Self-identifying flexible automatic handling method for self-discharging production of ring die

Abstract

The application provides a self-arrangement production self-identification flexible automatic handling method for ring mold production, which is applied to a handling system, and the handling system comprises a client, a factory module, a WMS module, an MES database, an automatic arrangement production module, a central dispatching subsystem, an AGV trolley, an AGV database, a work order material issuing traceability submodule, an OEE module, a data acquisition end, an RTB module, an SAP subsystem, an SAP database, an MES subsystem, a PDA operation module data input end, a PDA operation module and a ring mold quality control module. The flexible automatic handling method realizes the automatic arrangement production function and the flexible handling function in the ring mold production process through a receiving operation handling sub-method, a material issuing operation handling sub-method and an operation between processes handling sub-method, and solves the problems of handling confusion, non-standard ring mold storage and complicated arrangement production caused by site limitation and manual arrangement production.

Description

Technical Field

[0001] This invention belongs to the field of ring die production and handling technology, and particularly relates to a flexible automatic handling method for ring die production with self-dispatch and self-identification. Background Technology

[0002] A ring die is a regular circular workpiece and a core technical component required for processing feed production equipment. The production process of a ring die includes multiple steps such as rough turning, drilling and milling, gun drilling, chamfering, cleaning, heat treatment, tempering, finish turning, grinding, inspection, feeding and packaging. However, due to space limitations, ring dies need to be transported between different locations during production. At the same time, manual scheduling is required during production, which often results in missed or incorrect scheduling. Therefore, solving the problems of chaotic handling, non-standard storage, and complicated scheduling in the ring die processing process is of paramount importance. Summary of the Invention

[0003] In response to the problems raised in the background technology, this invention proposes a flexible automatic handling method for self-dispatch and self-identification in ring mold production.

[0004] To achieve this objective, the present invention adopts the following technical solution:

[0005] A flexible automatic transport method for self-scheduling and self-identification in ring mold production is applied to a transport system, which includes a client, a factory module, a WMS module, an MES database, an automatic scheduling module, a central scheduling subsystem, AGV carts, an AGV database, and a work order issuance and traceability submodule.

[0006] The automated scheduling and flexible automated handling method for ring die production includes a receiving and handling sub-method, which includes:

[0007] Step A: The client scans the three codes on the ring forging and enters them into the factory module to complete the receiving operation in the WMS module. The three codes include the receiving work order code, the storage location code, and the material ID code.

[0008] Step B: The WMS module generates a receiving record based on the entered three-code information, saves the receiving record and three-code information to the MES database, and uploads the receiving record and three-code information to the automatic scheduling module;

[0009] Step C: The work order material issuance traceability submodule built into the WMS module integrates the three-code information to form a source traceability report for the ring die forging receiving work order;

[0010] Step D: The automatic production scheduling module generates a material transfer task sheet for inbound goods based on the receiving record and three-code information, and sends the material list in the material transfer task sheet to the WMS module item by item;

[0011] Step E: The WMS module automatically matches the corresponding warehouse storage area as the unloading location according to the material transfer task table. The WMS module creates a receiving and handling task through the AGV-API interface and sends the receiving and handling task to the central scheduling subsystem. The receiving and handling task includes the picking location, the unloading location and the material ID code.

[0012] Step F: The central dispatching subsystem plans the AGV cart transportation route according to the receiving and handling task, and drives the AGV cart to perform the receiving and handling task;

[0013] Step G: The AGV has an automatic identification fork arm module. The automatic identification fork arm module detects whether the material ID code of the ring die forging to be transported is consistent with the material ID code in the receiving and handling task. If they are consistent, the ring die forging is transported to the corresponding unloading warehouse. If they are inconsistent, the receiving and handling task is stopped. After the receiving and handling task is completed, a completion message is sent to the central dispatch subsystem.

[0014] When the AGV encounters an obstacle on the planned transport route, it will alert the operator. If the operator does not respond, the central dispatching subsystem will replan the route and drive the AGV to transport the ring die forging to the abnormal area for storage.

[0015] Step H: After receiving the completion information, the central dispatch subsystem saves the receiving and handling task to the AGV database and synchronously returns the completion information to the WMS module through the AGV-API interface;

[0016] Step 1: The WMS module sends a query command for line-side warehouse location information to the central dispatch subsystem through the AGV-API interface. The central dispatch subsystem returns the line-side warehouse location information to the WMS module, and the WMS module saves the line-side warehouse location information to the MES database.

[0017] Preferably, the material handling system further includes an SAP subsystem, an SAP database, and an MES subsystem;

[0018] The automated scheduling and flexible automated handling method for ring die production includes a material feeding operation sub-method, which includes:

[0019] Step a: The WMS module saves the storage location information of the incoming material warehouse to the MES database. The storage location information of the incoming material warehouse includes the type of ring forgings stored in the corresponding storage location and the quantity of each type of ring forgings.

[0020] Step b: After receiving a new work order, the SAP subsystem saves the new work order to the SAP database, and the SAP database synchronizes the new work order to the MES database;

[0021] Step c: The MES subsystem retrieves the new work order and the storage location information of the incoming material warehouse from the MES database and forwards it to the automatic scheduling module. The automatic scheduling module calculates the start time for issuing materials for the new work order based on the processing conditions set by the machine tool processing capacity configuration module and the machine tool processing time configuration module.

[0022] Step d: The automatic scheduling module confirms whether there are ring die forgings for the production of new work orders in the incoming material warehouse based on the warehouse location information. If there are, the module arranges the material issuance for the new work order and integrates the ring die forgings that need to be issued that day into the material issuance task list for that day. The material issuance task list for that day is then sent to the WMS module.

[0023] Step e: The WMS module automatically matches the storage location of the incoming material warehouse containing the corresponding material as the picking location based on the material information of the ring die forging in the material issuance task list for the day.

