Automatic production scheduling method and system for precast beams

Abstract

The invention provides an automatic production scheduling method and system for precast beams, and relates to the technical field of production plan management systems. The automatic production scheduling system for the precast beams comprises the automatic production scheduling method for the precast beams, and the automatic production scheduling method for the precast beams comprises the steps that planned beam supply time and precast beam models of a single order are inquired, a plurality of orders are classified and sorted, and a plurality of production devices are classified according to the precast beam models capable of being produced; sorting the classified production equipment according to the predicted release time; the orders and the production equipment are firstly matched according to the model of the precast beam, then matching is conducted according to the order of the orders and the production equipment, and the matching relation between the orders and the production equipment is formed; and outputting a beam manufacturing plan based on the matching relationship between the order and the production equipment. According to the automatic production scheduling method and system for the precast beams, influence factors of production scheduling of the precast beams are comprehensively considered, automatic production scheduling of the precast beams can be achieved, the beam manufacturing plan can be directly output, and production scheduling efficiency and production scheduling accuracy are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of production planning management systems, and in particular to an automatic production scheduling method and system for prefabricated beams. Background Art

[0002] A precast beam yard is a place specially used for producing precast concrete beams. The beam supply unit precasts the beams in the beam yard according to the design requirements, and then transports them to the construction site for erection and installation. It is mainly used in infrastructure construction such as bridges and highways, which can greatly improve construction efficiency and quality.

[0003] During the production process of the precast beam yard, the beam-using unit places an order to the beam-supplying unit. The beam-supplying unit needs to formulate and dynamically adjust the production schedule in a timely manner to arrange production based on the latest order. Most of the existing production schedules are formulated by the precast beam yard and special personnel are arranged to manually schedule production. In order to ensure the quality of the precast beams, timely delivery and the economy of the precast beam yard's production, it is necessary to consider multiple factors during production scheduling, such as delivery time, beam storage time, beam yard production capacity, beam yard storage capacity, daily working hours of the beam yard, process continuity, raw material supply, beam yard production efficiency, and on-site construction requirements. Manual scheduling is labor-intensive, inefficient, and fails to fully utilize the beam yard's resources. Summary of the invention

[0004] The object of the present invention is to provide a method and system for automatic production scheduling of precast beams, so as to solve the technical problem that the production plan of precast beams in the prior art requires manual production scheduling.

[0005] In a first aspect, the present invention provides a method for automatically scheduling prefabricated beams, comprising:

[0006] Query the planned beam supply time, precast beam model, and standard process time of a single order, and calculate the earliest production start time and planned production time interval of the order;

[0007] Sort multiple orders by the earliest production start time of the orders. For multiple orders within the planned production time interval, classify them by the precast beam models of the orders, and after classification, sort them by the earliest production start time of the orders;

[0008] Multiple production equipment are classified according to the precast beam models that can be produced, and the classified production equipment are sorted according to the expected release time;

[0009] First, the orders and production equipment are matched according to the prefabricated beam models, and then matched according to the order of the orders and production equipment to form a matching relationship between the orders and production equipment;

[0010] Based on the matching relationship between the order and the production equipment, the beam manufacturing plan is output.

[0011] In an optional implementation, when calculating the earliest start production time and planned production time interval of an order, the standard process time and beam storage time of the order are obtained, and the earliest start production time of the order is obtained by subtracting the beam storage time from the planned beam supply time. The latest start production time of the order is obtained by subtracting the standard process time from the planned beam supply time. The earliest start production time and the latest start production time define the start production time interval of the task.

[0012] In an optional embodiment, when the prefabricated beam model of the order is compatible with multiple production equipment at the same time, the standard process time is the maximum standard process time of the multiple production equipment.

[0013] In an optional embodiment, the production equipment includes a production line and a fixed platform, and the production line includes a mobile platform.

[0014] In an optional embodiment, the estimated release time of the fixed pedestal is calculated by obtaining the process of the prefabricated beam currently being produced and the duration of the process. The estimated release time is the standard time of the current process minus the duration of the current process plus the standard time of the remaining process.

