rotation and translation of points {P i}, {Q i} to points {P′ i}, {Q′ i}. P and Q are reference blocks.

[0056]

[0057] Among them, M k,i is the i-th point among the three points selected from the P and Q standard feature plates for the k-th time, k = 1, 2,.., K, and M' k,i is the point corresponding to M k,i selected from the moved P and Q standard feature plates for the k-th time. R' wk , T′ wk is the translation matrix for the k-th time.

[0058] If R k is less than the set tolerance d, then this set of points is recorded as a reasonable point set, denoted as φ 1 ; otherwise it is recorded as an unreasonable point set, denoted as φ 2 .

[0059] Furthermore, the Kriging algorithm is used to improve the measurement accuracy of the vision system installed at the end of the robot (since the vision is installed at the end of the robot, the repeat positioning accuracy of the robot end directly determines the measurement accuracy of the vision system. Improving the accuracy of the robot end is to improve the measurement accuracy of the vision system without changing the measurement accuracy of the vision system). The specific formula is as follows:

[0060]

[0061] where r ij is the semi-variance, is the Kriging error, σ 2 is the variance, ω i , ω j are the weight coefficients, and n is the observed value.

[0062] S3: After confirming the production station, the station information and station content are transmitted to the AGV scheduling and management system. The scheduling and management system determines the stations that must be passed through in sequence according to the production process, and makes real-time adjustments and changes to the remaining stations according to the production busyness of the stations.

[0063] Specifically, after confirming the production station, the station information and station content are transmitted to the AGV scheduling and management system; the AGV scheduling and management system analyzes the key stations that must be strictly passed through in sequence according to the production process, and considers the real-time production status of each station to make dynamic adjustments and changes to the non-key stations to achieve optimized scheduling; the scheduling and management system sends an instruction to the AGV scheduling and management system of the switching island to instruct it to switch to the tooling that matches the product to be produced to ensure precise operation; after receiving the product, the AGV scheduling and management system moves the product to different process islands for corresponding operations according to the predetermined order of the process island chain; determines the stations that must be passed through in sequence according to the production process, and makes real-time adjustments and changes to the remaining stations according to the production busyness of the stations.

[0064] It should be noted that each flexible island adopts an independent layout, each island is configured according to its own hardware equipment, and unified management is carried out using the PLC within the island; in the case of unattended operation, various devices within the island are called to intelligently complete fixed process functions; these operations are controlled by the independent PLC within each island. This independent layout and control method reduces unnecessary direct interaction between islands and also reduces the amount of information interaction between the island and the cloud, ensuring that the operation process and status within the island are controlled by its independent PLC.

[0065] Furthermore, the connection relationship between islands is not pre-fixed, but determined according to the dynamic process requirements of the specific vehicle model to be produced; each flexible island will interact with the next corresponding island behind it in a trigger-based wireless transmission mode, and only transmit necessary operation information when needed. This on-demand transmission method can effectively reduce the failure rate of the entire production line and also reduce the amount of ineffective information interaction between irrelevant islands on the process route; each island will directly upload its own working status and information to the cloud in real time to achieve global monitoring and collaboration.

[0066] It should be noted that although each flexible island is independent, there is partial overlap in equipment functions to meet the requirements of production rhythm or redundancy. The present invention uses visual servo technology to replace the dynamic motor servo control feedback system, and uses a visual measurement system in the "switching island" to complete the "position loop" control in the servo system control.

[0067] S4: The system determines whether the currently produced vehicle model has been completed. If it is determined that the production is not completed, it queries the current production progress from the factory cloud.

[0068] Specifically, read the next vehicle model to be produced and send this information to the "switching island". After receiving the information, the "switching island" prepares to adjust the tooling on the next AGV arriving at the "switching island" to the next vehicle model to be produced according to the vehicle model production requirements.

[0069] S5: If a produced vehicle model on the AGV tooling in the "flexible island (or functional island)" is marked as completed by the electric control signal in the system, the workstations associated with this "flexible island" will start equipment and program switching, and at the same time, the main control host computer will start the production process of the next vehicle model of this "functional island".

