Intelligent regulation and control method for inter-process blockage material waiting

Abstract

The invention discloses an inter-process blocking material waiting intelligent regulation and control method, which comprises the following steps of: designing a theoretical operation beat of each process equipment on an automatic production line based on a required output beat, an equipment abnormal outage rate and a reject ratio; on the basis of a preset equipment beat range, the theoretical operation beat and a speed adjustment condition provided for different-line beat compensation, the actual operation beat of each process equipment on the automatic production line is determined, and self-compensation is carried out on the operation beat of each process equipment; and for equipment which does not complete self-compensation, different-line supply compensation is carried out by adopting equipment of the same process of different automatic production lines. Through intelligent means such as automatic production line rhythm design, dynamic rhythm regulation and control, rhythm self-compensation, abnormity self-repairing and dynamic cache design, time loss caused by equipment faults, unstable quality and material blockage is eliminated to the maximum extent, and the purposes of improving the OEE level of equipment and stabilizing output are achieved. The method is low in investment, easy to standardize and convenient for large-scale popularization.

Description

Technical Field

[0001] The invention relates to an intelligent control method for material blocking between processes, belonging to the technical field of production line control. Background Art

[0002] At present, there are serious problems of material blocking between various equipment in the automated production line (such as cutting and assembly lines). Due to the high incidence rate, large proportion, and difficulty in detection, monitoring, and analysis, it has become a difficult and painful problem that restricts the improvement of OEE (overall equipment efficiency). The following are the scenarios of material blocking and analysis: (1) Beat difference: There are beat differences between various equipment in the automated production line, resulting in unbalanced processes. When the production speed of the previous process is greater than the production speed of the next process, the next process will have material blocking. When the production speed of the previous process is less than the production speed of the next process, the next process will have material waiting. (2) Abnormal equipment shutdown: When the process encounters equipment failure, model change, insufficient pallet, shortage of raw materials, abnormal quality shutdown, abnormal process tooling, etc., the equipment cannot continue production. At this time, the next process will have material waiting and the previous process will have material blocking.

[0003] In summary, the problem of material waiting leads to a low OEE level and the inability to achieve KPI performance indicators such as output and efficiency. Summary of the invention

[0004] In order to solve the above problems, the present invention proposes an intelligent control method for material blockage between processes, which ensures the stable output of the automated production line and eliminates the impact of material blockage to the greatest extent through equipment rhythm range design, dynamic speed control of equipment and logistics lines, automatic compensation for underproduction rhythm, compensation for supply from different lines, self-repair of minor anomalies, cache design between processes and intelligent scheduling.

[0005] To achieve the above object, the present invention is achieved through the following technical solutions:

[0006] The present invention provides an intelligent control method for material blocking between processes, comprising:

[0007] Design the theoretical operation rhythm of each process equipment on the automated production line based on the required output rhythm, abnormal equipment downtime rate and defect rate;

[0008] Based on the preset equipment beat range, the theoretical operating beat and the speed adjustment provided for the beat compensation of the different lines, the actual operating beat of each process equipment on the automated production line is determined, and the operating beat of each process equipment is self-compensated;

[0009] For equipment that has not completed self-compensation, equipment in the same process of different automated production lines is used to perform off-line supply compensation.

[0010] Preferably, the design of the theoretical operation rhythm of each process equipment on the automated production line includes:

[0011] The initial beat when each process equipment on the automated production line starts normal operation for the first time is set as the demand output beat T. The beat is dynamically adjusted every minute based on the demand output beat, equipment abnormal downtime rate and defect rate to obtain the theoretical operation beat.

[0012] The abnormal downtime rate and defective rate refer to the unplanned downtime rate of the equipment and the defective rate of the equipment products from the time when the equipment first started normal operation to the current moment.

[0013] In this preferred solution, the theoretical operating rhythm is dynamically adjusted according to the current abnormal downtime rate and defective rate of the equipment to minimize time loss.

[0014] Preferably, the workshop is set to include two identical automated production lines, each of which is sequentially configured with four processes ABCD, each process has one device, the process equipment of automated production line 1 is A1, B1, C1, D1, and the process equipment of automated production line 2 is A2, B2, C2, D2;

[0015] The theoretical operation rhythm of each process equipment is designed as follows:

[0016] When the D1 equipment starts to operate normally for the first time, the initial beat is the demand output beat T. The theoretical operation beat per minute is dynamically adjusted based on the abnormal downtime rate and defect rate of the equipment, expressed as: ;

[0017] Among them, Y D1 %,L D1 % are the abnormal downtime rate and product defect rate of D1 equipment from the first start of operation to the present moment;

[0018] When the C1 device starts to operate normally for the first time, the initial beat is the theoretical operating beat of the D1 device , the theoretical operation rhythm per minute is dynamically adjusted based on the abnormal downtime rate and defect rate of the equipment, expressed as: ;

[0019] Among them, Y C1 %,L C1 % are the abnormal downtime rate and product defect rate of C1 equipment from the first start of operation to the present moment;