[0024] Step f: The WMS module creates a material dispatching and handling task for the central scheduling subsystem through the AGV-API interface. The material dispatching and handling task includes the picking location, unloading machine and material ID code. The central scheduling subsystem automatically allocates the waiting area storage location in the line-side warehouse of the unloading machine as the unloading location according to the material dispatching and handling task, and drives the AGV to execute the material dispatching and handling task.

[0025] Step g: The AGV's automatic identification forklift module detects whether the material ID code of the ring die forging to be transported matches the material ID code in the material dispatching task. If they match, the ring die forging is transported to the corresponding unloading location. If they do not match, the material dispatching task is stopped. After completing the material dispatching task, a completion message is sent to the central dispatching subsystem.

[0026] Step h: After receiving the completion information, the central dispatch subsystem saves the material handling task and unloading location to the AGV database, and synchronously returns the completion information to the WMS module through the AGV-API interface;

[0027] Step i: The WMS module sends a query command for line-side warehouse location information to the central dispatch subsystem through the AGV-API interface. The central dispatch subsystem returns the line-side warehouse location information to the WMS module, and the WMS module saves the line-side warehouse location information to the MES database.

[0028] Preferably, the handling system further includes a PDA operation module data input terminal, a data acquisition terminal, a PDA operation module, an RTB module, an OEE module, and a ring mold quality control module;

[0029] The automated scheduling and flexible automated handling method for ring die production includes an inter-process operation sub-method, which includes:

[0030] Step 1: The PDA operation module's data input terminal scans the storage location code of the waiting area storage location in the line-side warehouse where the ring die workpiece is stored and enters the storage location code into the PDA operation module to perform the unbinding operation of the waiting area storage location and the stored ring die workpiece. The PDA operation module sends an instruction to update the storage location information to the central scheduling subsystem through the AGV-API interface to update the storage location information of the waiting area storage location, thereby completing the unbinding operation of the ring die workpiece.

[0031] Step 2: Place the ring die workpiece in the processing area of ​​Step 1 onto the machine for processing. The data acquisition terminal scans the processing work order and records the processing time. After processing, store the ring die workpiece in the finished product area of ​​the line-side warehouse. The ring die workpiece is a ring die forging that has undergone one or more processing steps during the inter-process operation.

[0032] Step 3: The PAD operation module's data input terminal scans the storage location code, work order code, and material ID code of the finished product area storage location in Step 2, and inputs them into the PAD operation module to perform the binding operation between the finished product area storage location and the stored ring die workpiece. The PAD operation module sends an instruction to update the storage location information to the central scheduling subsystem through the AGV-API interface to update the storage location information of the finished product area storage location.

[0033] Step 4: The central dispatch subsystem verifies the work order code and material ID code uploaded in Step 3 with the work order code and material ID code saved in the receiving operation. If the verification is successful, the binding operation between the finished product area storage location and the ring die workpiece stored therein will be completed.

[0034] Step 5: The data acquisition terminal collects the work order hours and process status information of the ring die workpieces processed by the machine tools in each process. The process status information includes the completion information of the latest process. It is saved to the MES database through the OEE module. The RTB module uploads the work order hours and process status information saved in the MES database to the SAP subsystem for confirmation. After confirmation, it is saved to the SAP database. The SAP database synchronizes the confirmed work order hours and process status information to the MES database.

[0035] Step Six: The MES subsystem obtains the confirmed work order hours and process status information from the MES database, generates the latest completed process list based on the latest process completion information, and sends it to the automatic scheduling module. The automatic scheduling module sends a command to the central scheduling subsystem to query the finished product area storage location information through the AGV-API interface to check whether the finished product area storage location contains the ring mold workpiece on the latest completed process list. The central scheduling subsystem feeds back information to the automatic scheduling module based on the query results.

[0036] Step 7: The automatic scheduling module analyzes the feedback information sent by the central scheduling subsystem to obtain the OEE completion certificate and finished product warehouse location code certificate, and searches the ring die quality control module to query whether the ring die workpieces stored in the finished product area have QC inspection qualification certificates. If so, the three certificates in one transfer strategy is triggered.

[0037] Preferably, in step eight: when the three-certificate integration transfer strategy is triggered, the automatic production scheduling module generates a detailed plan list under the production scheduling conditions set by the machine tool processing capacity configuration module and the machine tool processing time configuration module. The detailed plan list includes the production scheduling tasks of multiple work orders. Each work order's production scheduling task corresponds to a picking location, that is, the finished product area location of the line-side warehouse where the ring die workpiece is stored.

[0038] Step 9: The automatic scheduling module assigns the unloading machine corresponding to the next process to each scheduling task based on the detailed plan list;

[0039] Step 10: The automatic scheduling module creates workpiece handling tasks to the central scheduling subsystem through the AGV-API interface. The workpiece handling task includes the picking location, unloading machine, and material ID code. The central scheduling subsystem assigns a corresponding unloading location to each unloading machine, which is the waiting area location in the line-side warehouse.

[0040] Step 11: The central dispatching subsystem drives the AGV to perform the workpiece handling task. The AGV's automatic identification fork arm module detects whether the material ID code of the ring die workpiece to be handled matches the material ID code in the workpiece handling task. If they match, the ring die workpiece is handled to the corresponding unloading location. If they do not match, the workpiece handling task is stopped. After completing the workpiece handling task, a completion message is sent to the central dispatching subsystem.

[0041] Step 12: After receiving the completion information, the central scheduling subsystem saves the workpiece handling task and unloading location to the AGV database, and synchronously returns the completion information to the automatic scheduling module through the AGV-API interface;

[0042] Step 13: The automatic scheduling module sends a line-side warehouse location information query command to the central scheduling subsystem through the AGV-API interface. The central scheduling subsystem returns the line-side warehouse location information to the automatic scheduling module, which then saves the line-side warehouse location information to the MES database.

[0043] Preferably, the OEE completion certificate represents the completion information of the latest process of the ring die workpiece saved to the MES database through the OEE module in step five;

[0044] The finished product location code voucher indicates that there is a real-time finished product area location code corresponding to the storage location of the completed ring die workpiece in the central scheduling subsystem;

[0045] A QC inspection certificate indicates that the QC inspection of the ring die workpiece has been completed in the latest process and has passed inspection.