[0070] Furthermore, this embodiment also provides a control system for the flexible island chain production mode, including a production scheduling module for performing production scheduling by receiving the vehicle model BOP and production progress information in the production instruction; a production workstation confirmation module for automatically confirming the required production workstations according to the vehicle model BOP and manufacturing process after receiving the production instruction; a real-time adjustment module for transmitting the workstation information and workstation content to the AGV scheduling and management system after confirming the production workstations. The scheduling and management system determines the workstations that must be passed through in sequence according to the production process, and makes real-time adjustments and changes to the remaining workstations according to the production busyness of the workstations; a system judgment module for judging whether the currently produced vehicle model has been completed through the adjustment result and performing corresponding operations.

[0071] This embodiment also provides a computer device, which is applicable to the control method of the dynamic island chain production mode, including a memory and a processor; the memory is used to store computer-executable instructions, and the processor is used to execute the computer-executable instructions to implement the control method of the dynamic island chain production mode proposed in the above embodiment.

[0072] The computer device can be a terminal, and the computer device includes a processor, a memory, a communication interface, a display screen, and an input device connected through a system bus. Among them, the processor of the computer device is used to provide computing and control capabilities. The memory of the computer device includes a non-volatile storage medium and an internal memory. The non-volatile storage medium stores an operating system and a computer program. The internal memory provides an environment for the operation of the operating system and the computer program in the non-volatile storage medium. The communication interface of the computer device is used to communicate with an external terminal in a wired or wireless manner, and the wireless manner can be implemented through WIFI, a carrier network, NFC (Near Field Communication), or other technologies. The display screen of the computer device can be a liquid crystal display screen or an electronic ink display screen, and the input device of the computer device can be a touch layer covering the display screen, or a button, a trackball, or a touchpad provided on the shell of the computer device, or an external keyboard, a touchpad, or a mouse, etc.

[0073] This embodiment also provides a storage medium, on which a computer program is stored, and when the program is executed by a processor, the following steps are implemented: the main control host computer of the current production line performs production scheduling by receiving the vehicle model BOP and production progress information in the production instruction; after receiving the production instruction, the system automatically confirms the required production workstations according to the vehicle model BOP and manufacturing process; after confirming the production workstations, the workstation information and workstation content are transmitted to the AGV scheduling management system, and the scheduling management system determines the workstations that must be passed through in sequence according to the production process, and makes real-time adjustments and changes to the remaining workstations according to the production busyness degree of the workstations; through the adjustment result, the system judges whether the currently produced vehicle model is completed. If it is judged that the production is not completed, the system queries the current production progress from the factory cloud; if it is judged that the production is completed, the relevant workstations start to perform equipment and program switching, and at the same time, the main control host computer starts the production process of the next vehicle model.

[0074] In summary, in the present invention, the execution actions within each flexible island are realized in a distributed management and control manner, reducing the centralized control redundancy in the entire production line; according to the island chain plan given by the cloud, the mobile tooling is flexibly scheduled to complete the operations of each flexible island; the system can real-time plan the waiting and routes between the mobile tooling and the flexible islands, enabling the equipment in each island to be fully utilized and exerting their maximum production capacity; the present invention is applicable to the control in a dark factory without manual intervention; when a certain flexible island fails, the system can call or switch the current task and the mobile tooling to make it complete the operation of the current island at other flexible islands; through flexible control, the present invention solves the problems of production process and control solidification, and improves the flexibility and adaptability of manufacturing.

[0075] Embodiment 2

[0076] Referring to Figures 1 to 2 , which is the second embodiment of the present invention. This embodiment provides a control method for a flexible island chain production mode. In order to verify the beneficial effects of the present invention, scientific demonstration is carried out through economic benefit calculation and simulation experiments.

[0077] Furthermore, in this production mode, a flexible control method is adopted to break the original production rhythm limit and control mode. Different from the traditional pulsed production line, the production rhythm is no longer determined by the bottleneck workstation, but by the key "number of flexible islands". By matching the production rhythm of each workstation with the corresponding "number of flexible islands", the production rhythm of the entire production line can be improved.

[0078] Specifically, for example, when the production rhythm of the "composite assembly island" is 30 JPH and the production rhythm of the "repair welding island" is 60 JPH, one "repair welding island 1" can be used to match two "composite assembly islands 1&2", so as to achieve a production rhythm of 60 JPH for the entire production line. If it is necessary to increase production capacity, only need to add "repair welding island 2" beside the "repair welding island 1", and add "composite assembly islands 3&4" beside the "composite assembly islands 1&2". In this way, compared with the traditional pulsed production line, it becomes easier to expand production as long as there is enough factory space.