[0015] In an optional embodiment, the production line includes multiple production areas, and the production areas include a concrete pouring area, a curing area, and a tensioning area. The estimated release time of each production area is obtained as the estimated release time of the production line. The estimated release time of the production area is the larger of the following two: the standard time of the current process minus the duration of the current process, and the estimated release time of the production area of ​​the next process.

[0016] In an optional implementation, the beam making plan includes the planned beam making time of the order and the daily planned beam making task. The planned beam making time of the order is the estimated release time of the production equipment. If the planned beam making time of the order exceeds the daily working hours, it will be postponed to the next working day. In the daily planned beam making task, when the remaining duration of the working day is less than the process duration, the process will be postponed to the next working day.

[0017] In an optional implementation, the output beam-making plan includes order information, planned production equipment, planned beam-making time, and daily planned beam-making tasks.

[0018] In an optional implementation, material recommendations are output based on the beam manufacturing plan, and the material recommendations include a material requirement list and a material replenishment recommendation list.

[0019] The automatic scheduling method for precast beams provided by the present invention comprehensively considers the factors affecting the scheduling of precast beams, including order information, production equipment, etc., can realize automatic scheduling of precast beams, can directly output beam manufacturing plans, improves scheduling efficiency and scheduling accuracy, and makes full use of beam yard resources.

[0020] In a second aspect, the present invention provides an automatic production scheduling system for precast beams, including a client, a device terminal, a data terminal and a server terminal. The client is an application running on a user device, and the client executes an automatic production scheduling method for precast beams according to any one of the aforementioned implementations.

[0021] The automatic scheduling system for precast beams provided by the present invention comprehensively considers the factors affecting the scheduling of precast beams, including order information, production equipment, etc., can realize automatic scheduling of precast beams, can directly output beam manufacturing plans, improves scheduling efficiency and scheduling accuracy, and makes full use of beam yard resources. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] In order to more clearly illustrate the specific implementation methods of the present invention or the technical solutions in the prior art, the drawings required for use in the specific implementation methods or the description of the prior art will be briefly introduced below. Obviously, the drawings described below are some implementation methods of the present invention. For ordinary technicians in this field, other drawings can be obtained based on these drawings without paying creative work.

[0023] Figure 1 A flowchart of the automatic production scheduling system for prefabricated beams provided in an embodiment of the present invention;

[0024] Figure 2 A schematic diagram of order sorting of the method for automatic production scheduling of prefabricated beams provided in an embodiment of the present invention;

[0025] Figure 3 A schematic diagram of order classification for the method for automatic production scheduling of precast beams provided in an embodiment of the present invention;

[0026] Figure 4 A schematic diagram of production equipment arrangement of a method for automatically scheduling production of precast beams provided in an embodiment of the present invention;

[0027] Figure 5 A schematic diagram of matching orders and production equipment in the method for automatic production scheduling of prefabricated beams provided in an embodiment of the present invention;

[0028] Figure 6 A schematic diagram of formulating a beam production plan for the automatic production scheduling method for precast beams provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0029] In order to make the purpose, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Generally, the components of the embodiments of the present invention described and shown in the drawings here can be arranged and designed in various different configurations.

[0030] Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the invention claimed for protection, but merely represents selected embodiments of the present invention. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0031] It should be noted that similar reference numerals and letters denote similar items in the following drawings, and therefore, once an item is defined in one drawing, further definition and explanation thereof is not required in subsequent drawings.

[0032] In the description of the present invention, it should be noted that the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inside", "outside", etc. indicate positions or positional relationships based on the positions or positional relationships shown in the accompanying drawings, or the positions or positional relationships in which the product of the invention is usually placed when in use. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific position, be constructed and operated in a specific position, and therefore cannot be understood as limiting the present invention. In addition, the terms "first", "second", "third", etc. are only used to distinguish the description, and cannot be understood as indicating or implying relative importance.