[0046] Preferably, when the AGV is performing receiving, material dispatching, or workpiece handling tasks, if there are materials obstructing the warehouse location in front of the picking location, the AGV will prioritize moving the obstructed materials to the nearest available warehouse location.

[0047] Preferably, both the storage area in the incoming material warehouse for storing ring forgings and the storage area in the processing area of ​​the line-side warehouse are equipped with a limiting zone. The limiting zone is formed by two sets of positioning rods arranged horizontally at intervals. The limiting zone is used for vertical storage of ring forgings.

[0048] Both the finished product area and the waiting-to-process area of ​​the line-side warehouse used to store ring die workpieces are equipped with inverted convex oil collection areas.

[0049] The inverted convex oil collection area is used to vertically store ring die workpieces and collect the oil dripping from the ring die workpieces. Attached Figure Description

[0050] Figure 1 This is a schematic diagram of the receiving and handling operation of the present invention;

[0051] Figure 2 This is a schematic diagram of the material handling process of the present invention;

[0052] Figure 3 This is a schematic diagram of inter-process handling of the present invention;

[0053] Figure 4 This is a schematic diagram of the material flow and the operation of each process in the workshop according to the present invention. Detailed Implementation

[0054] The technical solution of the present invention will be further described below with reference to the accompanying drawings and specific embodiments.

[0055] To enable those skilled in the art to better understand the present invention, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings of the embodiments of the present invention. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0056] The terms "first," "second," etc., used in the specification, claims, and accompanying drawings of this invention are used to distinguish different objects, not to describe a specific order. Furthermore, the terms "comprising" and "having," and any variations thereof, are intended to cover non-exclusive inclusion. For example, a process, method, apparatus, product, or end that includes a series of steps or units is not limited to the listed steps or units, but may optionally include steps or units not listed, or may optionally include other steps or units inherent to these processes, methods, products, or ends.

[0057] In this document, the term "embodiment" means that a particular feature, structure, or characteristic described in connection with an embodiment may be included in at least one embodiment of the invention. The appearance of this phrase in various places throughout the specification does not necessarily refer to the same embodiment, nor is it a separate or alternative embodiment mutually exclusive with other embodiments. It will be explicitly and implicitly understood by those skilled in the art that the embodiments described herein can be combined with other embodiments.

[0058] To better illustrate the technical solution of this application, the terms used in this technical solution will be explained first. Specifically, in this invention, "ring die forging" refers to an unprocessed ring die blank, and "ring die workpiece" refers to a processed ring die blank. In this embodiment, as shown in the attached... Figure 4 As shown, the material from the incoming material to the processing area of ​​the line-side warehouse in the first process is called a ring die forging, and the material from the first process to the last process is called a ring die workpiece.

[0059] Furthermore, such as Figure 4 As shown, this invention establishes three handling routes based on the ring die processing production flow: "unloading area → incoming material warehouse" for receiving operations; "incoming material warehouse → roughing area (i.e., the waiting area storage location in the line-side warehouse)" for issuing materials; and "finished product area in the line-side warehouse of the previous process → waiting area in the line-side warehouse of the next process" for inter-process operations. It should be noted that... Figure 4 The process involves multiple steps, each with its own line-side warehouse. Each line-side warehouse is divided into a waiting-to-process area and a finished product area. Based on the three transport routes mentioned above, all storage locations can be categorized as unloading area locations, incoming material storage area locations, line-side warehouse waiting-to-process area locations, and line-side warehouse finished product area locations. A line-side warehouse refers to a storage location allocated to each machine within the workshop. These locations are situated next to the machine. Part of each machine's storage location is used to store parts awaiting processing (this part is called the line-side warehouse waiting-to-process area), and the other part is used to store finished products (this part is called the line-side warehouse finished product area).

[0060] All storage locations have internal dimensions of 1600 x 550 mm, with yellow lines 50 mm wide. This ensures the AGV can travel 600 mm forward from each location. Each location has a designated location code. Both the incoming material storage area and the line-side processing area use positioning rods to prevent the ring mold from rolling. The rods have an interface of 30 x 20 mm, and the distance between two rods is 280 mm. The difference between the incoming material storage area and the line-side processing area is the spacing between columns. There are no pre-reserved gaps between columns in the incoming material storage area, improving space utilization. In contrast, a 200 mm gap is reserved between columns in the line-side processing area to facilitate employee passage. The distance between columns in the finished product area and the inventory area is also 200mm. The biggest difference between these and the two types of storage locations mentioned above is that they have an inverted "convex" shaped oil collection groove at the bottom. This type of storage location is mainly used in processes where ring die workpieces have a large amount of machine oil after processing, such as drilling, milling, gun drilling, and chamfering. The oil collection groove is used to collect the machine oil on the ring die workpieces and to position the workpieces. The top of the groove consists of a bottom support grid plate and two left and right positioning grid plates.

[0061] Furthermore, the methods and steps for receiving goods can be described through the following examples and appendices. Figure 1 Explanation:

[0062] 1.1 First, employees place the ring forgings to be received in their designated locations in the unloading area and attach material ID codes to the ring forgings.

[0063] 1.2 Use the mobile client to continuously scan the receiving work order code, storage location code and material ID code, and scan the information of the three codes into the factory module. The three codes are combined to complete the receiving operation in the WMS module.

[0064] 1.3 The WMS module generates a receiving record and saves it to the MES database along with the three-code information. Since the storage location code of the three codes is the picking storage location code of the ring die forging warehousing operation, the MES subsystem can obtain the receiving record and picking storage location (i.e., the storage location in the unloading area in 1.1) from the MES database and transmit the above information to the automatic scheduling module.

[0065] 1.4 Meanwhile, the work order material issuance traceability module embedded in the WMS module can integrate the information involved in the "three codes in one" to form a real-time updated report on the source traceability of the ring die forging receiving work order, namely the ring die forging receiving work order source traceability report.