[0079] Furthermore, the control within each "flexible island" is uniformly arranged by the PLC, and the equipment starts to execute the corresponding program only after receiving the PLC signal. For example, in the "repair welding island", the robot only executes the repair welding program after receiving the actionable signal sent by the PLC, and feeds back the signal to the PLC after completion. Using an ABB PLC with a fast scan cycle, the speed of communication and control is very fast, which can be completed within every 5 milliseconds.

[0080] Preferably, for the AGV transportation system, the preferred solution is to tow the tooling and the white body by the AGV, with a maximum running speed of 0.3 m / s and a load of 1.2 tons. When the AGV transports parts and items such as the material box to the work station or transports an empty material box, the speed is 0.5 m / s. Therefore, the type, load, speed, and route of the AGV are calculated in real time and adjusted and optimized accordingly as the number of special "Smart Islands" increases.

[0081] Furthermore, considering the requirements of short time and small route turning space, the distance between the "Smart Islands" is set to be 2 AGV body lengths, that is, 8 meters.

[0082] Even further, the AGV scheduling system completes the planning of the entire route within 6 seconds and hands over the real-time control to the controller on the AGV. For example, automatic navigation is achieved by visually comparing the map. When the AGV reaches the designated position, the NTF on the AGV transmits the relevant information to the PLC within the "Smart Island", and the PLC notifies the upper computer to wait for the next execution command.

[0083] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to the preferred embodiments, those of ordinary skill in the art should understand that the technical solutions of the present invention can be modified or equivalently replaced without departing from the spirit and scope of the technical solutions of the present invention, and they should all be covered by the scope of the claims of the present invention.

Claims

1. A control method for the dynamic island chain production mode, characterized in that: It includes, The main control host computer of the current production line performs production scheduling by receiving the vehicle type BOP and production progress information in the production order; After receiving the production order, the system automatically confirms the required production workstations according to the vehicle type BOP and manufacturing process; After confirming the production workstations, the workstation information and workstation content are transmitted to the AGV scheduling management system. The scheduling management system determines the workstations that must be passed through in sequence according to the production process, and makes real-time adjustments and changes to the remaining workstations according to the production busyness of the workstations; The system determines whether the currently produced vehicle type has been completed. If it is judged that the production is not completed, it queries the current production progress from the factory cloud; If a produced vehicle type on the AGV tooling in the dynamic island is marked as completed by the electric control signal in the system, the workstations associated with this dynamic island start to perform equipment and program switching, and at the same time, the main control host computer starts the production process of the next vehicle type of this functional island; The system automatically confirming the required production workstations according to the vehicle type BOP and manufacturing process includes the following steps: The main control host computer analyzes the vehicle type information in the production order, and determines the types and quantities of all components required to form this vehicle type according to the preset BOM list of vehicle type production equipment; The main control host computer queries the preset manufacturing process route database according to the component types to determine the processing procedures and processes of each component; By summarizing the process information of all components, the main control host computer plans the complete manufacturing process flow of this vehicle type, and determines which production workstations need to be enabled to complete this process route; For the workstations that require important production equipment in the process route, the main control host computer makes advance scheduling to ensure that the equipment is ready when reaching this process; During the production process, the main control host computer makes timely scheduling of the workstations that need to be enabled subsequently according to the real-time production progress information to ensure smooth flow operation between each process; If the process route needs to adjust the process sequence or add processes, the main control host computer updates the production line scheduling plan by re-analyzing the optimized process route; The main control host computer making advance scheduling also includes using the Kriging algorithm to improve the measurement accuracy of the vision system installed at the end of the robot. The specific formula is as follows: Among them, r ij is the semi-variance, is the Kriging error, σ 2 is the variance, ω i and ω j are the weight coefficients, and n is the observed value; By using the vision device and algorithm to achieve real-time detection and correction of the positioning accuracy of the loaded parts, the welding channel of the welding robot in the workstation is expanded and there is no docking interference due to the robot trajectory, improving the production beat. The specific formula is as follows: [u c ,u c ,1] T = A·[R,t]·[x w ,y w ,z w ,1] T where A is the camera intrinsic matrix, R is the spatial rotation matrix, t is a 3×1 spatial translation matrix, and (u c , v c ) is the pixel coordinate system, and (x w , y w , z w ) is the robot coordinate system; Among them, R w , T w are respectively the 3×3 rotation matrix and the 3×1 translation matrix that describe the rotation and translation of points {P i} and {Q i} to points {P i '} and {Q i '}. P and Q are reference blocks; The main control host computer making advance scheduling also includes achieving real-time detection and correction of the positioning accuracy of the loaded parts through the vision device and algorithm. The specific formula is as follows: Among them, M k,i is the i-th point among the three points selected from the P and Q standard feature plates for the k-th time, k = 1, 2,.., K, and M' k,i is the point corresponding to M selected from the moved P and Q standard feature plates for the k-th time k,i , and R' wk , T w ' k is the translation matrix for the k-th time.