[0033] In addition, the terms "horizontal", "vertical", "overhanging" and the like do not mean that the components are required to be absolutely horizontal or overhanging, but can be slightly tilted. For example, "horizontal" only means that its direction is more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but can be slightly tilted.

[0034] In the description of the present invention, it is also necessary to explain that, unless otherwise clearly specified and limited, the terms "set", "install", "connect", and "connect" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection; it can be a mechanical connection or an electrical connection; it can be a direct connection, or it can be indirectly connected through an intermediate medium, or it can be the internal communication of two elements. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0035] Some embodiments of the present invention are described in detail below in conjunction with the accompanying drawings. In the absence of conflict, the following embodiments and features in the embodiments can be combined with each other.

[0036] Embodiment 1

[0037] This embodiment provides a method for automatically scheduling prefabricated beams, including:

[0038] Query the planned beam supply time, precast beam model, and standard process time of a single order, and calculate the earliest production start time and planned production time interval of the order;

[0039] Sort multiple orders by the earliest production start time of the orders. For multiple orders within the planned production time interval, classify them by the precast beam models of the orders, and after classification, sort them by the earliest production start time of the orders;

[0040] Multiple production equipment are classified according to the precast beam models that can be produced, and the classified production equipment are sorted according to the expected release time;

[0041] First, the orders and production equipment are matched according to the prefabricated beam models, and then matched according to the order of the orders and production equipment to form a matching relationship between the orders and production equipment;

[0042] Based on the matching relationship between the order and the production equipment, the beam manufacturing plan is output.

[0043] The automatic scheduling method for precast beams provided in this embodiment comprehensively considers the factors affecting the scheduling of precast beams, including order information, production equipment, etc., can realize automatic scheduling of precast beams, can directly output beam manufacturing plans, improve scheduling efficiency and scheduling accuracy, and make full use of beam yard resources.

[0044] This method can automatically formulate a production plan based on the planned beam supply time of the order to ensure that the order can be delivered on time. The planned beam supply time of the order is also the delivery time of the order.

[0045] The method can also be applied to different precast beam models, and can be allocated to corresponding production equipment according to the precast beam model of the order.

[0046] In an optional implementation, when calculating the earliest start production time and planned production time interval of an order, the standard process time and beam storage time of the order are obtained, and the earliest start production time of the order is obtained by subtracting the beam storage time from the planned beam supply time. The latest start production time of the order is obtained by subtracting the standard process time from the planned beam supply time. The earliest start production time and the latest start production time define the start production time interval of the task.

[0047] The storage time of precast beams after production cannot exceed a certain period, otherwise quality problems will occur and the precast beams cannot be used. This period is called the beam storage time. The beam storage time can be set to three months. Based on the planned beam supply time, beam storage time and standard process time of the order, the start production time interval of the order is determined, and production is scheduled according to the start production time interval of the order. On the premise of meeting the order's beam use time and beam storage time, more adjustment intervals can be provided.

[0048] like Figure 2 As shown in the figure, the order includes information such as beam type, precast beam height, bridge name, span number, span number, beam number, etc. The beam type specifically includes side beams and middle beams. The beam type and precast beam height are combined to form the precast beam model for classification. After classification, the orders are sorted according to the earliest planned beam supply time, that is, the earliest production start time. The result of sorting the orders by the earliest planned beam supply time is consistent with the result of sorting by the earliest production start time.

[0049] Production equipment includes two types: production line and fixed pedestal. The production line includes a mobile pedestal. The fixed pedestal and the mobile pedestal have different standard process times when processing the same process. Since the precast beam model of this order can be adapted to both the fixed pedestal and the mobile pedestal, the largest standard process time of the two is recorded as the standard process time of this order. No matter which production equipment is selected in the subsequent production scheduling, it can ensure that the latest start time of the order can complete the generation of the precast beams of the order in time.

[0050] In the production equipment, the production processes that need to occupy the production equipment are concrete pouring, curing, and tensioning, so only these three processes are used to calculate the expected release time of the production equipment.