[0020] When the B1 equipment starts to operate normally for the first time, the initial beat is the theoretical operating beat of the C1 equipment. The theoretical operating beat per minute is dynamically adjusted based on the abnormal downtime rate and defect rate of the equipment, expressed as: ;

[0021] Among them, Y B1 %,L B1% are the abnormal downtime rate and product defect rate of B1 equipment from the first start of operation to the present moment;

[0022] When the A1 equipment starts to operate normally for the first time, the initial beat is the theoretical operating beat of the B1 equipment. The theoretical operating beat per minute is dynamically adjusted based on the abnormal downtime rate and defect rate of the equipment, expressed as: ;

[0023] Among them, Y A1 %,L A1 % are the abnormal downtime rate and product defect rate of A1 equipment from the first start of operation to the present moment;

[0024] Design the theoretical operating rhythm of each process equipment in the automated production line 2 in the same way.

[0025] In this preferred solution, the theoretical operation rhythm is dynamically adjusted according to the current abnormal downtime rate and defect rate of the equipment to minimize the time loss. The D1, C1, B1, and A1 equipment are dynamically adjusted in sequence to recover the production loss.

[0026] Preferably, the method further includes designing the equipment beat range based on the equipment demand output beat, the equipment historical abnormal downtime rate and the historical defect rate, as follows:

[0027] The demand output rhythm of D1 equipment is T, and the rhythm range of D1 equipment is set as: ;

[0028] Among them, LY D1 % is the historical abnormal downtime rate of D1 equipment, LL D1 % is the historical defect rate of D1 equipment,

[0029] The historical abnormal downtime rate and historical defect rate refer to the equipment unplanned downtime rate and equipment product defect rate within the equipment production calendar time;

[0030] The demand output rhythm of C1 equipment is the fastest design rhythm of D1 equipment , the beat range of the C1 device is set to: ,

[0031] Among them, LY C1 % is the historical abnormal downtime rate of C1 equipment, LL C1 % is the historical defect rate of C1 equipment;

[0032] The demand output rhythm of B1 equipment is the fastest design rhythm of C1 equipment , the beat range of the B1 device is set to:

[0033] ;

[0034] Among them, LY B1 % is the historical abnormal downtime rate of B1 equipment, LL B1 % is the historical defect rate of B1 equipment;

[0035] The demand output rhythm of A1 equipment is the fastest design rhythm of B1 equipment. The rhythm range of A1 equipment is set as:

[0036] ;

[0037] Among them, LY A1 % is the historical abnormal downtime rate of A1 equipment, LL A1 % is the historical defect rate of A1 equipment;

[0038] Design the beat range of each process equipment in automated production line 2 in the same way.

[0039] In this preferred solution, the equipment cycle range is designed based on the equipment demand output cycle, historical abnormal downtime rate and historical defect rate, among which D1 equipment has the fastest design cycle and the slowest design maximum speed, C1 equipment is second, and A1 equipment has the fastest design cycle and the fastest design maximum speed. Based on this, the product quality level within the design cycle range of each equipment is within the standard requirements.

[0040] Preferably, the actual operation rhythm of each process equipment on the automated production line is determined based on the preset equipment rhythm range, the theoretical operation rhythm and the speed adjustment provided for the rhythm compensation of the different lines, and the operation rhythm of each process equipment is self-compensated, including:

[0041] ① If CT D1k设计 >T D1k理论 , then CT D1k实际 =CT D1k设计 CT D1k设计 is the fastest designed beat of the k-th single-minute D1 device, which is the minimum value of the device beat range, T D1k理论 is the theoretical operating rhythm of the k-th single-minute D1 device, CT D1k实际 is the actual operating rhythm of the D1 device in the kth single minute;

[0042] ② If CT D1k设计 ≤CT D1k理论 , and the current cumulative beat difference total time ≥ the next beat difference total time to be compensated within the kth single minute, then CT D1k实际 =CT D1k设计 ;

[0043] At this time, if the equipment of the same process in different lines has surplus beat, it will receive the beat compensation of different lines. After compensation, the total accumulated beat difference time of D1 equipment is: the total accumulated beat difference time before compensation - the total beat difference time to be compensated in the kth minute - the total beat difference time provided by the different lines in the kth minute;

[0044] The current cumulative beat difference total time is expressed as:

[0045] ;

[0046] a i =60*[(CT D1i设计 -CT D1i理论 ) / CT D1i设计 ];

[0047] b j =60*[(CT D1j理论 -CT D1j设计 ) / CT D1j理论 ];

[0048] Among them, a i is the total beat difference time in the single minute with the upper beat difference of the ith one, b j is the total beat difference time within the jth minute with the next beat difference;

[0049] The total time of the next beat difference that needs to be compensated in the kth single minute is expressed as: 60*[(CT D1k理论 -CT D1k设计 ) / CT D1k理论 ];

[0050] ③If CT D1k设计 ≤CT D1k理论 , and the current cumulative beat difference total time is less than the next beat difference total time to be compensated within the kth single minute, and the current cumulative beat difference total time is ≠ 0,