2. The control method for the dynamic island chain production mode according to claim 1, characterized in that: The production scheduling includes the following steps: By using the computing power of the cloud to correspond the product with the corresponding process, calling the islands with the same function in real time during production to meet the production, reducing production waiting, and distributing them to each island for execution. At the same time, these manufacturing islands are connected according to the process flow to form a complete island chain system; The cloud uses wireless transmission technology to guide the mobile tooling to move between different flexible islands in real time, and monitors its travel route and working status; The cloud analyzes the process requirements of the product to be produced in real time according to the production instructions, and plans an island chain suitable for producing the product; After the island chain is generated, the main control host computer of the current production line performs production scheduling by receiving the vehicle model BOP and production progress information in the production instructions.

3. The control method for the flexible island chain production mode according to claim 2, characterized in that: The advance scheduling of the main control host computer includes controlling the robot in the island to dock with the vision servo positioning device through the PLC. The specific formula is as follows: where b is the distance from the upper plane of the conical table to the laser rangefinder emission point, and x, y, and z are the center coordinates of the bottom surface of the conical table; Among them, A' x 、A' y 、A' z 、B' x 、B' y 、B' z 、C' x 、C' y 、C' z respectively represent the x, y, and z coordinates of points A', B', and C', and t A 、t B 、t C are the distances from the laser rangefinder to the frustum respectively, and T is a constant; where α A is the tilt angle of the laser angle at point A', and β A is the azimuth angle of the laser angle at point A'. x, y, and z are the coordinates of the center of the bottom surface of the frustum of a cone. x A , y A , and z A are the point coordinates where the laser emitter A irradiates on the frustum of a cone, and Δx, Δy, and Δz are the offsets.

4. The control method for the flexible island chain production mode according to claim 1, characterized in that: The steps for the scheduling management system to determine the workstations that must be passed in sequence according to the production process include: After confirming the production workstations, the workstation information and workstation content are transmitted to the AGV scheduling management system; The AGV scheduling management system analyzes the key workstations that must be strictly passed in sequence according to the production process, and considers the real-time production status of each workstation, and dynamically adjusts and changes the non-key workstations to achieve optimized scheduling; The scheduling management system sends an instruction to the AGV scheduling management system of the switching island, instructing it to switch to the tooling that matches the product to be produced to ensure precise operation; After receiving the product, the AGV scheduling management system moves the product to different process islands for corresponding operations according to the predetermined order of the process island chain; Determine the workstations that must be passed in sequence according to the production process, and make real-time adjustments and changes to the remaining workstations according to the production busyness of the workstations.

5. A flexible island chain production mode control system, based on the flexible island chain production mode control method according to any one of claims 1 to 4, characterized in that: It also includes, A production scheduling module, which is used to perform production scheduling by receiving the vehicle model BOP and production progress information in the production instructions; A production workstation confirmation module, which is used to automatically confirm the required production workstations according to the vehicle model BOP and manufacturing process after receiving the production instructions; A real-time adjustment module, which is used to transmit the workstation information and workstation content to the AGV scheduling management system after confirming the production workstations. The scheduling management system determines the workstations that must be passed in sequence according to the production process, and makes real-time adjustments and changes to the remaining workstations according to the production busyness of the workstations; A system judgment module, which is used to judge whether the current vehicle model in production is completed according to the adjustment result, and perform corresponding operations.

6. A computer device, including a memory and a processor, the memory stores a computer program, characterized in that: When the processor executes the computer program, the steps of the flexible island chain production mode control method according to any one of claims 1 to 4 are implemented.

7. A computer-readable storage medium, on which a computer program is stored, characterized in that: When the computer program is executed by the processor, the steps of the flexible island chain production mode control method according to any one of claims 1 to 4 are implemented.

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