[0066] 1.5 The automatic scheduling module generates a material transfer task list for inbound materials and sends it to the WMS module item by item according to the list. The WMS module then automatically matches a storage location in the incoming material warehouse as the unloading location for the received material transfer task. The automatic allocation logic is to allocate the innermost storage location in the available storage area of ​​the incoming material warehouse that is closest to the picking location as the unloading location.

[0067] 1.6 The WMS module creates receiving and handling tasks (including picking locations, unloading locations, and material ID codes) and sends them to the central dispatch subsystem via the AGV-API interface;

[0068] 1.7 After receiving the receiving and handling task, the central dispatch subsystem will drive the AGV to the picking location, since the task information already contains the picking location and unloading location.

[0069] 1.8 Upon arrival at the pickup location, the AGV uses the "automatic identification fork arm module" to check whether the material ID code on the ring die forging matches the material ID code information in the receiving and handling task. If they match, the handling task continues, lifting the ring die forging and moving it to the unloading location. If they do not match, the task is stopped.

[0070] 1.9 After the transport is completed, the AGV sends a task completion confirmation message to the central dispatch subsystem, which then saves the transport task to the AGV database. Simultaneously, it returns task completion information to the WMS module via the AGV-API interface.

[0071] 1.10. The WMS module sends a query command for the warehouse location information of the line-side warehouse to the central dispatch subsystem through the AGV-API interface. The central dispatch subsystem then returns the warehouse location information of the line-side warehouse to the WMS module. The WMS module saves the information in the MES database for use by the entire MES subsystem.

[0072] In one embodiment, the so-called three codes refer to the receiving work order code, the storage location code, and the material ID code, all of which are QR codes. The receiving work order code is a QR code affixed to the label on the ring forging by the supplier upon delivery, containing work order information. The storage location code is an identifier for the storage location, preset during the storage location design, and its information is recorded in the MES database. The storage location codes for the incoming material storage area and unloading area are managed by the WMS module and recorded in the MES database, while the storage location codes for the line-side warehouse are managed by the central scheduling subsystem, and their information is also recorded in the AGV database. The material ID code is a QR code printed on a PVC board with a strong magnet on the back, containing a number (P + 5 digits, e.g., P00000). This serves as the identification credential for the ring forging during material handling throughout the workshop production process. The PVC board, with its strong magnet, adheres magnetically to the ring forging and is uniformly affixed to the top of the side of the ring forging facing the AGV for automatic identification and scanning by the AGV's forklift module.

[0073] When receiving goods in the workshop, after the ring die forgings arrive, they are first unloaded onto their designated storage location in the unloading area. Next, a material ID code is placed on the forging. Then, the material ID code, work order code, and unloading area storage location code are scanned consecutively. Once all three codes are scanned, it signifies that the forging has been received, and a receiving record is generated in the WMS module. Simultaneously, the material ID code is linked to the ring die forging's work order information and stored in the work order issuance traceability module of the WMS module.

[0074] Furthermore, the method and steps for the material feeding operation can be illustrated by the following examples and appendices. Figure 2 Explanation:

[0075] 2.1 After receiving a new work order, the SAP subsystem saves the new work order information to the SAP database, and then the SAP database synchronizes the new work order information to the MES database.

[0076] 2.2 The WMS module manages the storage location information of the incoming material warehouse and saves the information to the MES database. The MES subsystem can obtain the information of the storage location of the incoming material warehouse from the MES database, mainly which storage location contains which ring die forgings and the quantity of each type of ring die forging.

[0077] 2.3 The MES subsystem retrieves new work order information from the SAP subsystem from the MES database, such as delivery date and total work order hours, and transmits the above information to the automatic scheduling module. The automatic scheduling module calculates the material issuance start time of the work order in conjunction with the conditions set by the machine tool processing capacity configuration module and the machine tool processing time configuration module.

[0078] 2.4 The MES subsystem retrieves new work order information from the SAP subsystem from the MES database, including information on which material number of the ring forging is used to manufacture the work order. The automatic scheduling module uses this information to search the MES database for suitable ring forgings in the incoming material warehouse to produce this work order, since the MES subsystem has already obtained the information on the storage location in the incoming material warehouse in step 2.2.

[0079] 2.5 Once the automatic scheduling module finds a suitable ring forging in the incoming material warehouse, it can arrange material issuance for the work order and assign an unloading machine. At the same time, the automatic scheduling module integrates the work orders that need material issuance that day into a task list for material issuance that day.

[0080] 2.6 The automatic scheduling module issues material transfer tasks to the WMS module one by one according to the material transfer task list for the day. The WMS module automatically matches a storage location in the incoming material warehouse that stores the above materials as the picking location based on the material information of the ring die forging in the received material transfer task (because the storage location information of the incoming material warehouse is managed by the WMS module, it can be matched automatically).

[0081] 2.7 The WMS module creates material handling tasks (including picking locations, unloading machines, and material ID codes) and sends them to the central scheduling subsystem through the AGV-API interface.

[0082] 2.8 After receiving the material dispatching task, the central dispatching subsystem will automatically allocate an unloading storage location to the unloading machine's waiting area based on the automatic storage location allocation logic (which refers to allocating the innermost storage location in the idle storage area of ​​the unloading machine's waiting area as the unloading storage location) according to the automatic storage location allocation logic (the logic refers to allocating the innermost storage location in the idle storage area of ​​the unloading machine's waiting area as the unloading storage location). Then, it will drive the AGV to the storage location.

[0083] 2.9 Upon arrival at the pickup location, the AGV uses the "automatic identification forklift module" to check whether the material ID code on the ring die forging matches the material ID code information in the handling task. If they match, the handling task continues, lifting the ring die forging and moving it to the unloading location.