[0051] Among them, the calculation method of the estimated release time of the fixed pedestal is to obtain the process of the prefabricated beam currently being produced and the duration of the process. The estimated release time is the standard time of the current process minus the duration of the current process plus the standard time of the remaining processes.

[0052] When the production equipment is a production line, the production line includes multiple production areas, and the production areas include concrete pouring area, curing area and tensioning area. The estimated release time of each production area is obtained as the estimated release time of the production line. The estimated release time of the production area is the larger of the following two: the standard time of the current process minus the duration of the current process, and the estimated release time of the production area of ​​the next process.

[0053] like Figure 3 As shown, after the order classification is completed, the prefabricated beam model of the order can be matched with the production equipment. The production line / pedestal in the figure is the production equipment, and the matching process is the process of finding a suitable pedestal.

[0054] like Figure 4 As shown, the production equipment is sorted according to the expected release time. The production lines / stands in the figure are the production equipment, and the stand sorting is the sorting of the production equipment.

[0055] like Figure 5 As shown, after the orders and production equipment are classified and sorted, a matching relationship between the orders and the production equipment is formed.

[0056] In an optional embodiment, when the prefabricated beam model of the order is compatible with multiple production equipment at the same time, the standard process time is the maximum standard process time of the multiple production equipment.

[0057] In an optional implementation, the beam making plan includes the planned beam making time of the order and the daily planned beam making task. The planned beam making time of the order is the estimated release time of the production equipment. If the planned beam making time of the order exceeds the daily working hours, it will be postponed to the next working day. In the daily planned beam making task, when the remaining time of the working day is less than the process time, the process will be postponed to the next working day. The daily working hours are the working hours of each working day, and the remaining time of the working day is the total working hours minus the working hours occupied by the scheduled processes.

[0058] Among the various processes of prefabricated beam production, only the maintenance process does not need to consider the rest time of the beam yard and can be carried out uninterruptedly. Other processes must be completed within one working day and cannot be carried out overnight. Therefore, when formulating the planned beam production time and daily planned beam production tasks for an order, the length of the working day must be considered.

[0059] At the same time, the working hours of a working day can be adjusted and can be extended based on the standard working day length. Therefore, the working day length should be taken into consideration when formulating the planned beam making time and daily planned beam making tasks for an order, and the production plan of precast beams can be adjusted more flexibly according to the specific situation.

[0060] like Figure 6 As shown, the calculation of the planned beam making time for the production of fixed pedestals is relatively simple. It is the estimated release time of the selected pedestal. If the planned beam making time of the order exceeds the daily working hours, it will be postponed to the next working day. For production lines or mobile pedestals, only the estimated release time of the concrete pouring area, curing area and tensioning area needs to be considered. The planned beam making time for the production is the estimated release time of the concrete pouring area of ​​the selected production line. If the planned beam making time of the order exceeds the daily working hours, it will be postponed to the next working day. The curing process in the curing area can be carried out overnight without postponing the beam making time.

[0061] In an optional implementation, the output beam-making plan includes order information, planned production equipment, planned beam-making time, and daily planned beam-making tasks.

[0062] Among them, the planned production equipment includes not only the type of production equipment, but also the specific number of the production equipment.

[0063] In an optional implementation, material recommendations are output based on the beam manufacturing plan, and the material recommendations include a material requirement list and a material replenishment recommendation list.

[0064] The material requirement list is the material list and quantity required for the production order. Calculate the standard material consumption of each type of precast beam separately, and add up the standard material consumption of each type to get the material requirement. When calculating the standard material consumption of each type of precast beam, multiply the standard material consumption of the precast beam of that type by its production quantity.

[0065] Among them, the material replenishment suggestion list is a material replenishment plan recommended according to the production order based on the current material inventory of the precast beam yard. The material replenishment plan includes the replenishment time, where the replenishment time is the date when the estimated material consumption reaches the current inventory minus the minimum inventory warning. The material replenishment plan includes the material replenishment quantity, and the calculation logic of the material replenishment quantity is the maximum inventory capacity minus the minimum inventory warning. Different material replenishment plans are displayed in the order of replenishment time.