[0084] 2.10 After the transport is completed, the AGV sends a task completion confirmation message to the central dispatch subsystem. The central dispatch subsystem then saves this transport task along with the unloading location to the AGV database. Simultaneously, it returns task completion information to the WMS module via the AGV-API interface.

[0085] 2.11 The WMS module sends a query command for line-side warehouse location information to the central dispatch subsystem through the AGV-API interface. The central dispatch subsystem then returns the warehouse location information of the line-side warehouse to the WMS module, which stores the information in the MES database for use by the entire MES subsystem.

[0086] Furthermore, the methods and steps for inter-process operations can be illustrated by the following examples and appendices. Figure 3 Explanation:

[0087] 3.1 Employees use the PDA operation module's data input terminal to perform a warehouse location unbinding operation. The purpose is to remove the binding relationship between the warehouse location in the processing area and the ring die workpiece stored on it. The warehouse location code of the processing area (in this application, each machine is limited to having a processing area) is scanned into the PDA operation module. Subsequently, the PDA operation module sends an update warehouse location information instruction to the central scheduling subsystem through the AGV-API interface to update the warehouse location information and complete the unbinding operation (Note: The processing area warehouse location and the finished product warehouse location in the line-side warehouse are both managed by the central scheduling subsystem).

[0088] 3.2. Employees hoist the ring die workpiece from the waiting area storage location to the machine, scan the work order at the data acquisition terminal, start recording the processing time, and after processing is completed, hoist the ring die workpiece to the finished product storage location near the machine.

[0089] 3.3 Employees use the PDA operation module's data input terminal to perform warehouse location binding operations, the purpose of which is to bind the finished product area warehouse location to the ring die workpiece placed on it. The finished product area warehouse location code (note: the finished product area warehouse location is shared by all machines), work order code, and material ID code are scanned into the PDA operation module. The PDA operation module then sends an update warehouse location information command to the central scheduling subsystem via the AGV-API interface.

[0090] 3.4 The central dispatch subsystem verifies the accuracy of the uploaded work order code and material ID code by using the work order code and material ID code stored in the AGV database during the receiving operation. If the verification is successful, the binding operation is completed, the storage location information is updated, and a success message is returned to the PDA operation module; otherwise, an error message is returned. (Note: The processing area and finished product storage locations in the line-side warehouse are both managed by the central dispatch subsystem.)

[0091] 3.5. Employees input the process completion command at the data acquisition terminal, and the work time and process completion information of the work order are collected into the OEE module.

[0092] 3.6 The OEE module collects the working hours and process status information of each work order at each data acquisition terminal, and then integrates the information of all work orders and saves it into the MES database.

[0093] 3.7 The RTB module uploads the work order hours and process status information from the information saved to the MES database by the OEE module in step 3.4 to the SAP subsystem. After confirming the above information, it saves it to the SAP database, and then the SAP database synchronizes the above confirmation information back to the MES database.

[0094] 3.8 The MES subsystem obtains the real-time work order process status information from the OEE module from the MES database, knows which work orders have which latest process has been completed, and generates a list to send the information to the automatic scheduling module.

[0095] 3.9 The automatic scheduling module then sends a query command for the lineside warehouse location to the central scheduling subsystem via the AGV-API interface to check whether the ring mold workpiece in the list described in step 3.7 is in the lineside warehouse location. The central scheduling subsystem then returns the information to the automatic scheduling module.

[0096] 3.10 The automatic scheduling module analyzes the returned information and confirms which warehouse location (finished product warehouse location code certificate) the ring die workpiece of the work order whose latest process has been completed (OEE completion certificate) in the list mentioned in step 3.7 is located. Then, the automatic scheduling module searches the ring die quality control module to query whether the ring die workpiece stored in the finished product warehouse has a QC inspection certificate.

[0097] 3.11. After the employee enters the inspection certificate of the finished ring die workpiece into the ring die inspection data input terminal, the automatic scheduling module collects the three certificates of the ring die workpiece (finished product warehouse location code certificate, OEE completion certificate, and QC inspection certificate), triggering the "three certificates in one transfer strategy".

[0098] 3.12 The automatic production scheduling module automatically schedules production and generates a detailed plan list under the conditions set by the machine tool processing capacity configuration module and the machine tool processing time configuration module.

[0099] 3.13. Since the automatic scheduling module has already obtained the three certificates of the ring die workpiece in step 3.10, the automatic scheduling module can assign each task on the detailed plan list to the picking location of the AGV trolley (i.e., the finished product location code). After obtaining the picking location, the automatic scheduling module will arrange the unloading machine of the next process for the task on the detailed plan list.

[0100] 3.14 The automatic scheduling module creates workpiece handling tasks (including picking locations, unloading machines, and material ID codes) and sends them to the central scheduling subsystem through the AGV-API interface.

[0101] 3.15 After receiving the workpiece handling task, the central dispatch subsystem will automatically allocate an unloading machine without unloading storage space in the task information. The allocation logic is to allocate the innermost storage space in the idle storage space area of ​​the unloading machine's waiting area as the unloading storage space. Then, the AGV trolley will drive to the unloading storage space.

[0102] 3.16. Upon arrival at the pickup location, the AGV uses the automatic identification fork arm module to check whether the material ID code on the ring die forging matches the material ID code information in the handling task. If they match, the handling task continues, lifting the ring die forging and moving it to the unloading location.

[0103] 3.17 After the transport is completed, the AGV sends a task completion confirmation message to the central scheduling subsystem. The AGV central scheduling subsystem then saves this transport task along with the unloading location to the AGV database. At the same time, it returns task completion information to the automatic scheduling module through the AGV-API interface.

[0104] 3.18 The automatic scheduling module sends a query command for line-side warehouse location information to the central scheduling subsystem through the AGV-API interface. The central scheduling subsystem then returns the warehouse location information of the line-side warehouse to the automatic scheduling module, which saves the information in the MES database for use by the entire MES subsystem.

[0105] In one embodiment, the "three certificates" refer to the finished product location code certificate, the OEE (Outcome Execution) completion certificate, and the QC (Quality Control) inspection certificate. The finished product location code certificate refers to the real-time location code in the central scheduling subsystem's database that corresponds to the storage location of the ring die workpiece in the online side warehouse finished product area; the OEE completion certificate refers to the completion information corresponding to the ring die workpiece in the OEE module; and the QC inspection certificate refers to the QC inspection qualification information corresponding to the ring die workpiece in the ring die quality control module. Once the three certificates are complete, the automatic production scheduling module is automatically triggered to generate a detailed production plan and a material transfer task, transferring the processed ring die workpiece to the storage area.

[0106] In one embodiment, the machine tool processing capability configuration module is embedded in the MES subsystem. This module categorizes machine tools into processing centers based on their processing capabilities. It sets the processing center's capabilities by outer diameter range, ability to process countersunk holes, tapered holes, countersunk hole range, through hole range, inner diameter range, and length range. Within each processing center, a suitable machine tool is configured, and a usage priority is assigned, with '1' indicating priority usage, and so on. When scheduling production, the automatic scheduling module retrieves relevant work order information from the MES database, such as the outer diameter, inner diameter, countersunk hole, and tapered hole data of the ring die to be produced. It then automatically matches the appropriate machine tool from this module for processing. Furthermore, the machine tool's number automatically becomes the AGV's unloading machine number during automatic AGV transport.

[0107] In another embodiment, the machine tool processing time configuration module is embedded in the MES subsystem. This module sets the weekly production processing time for all available machine tools in the workshop. It manages machine tools by grouping them by type, and allows setting production scheduling time intervals, shift hours, shift efficiency, number of shifts per day, machine tool utilization, and can adjust the number of working days for the following week based on actual leave. This provides a suitable working time setting to coordinate with the automatic scheduling module's automatic scheduling operation.

[0108] In one embodiment, the automatic identification forklift module is a forklift arm installed on an AGV that can both lift vertically and move horizontally, and it also has functions such as automatic scanning, obstacle detection, identification of the center position of an object, and identification of the existence of an object.

[0109] It can be understood as primarily composed of a fork arm support, fork arm support protective pads, fork arm connecting rods, scanner mounting base, several sensors, and a scanner. The sensors include photoelectric sensors and lidar sensors. The photoelectric sensor detects whether there are obstacles in front of the fork arm's tip; if an obstacle is found, the AGV stops to protect the fork arm and the obstacle. The lidar sensor locates the center position of the ring die forging or workpiece, or detects whether there is a ring die forging or workpiece on the fork arm connecting rod. The scanner is a high-precision scanner that scans the material ID code on the ring die forging or workpiece to the central scheduling subsystem for information identification, determining whether the material is correct.

[0110] The length of the fork arm (from the outermost end face of the scanner mounting base to the protective pad of the fork arm bracket) cannot exceed the length of one storage location. Otherwise, when the fork arm is operated, it will interfere with the ring die forgings or workpieces stored in the adjacent storage location behind the picking location, damaging the precision instruments (i.e., photoelectric sensors and scanners) in the scanning mounting base of the fork arm. However, it cannot be designed too short either. If the fork arm is designed to be very short, a safety accident may easily occur when the fork arm lifts a large ring die forging or workpiece.

[0111] When the AGV (Automated Guided Vehicle) approaches the picking location, it adjusts its position so that the front is directly facing the location, and the forks are lowered to their lowest position. It then slowly approaches the workpiece or forging in front of the ring die. When the photoelectric sensor at the front of the fork arm detects an object (approximately 100mm away), the AGV stops and begins to raise the forks. Simultaneously, the lidar sensor at the base of the fork arm begins scanning the object. When the fork arm is raised to its maximum outer diameter (based on the handling command received by the AGV), the lidar sensor completes the scan and calculates the object's center position using an algorithm. The AGV then horizontally moves the forks, positioning them directly above the object's center. The scanner at the front of the forklift starts scanning for material ID codes ahead. If the detected material ID code matches the one uploaded during task creation, the forklift is lowered to the center of the object. After that, as long as the photoelectric sensor at the front of the forklift does not detect any obstacles ahead, the AGV continues to move slowly forward until it reaches the stopping position of the picking location and stops. At the same time, the laser radar sensor located directly above the forklift's protective bracket detects whether the forklift has picked up the object. If it has, the forklift is raised and the object is lifted, thus completing the picking up of the ring forging or workpiece. Because the laser radar sensor detects that an object is hanging on the forklift, the AGV immediately updates its status from empty to loaded.

[0112] In the optimal embodiment, the flexible automated handling of this solution is mainly reflected in the following three aspects:

[0113] a. Flexible control over pickup:

[0114] a1. When the picking location is located in the incoming material warehouse, since the locations in the incoming material warehouse are managed by the WMS module, before issuing a handling task to the AGV, the WMS module queries the inventory information. If it finds that there is a full warehouse in front of the picking location that is blocking the AGV from reaching the picking location, the WMS module will not only issue a handling instruction for the target task, but also automatically issue a handling instruction for the full warehouse in front of the picking location. The AGV will then prioritize removing the ring die forgings or workpieces from the full warehouse in front of the picking location and move them to the nearest available warehouse for storage.

[0115] a2. Regarding the situation where the picking location originates from the online material warehouse, since the warehouse location at the line edge is managed by the central dispatch subsystem, before issuing a handling task to the AGV, the central dispatch subsystem checks the inventory information and finds that there is a full warehouse in front of the picking location that is preventing the AGV from reaching the picking location. After receiving the handling instruction for the target task, the central dispatch subsystem will automatically issue a handling instruction to the full warehouse in front of the picking location, and use the AGV to prioritize moving the ring die forgings or workpieces from the full warehouse in front of the picking location, and move them to the nearest available warehouse location for storage.