[0066] In an optional implementation, the beam supply unit can adjust the beam production plan according to actual conditions, and after confirmation, update the beam production suggestion to the beam production plan to form a formal production suggestion. The material suggestion can be updated according to the adjusted beam production suggestion.

[0067] Embodiment 2

[0068] This embodiment provides a prefabricated beam automatic production scheduling system, including a client, a device terminal, a data terminal and a server terminal. The client is an application running on a user device, and the client executes a prefabricated beam automatic production scheduling method according to any one of the aforementioned implementations.

[0069] The client also interacts with the server to obtain data and execute tasks. In addition to the automatic scheduling of precast beams, the functions executed include the following:

[0070] Precast beam component information management: used to manage all precast beam basic information, such as section, bridge name, span number, span number, beam number, beam type, etc.;

[0071] Production pedestal information management: used to manage the basic information of all production pedestals, such as the production line and pedestal name. The production pedestals here include fixed pedestals and mobile pedestals. The mobile pedestals have production line information, and both the mobile pedestals and fixed pedestals have pedestal names, types, specific numbers, etc.;

[0072] Information management of beam storage pedestals: used to manage all basic information of beam storage pedestals, such as beam storage area and pedestal name;

[0073] Standardized information management of beam production: used to manage dynamically configurable factors affecting production scheduling, including daily production scheduling hours, the range of production pedestals that can be used for the production of different beam types, standard process time (standard time for each production process), and standard material consumption (using the standard consumption of each material);

[0074] Order management: used to manage all order task information, such as required beam information, planned beam supply time, order progress (ordered, beam making, completed, beam shipped);

[0075] Beam production plan: a formal production plan used to manage the precast beam yard;

[0076] Material inventory: used to manage the material warehousing information and material inventory information of the precast beam yard. Material inventory = total warehousing amount - total consumption. The total consumption is calculated based on the standard material consumption of the precast beams produced.

[0077] The equipment terminal senses the production status of precast beams and equipment occupancy through sensors and radio frequency identification (RFID).

[0078] 1) Pedestal scheduling and control terminal: by installing a scheduling system terminal on the pedestal to sense the status of each production pedestal process and store the prefabricated beam information on the beam storage pedestal;

[0079] 2) Template opening and closing control terminal: template closing time collection is used to determine the start time of the concrete pouring process;

[0080] 3) Maintenance control terminal: collect the start time of the maintenance process;

[0081] 4) Tensioning control terminal: collect the start time of the tensioning process;

[0082] 5) Weighbridge control terminal: collects material entry information.

[0083] The data end collects data from the equipment terminal through the data interface, and transmits the collected data to the server end, and the server end and the client end interact with each other. The specific data includes the current production process node of the precast beam, the occupancy of the production pedestal in the production area and the current production precast beam information, the occupancy of the storage pedestal in the storage area and the current storage precast beam information, and the material storage information.

[0084] Among them, the server side includes data reception and analysis, database, automatic production scheduling algorithm model and calculation. The data reception and analysis module receives the data transmitted by the data end and stores it through the database. The client can call the database data and store the client data in the database. The automatic production scheduling algorithm model and calculation can calculate the necessary parameters such as the prefabricated beam order input by the client through the automatic production scheduling model to generate production scheduling suggestions.

[0085] In the above embodiment, data such as whether prefabricated beams are being produced in the current production line production area / production pedestal, the process in which the current prefabricated beams are being produced and the duration of the process are collected by installing multiple equipment control terminals. If this data can be obtained through manual entry or other methods, it is also possible to realize automatic production scheduling in this embodiment to form beam manufacturing suggestions.