[0116] b. Flexible control of unloading:

[0117] When the unloading location is blocked (since the unloading location is provided by the central scheduling subsystem or WMS module, theoretically there is no obstruction; if an obstruction occurs, it is an abnormal situation), the AGV can automatically identify this situation. The AGV will then report the fault and prompt manual handling. If no one handles it within the preset time, the central scheduling subsystem will replan the route and call the AGV to transfer the workpiece that cannot be unloaded to the abnormal area for storage (Note: If there is a production plan for the workpiece in the abnormal area later, the AGV will prioritize its handling).

[0118] c. Flexible control of route planning:

[0119] AGVs can start transporting goods from any pre-planned route in the workshop without needing to return to a specific starting position.

[0120] The technical principles of the present invention have been described above with reference to specific embodiments. These descriptions are merely for explaining the principles of the invention and should not be construed as limiting the scope of protection of the invention in any way. Based on this explanation, those skilled in the art can readily conceive of other specific embodiments of the invention without inventive effort, and these embodiments will all fall within the scope of protection of the present invention.

Claims

1. A flexible automatic handling method for self-distribution and self-identification in ring die production, characterized in that: It is applied to a material handling system, which includes a client, a factory module, a WMS module, an MES database, an automatic production scheduling module, a central scheduling subsystem, AGV carts, an AGV database, and a work order material issuance and traceability submodule. The automated scheduling and flexible automated handling method for ring die production includes a receiving operation sub-method, which includes: Step A: The client scans the three codes on the ring forging and enters them into the factory module to complete the receiving operation in the WMS module. The three codes include the receiving work order code, the storage location code, and the material ID code. Step B: The WMS module generates a receiving record based on the entered three-code information, saves the receiving record and three-code information to the MES database, and uploads the receiving record and three-code information to the automatic scheduling module; Step C: The work order material issuance traceability submodule built into the WMS module integrates the three-code information to form a source traceability report for the ring die forging receiving work order; Step D: The automatic production scheduling module generates a material transfer task sheet for inbound goods based on the receiving record and three-code information, and sends the material list in the material transfer task sheet to the WMS module item by item; Step E: The WMS module automatically matches the corresponding warehouse storage area as the unloading location according to the material transfer task table. The WMS module creates a receiving and handling task through the AGV-API interface and sends the receiving and handling task to the central scheduling subsystem. The receiving and handling task includes the picking location, the unloading location and the material ID code. Step F: The central dispatching subsystem plans the AGV cart transportation route according to the receiving and handling task, and drives the AGV cart to perform the receiving and handling task; Step G: The AGV has an automatic identification fork arm module. The automatic identification fork arm module detects whether the material ID code of the ring die forging to be transported is consistent with the material ID code in the receiving and handling task. If they are consistent, the ring die forging is transported to the corresponding unloading warehouse. If they are inconsistent, the receiving and handling task is stopped. After the receiving and handling task is completed, a completion message is sent to the central dispatch subsystem. When the AGV encounters an obstacle on the planned transport route, it will alert the operator. If the operator does not respond, the central dispatching subsystem will replan the route and drive the AGV to transport the ring die forging to the abnormal area for storage. Step H: After receiving the completion information, the central dispatch subsystem saves the receiving and handling task to the AGV database and synchronously returns the completion information to the WMS module through the AGV-API interface; Step 1: The WMS module sends a query command for line-side warehouse location information to the central dispatch subsystem through the AGV-API interface. The central dispatch subsystem returns the line-side warehouse location information to the WMS module, and the WMS module saves the line-side warehouse location information to the MES database.

2. The self-distribution and self-identification flexible automatic handling method for ring die production according to claim 1, characterized in that: The material handling system also includes an SAP subsystem, an SAP database, and an MES subsystem; The automated scheduling and flexible automated handling method for ring die production includes a material feeding operation sub-method, which includes: Step a: The WMS module saves the storage location information of the incoming material warehouse to the MES database. The storage location information of the incoming material warehouse includes the type of ring forgings stored in the corresponding storage location and the quantity of each type of ring forgings. Step b: After receiving a new work order, the SAP subsystem saves the new work order to the SAP database, and the SAP database synchronizes the new work order to the MES database; Step c: The MES subsystem retrieves the new work order and the storage location information of the incoming material warehouse from the MES database and forwards it to the automatic scheduling module. The automatic scheduling module calculates the start time for issuing materials for the new work order based on the processing conditions set by the machine tool processing capacity configuration module and the machine tool processing time configuration module. Step d: The automatic scheduling module confirms whether there are ring die forgings for the production of new work orders in the incoming material warehouse based on the warehouse location information. If there are, the module arranges the material issuance for the new work order and integrates the ring die forgings that need to be issued that day into the material issuance task list for that day. The material issuance task list for that day is then sent to the WMS module. Step e: The WMS module automatically matches the storage location of the incoming material warehouse containing the corresponding material as the picking location based on the material information of the ring die forging in the material issuance task list for the day. Step f: The WMS module creates a material dispatching and handling task for the central scheduling subsystem through the AGV-API interface. The material dispatching and handling task includes the picking location, unloading machine and material ID code. The central scheduling subsystem automatically allocates the waiting area storage location in the line-side warehouse of the unloading machine as the unloading location according to the material dispatching and handling task, and drives the AGV to execute the material dispatching and handling task. Step g: The AGV's automatic identification forklift module detects whether the material ID code of the ring die forging to be transported matches the material ID code in the material dispatching task. If they match, the ring die forging is transported to the corresponding unloading location. If they do not match, the material dispatching task is stopped. After completing the material dispatching task, a completion message is sent to the central dispatching subsystem. Step h: After receiving the completion information, the central dispatch subsystem saves the material handling task and unloading location to the AGV database, and synchronously returns the completion information to the WMS module through the AGV-API interface; Step i: The WMS module sends a query command for line-side warehouse location information to the central dispatch subsystem through the AGV-API interface. The central dispatch subsystem returns the line-side warehouse location information to the WMS module, and the WMS module saves the line-side warehouse location information to the MES database.