[0086] Combination Figure 1 A method and system for automatic scheduling of precast beams provided in the above-mentioned embodiment, the business process used by the automatic scheduling system for precast beams is that first, the beam-using unit places an order task through the order management function, and the order task must include the required beam information and the planned beam supply time; after obtaining the order task, the beam-supplying unit uses the automatic scheduling function to generate beam-making suggestions, and the generated beam-making suggestions can be adjusted by the beam-supplying unit according to actual conditions. After confirmation, the beam-making suggestions are updated to the beam-making plan to form a formal production suggestion. The precast beam yard produces according to the beam-making plan, completes the processes of steel bar binding, concrete pouring, maintenance, tensioning, beam storage, and grouting, and finally delivers the beams according to the needs of the beam-using unit, at which point the production of the precast beams is completed.

[0087] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, rather than to limit it. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the aforementioned embodiments, or replace some or all of the technical features therein with equivalents. However, these modifications or replacements do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. A method for automatically scheduling prefabricated beams, characterized in that: include: Query the planned beam supply time, precast beam model, and standard process time of a single order, and calculate the earliest production start time and planned production time interval of the order; Sort multiple orders by the earliest production start time of the orders. For multiple orders within the planned production time interval, classify them by the precast beam models of the orders, and after classification, sort them by the earliest production start time of the orders; Multiple production equipment are classified according to the precast beam models that can be produced, and the classified production equipment are sorted according to the expected release time; First, the orders and production equipment are matched according to the prefabricated beam models, and then matched according to the order of the orders and production equipment to form a matching relationship between the orders and production equipment; Based on the matching relationship between the order and the production equipment, the beam manufacturing plan is output.

2. The method for automatic production scheduling of precast beams according to claim 1, characterized in that: When calculating the earliest start production time and planned production time interval of an order, obtain the standard process time and beam storage time of the order, subtract the beam storage time from the planned beam supply time to get the earliest start production time of the order, and subtract the standard process time from the planned beam supply time to get the latest start production time of the order. The earliest start production time and the latest start production time define the start production time interval of the task.

3. The method for automatic production scheduling of precast beams according to claim 2, characterized in that: When the precast beam model of an order is compatible with multiple production equipment at the same time, the standard process time shall be the maximum standard process time of multiple production equipment.

4. The method for automatic production scheduling of precast beams according to claim 1, characterized in that: The production equipment comprises a production line and a fixed platform, and the production line comprises a movable platform.

5. The method for automatic production scheduling of precast beams according to claim 4, characterized in that: The method for calculating the estimated release time of the fixed pedestal is to obtain the process of the prefabricated beam currently being produced and the duration of the process. The estimated release time is the standard time of the current process minus the duration of the current process plus the standard time of the remaining processes.

6. The method for automatically scheduling precast beams according to claim 4, characterized in that: The production line includes multiple production areas, including concrete pouring area, curing area and tensioning area. The estimated release time of each production area is obtained as the estimated release time of the production line. The estimated release time of the production area is the larger of the following two: the standard time of the current process minus the duration of the current process, and the estimated release time of the production area of ​​the next process.

7. The method for automatic production scheduling of precast beams according to claim 1, characterized in that: The beam making plan includes the planned beam making time of the order and the daily planned beam making tasks. The planned beam making time of the order is the estimated release time of the production equipment. If the planned beam making time of the order exceeds the daily working hours, it will be postponed to the next working day. In the daily planned beam making tasks, when the remaining time of the working day is less than the process time, the process will be postponed to the next working day.

8. The method for automatic production scheduling of precast beams according to claim 7, characterized in that: The output beam-making plan includes order information, planned production equipment, planned beam-making time and daily planned beam-making tasks.

9. The method for automatic production scheduling of precast beams according to claim 8, characterized in that: Output material recommendations based on the beam manufacturing plan, which include a material requirement list and a material replenishment recommendation list.

10. An automatic production scheduling system for prefabricated beams, characterized in that: It includes a client, a device terminal, a data terminal and a server side, wherein the client is an application program running on a user device, and the client executes the automatic production scheduling method for prefabricated beams according to any one of claims 1 to 9.

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