3. The self-distribution and self-identification flexible automatic handling method for ring die production according to claim 2, characterized in that: The material handling system also includes a PDA operation module data input terminal, a data acquisition terminal, a PDA operation module, an RTB module, an OEE module, and a ring mold quality control module; The automated scheduling and flexible automated handling method for ring die production includes an inter-process operation sub-method, which includes: Step 1: The PDA operation module's data input terminal scans the storage location code of the waiting area storage location in the line-side warehouse where the ring die workpiece is stored and enters the storage location code into the PDA operation module to perform the unbinding operation of the waiting area storage location and the stored ring die workpiece. The PDA operation module sends an instruction to update the storage location information to the central scheduling subsystem through the AGV-API interface to update the storage location information of the waiting area storage location, thereby completing the unbinding operation of the ring die workpiece. Step 2: Place the ring die workpiece in the processing area of ​​Step 1 onto the machine for processing. The data acquisition terminal scans the processing work order and records the processing time. After processing, store the ring die workpiece in the finished product area of ​​the line-side warehouse. The ring die workpiece is a ring die forging that has undergone one or more processing steps during the inter-process operation. Step 3: The PAD operation module's data input terminal scans the storage location code, work order code, and material ID code of the finished product area storage location in Step 2, and inputs them into the PAD operation module to perform the binding operation between the finished product area storage location and the stored ring die workpiece. The PAD operation module sends an instruction to update the storage location information to the central scheduling subsystem through the AGV-API interface to update the storage location information of the finished product area storage location. Step 4: The central dispatch subsystem verifies the work order code and material ID code uploaded in Step 3 with the work order code and material ID code saved in the receiving operation. If the verification is successful, the binding operation between the finished product area storage location and the ring die workpiece stored therein will be completed. Step 5: The data acquisition terminal collects the work order hours and process status information of the ring die workpieces processed by the machine tools in each process. The process status information includes the completion information of the latest process. It is saved to the MES database through the OEE module. The RTB module uploads the work order hours and process status information saved in the MES database to the SAP subsystem for confirmation. After confirmation, it is saved to the SAP database. The SAP database synchronizes the confirmed work order hours and process status information to the MES database. Step Six: The MES subsystem obtains the confirmed work order hours and process status information from the MES database, generates the latest completed process list based on the latest process completion information, and sends it to the automatic scheduling module. The automatic scheduling module sends a command to the central scheduling subsystem to query the finished product area storage location information through the AGV-API interface to check whether the finished product area storage location contains the ring mold workpiece on the latest completed process list. The central scheduling subsystem feeds back information to the automatic scheduling module based on the query results. Step 7: The automatic scheduling module analyzes the feedback information sent by the central scheduling subsystem to obtain the OEE completion certificate and finished product location code certificate, and searches the ring die quality control module to query whether the ring die workpieces stored in the finished product area have QC inspection certificates. If so, the three certificates are combined into one and the transfer strategy is triggered.

4. The self-distribution and self-identification flexible automatic handling method for ring die production according to claim 3, characterized in that: Step 8: When the three-certificate integration transfer strategy is triggered, the automatic production scheduling module generates a detailed plan list under the production scheduling conditions set by the machine tool processing capacity configuration module and the machine tool processing time configuration module. The detailed plan list includes the production scheduling tasks of multiple work orders. Each work order's production scheduling task corresponds to a picking location, that is, the finished product area storage location of the line-side warehouse where the ring die workpiece is stored. Step 9: The automatic scheduling module assigns the unloading machine corresponding to the next process to each scheduling task based on the detailed plan list; Step 10: The automatic scheduling module creates workpiece handling tasks to the central scheduling subsystem through the AGV-API interface. The workpiece handling task includes the picking location, unloading machine, and material ID code. The central scheduling subsystem assigns a corresponding unloading location to each unloading machine, which is the waiting area location in the line-side warehouse. Step 11: The central dispatching subsystem drives the AGV to perform the workpiece handling task. The AGV's automatic identification fork arm module detects whether the material ID code of the ring die workpiece to be handled is consistent with the material ID code in the workpiece handling task. If they are consistent, the ring die workpiece is handled to the corresponding unloading warehouse. If they are inconsistent, the workpiece handling task is stopped. After completing the workpiece handling task, a completion message is sent to the central scheduling subsystem. Step 12: After receiving the completion information, the central scheduling subsystem saves the workpiece handling task and unloading location to the AGV database, and synchronously returns the completion information to the automatic scheduling module through the AGV-API interface; Step 13: The automatic scheduling module sends a line-side warehouse location information query command to the central scheduling subsystem through the AGV-API interface. The central scheduling subsystem returns the line-side warehouse location information to the automatic scheduling module, which then saves the line-side warehouse location information to the MES database.

5. The self-distribution and self-identification flexible automatic handling method for ring die production according to claim 4, characterized in that: The OEE completion certificate represents the completion information of the latest process of the ring die workpiece, which is saved to the MES database through the OEE module in step five. The finished product location code voucher indicates that there is a real-time finished product area location code corresponding to the storage location of the completed ring die workpiece in the central scheduling subsystem; A QC inspection certificate indicates that the QC inspection of the ring die workpiece has been completed in the latest process and has passed inspection.

6. The self-distribution and self-identification flexible automatic handling method for ring die production according to claim 5, characterized in that: When the AGV is performing receiving, material dispatching, or workpiece handling tasks, if there are materials obstructing the warehouse location in front of the picking location, the AGV will prioritize moving the obstructed materials to the nearest available warehouse location.

7. The self-distribution and self-identification flexible automatic handling method for ring die production according to claim 5, characterized in that: Both the incoming material storage area and the processing area of ​​the line-side warehouse for storing ring forgings are equipped with limiting zones. The limiting zones are formed by two sets of positioning rods arranged horizontally at intervals. The limiting zones are used for vertical storage of ring forgings. Both the finished product area and the waiting-to-process area of ​​the line-side warehouse used to store ring die workpieces are equipped with inverted convex oil collection areas. The inverted convex oil collection area is used to vertically store ring die workpieces and collect the oil dripping from the ring die workpieces.

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