[0051] Then the kth minute starts with CT D1k实际 =CT D1k设计 After the compensation is completed, determine whether the different line needs to provide beat compensation. If beat compensation is required, the subsequent time within the single minute will still operate at the fastest designed beat, or when the total cumulative beat difference time of the different line is just compensated within the single minute, the actual operation beat is adjusted to the theoretical operation beat; after compensation, the total cumulative beat difference time of the D1 equipment is 0;

[0052] ④ If CT D1k设计 ≤CT D1k理论, and the current cumulative beat difference total time = 0, then no self-compensation is performed, and it is determined whether beat compensation is required for the different line. If beat compensation is required, the fastest designed beat is operated within the single minute, or the actual operation beat is adjusted to the theoretical operation beat when the cumulative beat difference time of the different line is just compensated within the single minute;

[0053] The C1 device, B1 device and A1 device are compensated in the same way;

[0054] The same method is used to compensate the A2, B2, C2, and D2 devices of the automated production line 2.

[0055] In this preferred solution, the beat compensation is performed on each device of the automated production line every minute to minimize the time loss caused by material blockage, so as to ensure the stable output of the automated production line.

[0056] Preferably, the provision of beat compensation by different lines means that when the equipment self-compensation is not completed, that is, the current cumulative beat difference total time ≠ 0, and the equipment of the same process of another production line has surplus beat, interactive beat compensation is performed between the equipment of the same process of the automated production lines 1 and 2;

[0057] Among them, "beat surplus" means that the total time of the current cumulative beat difference of the equipment in the same process of another production line is 0, and the fastest designed beat is less than or equal to the theoretical operating beat;

[0058] The beat compensation provided by the different lines specifically includes:

[0059] ①. D2 equipment can provide compensation for different supply lines in a single minute:

[0060] If the total accumulated beat difference time of the D1 device after self-compensation is ≥ the total beat difference time of the D2 device compensated in the kth single minute, then CT D2k实际 =CT D2k设计 ;

[0061] Then the total time of the next beat difference of the different-line supply compensation in the kth single minute = 60*[(CT D2k理论 -CT D2k设计 ) / CT D2k理论 ];

[0062] If the total accumulated beat difference time of the D1 device after self-compensation is less than the total beat difference time of the D2 device during the entire k-th minute compensation, and the total accumulated beat difference time of the D1 device after self-compensation is ≠ 0,

[0063] Then the total time of the next beat difference that needs to be compensated for the different lines in the kth single minute = the total accumulated beat difference time of the D1 equipment after compensation, and the D2 equipment operates at the fastest designed beat in the first half of the k single minutes, and resumes to the theoretical beat after the compensation for the different line supply is completed;

[0064] ②. D2 equipment performs self-compensation in the first half t1 of a single minute, and provides compensation for the supply of different lines in the second half t2:

[0065] If the total accumulated beat difference time of the D1 device after self-compensation is ≥ the total beat difference time compensated by the D2 device during the second half of the kth single minute, then CT D2k实际 =CT D2k设计 ;

[0066] Then the total time of the next beat difference of the off-line D2 equipment supply compensation in the kth single minute = t2*[(CT D2k理论 -CT D2k设计 ) / CT D2k理论 ];

[0067] If the total accumulated beat difference time after self-compensation of the D1 device is less than the total beat difference time of the D2 device in the second half of the kth minute t2 time compensation, and the total accumulated beat difference time after self-compensation of the D1 device is ≠ 0,

[0068] Then the total beat difference time of the D2 device that needs to be compensated by the different line supply in the second half t2 of the kth single minute = the total accumulated beat difference time of the D1 device after self-compensation, and the D2 device in the first half t2 of the kth single minute 2前 Time runs at the fastest design rhythm, and after the compensation of different line supply is completed, t 2后 Time returns to its theoretical rhythm.

[0069] In this preferred solution, the rhythm of the automated production line equipment is compensated by the supply of different lines, so that the parallel production lines can all produce at the optimal operating rhythm, eliminate time loss to the greatest extent, and ensure stable output of the automated production lines.

[0070] Preferably, the method further comprises: performing cache control between processes as follows:

[0071] Establish a buffer stock between every two processes, and the buffer stock is independent of the standard work-in-progress flowing on the automated production line;

[0072] When the standard work-in-process between two devices reaches the maximum value, the excess products flow into the buffer stock. When the standard work-in-process drops to the lower water level, the buffer stock products automatically flow into the standard work-in-process.

[0073] In this preferred solution, the time loss caused by equipment failure is eliminated through a cache mechanism to achieve the purpose of improving the equipment OEE level and stabilizing output.

[0074] Preferably, the method further comprises: performing cache control between different automated production lines, as follows:

[0075] If the B1 equipment on the automated production line 1 stops abnormally, the C1 equipment has consumed the standard work-in-progress and buffer inventory between the B1 equipment and the C1 equipment, or the buffer inventory between the B2 equipment and the C2 equipment has reached the maximum value and the buffer inventory between the B1 equipment and the C1 equipment has not reached the maximum value, the C1 equipment receives the output of the B2 equipment on the automated production line 2 and the buffer inventory between the B2 equipment and the C2 equipment; if the C1 equipment has consumed the standard work-in-progress and buffer inventory between the B1 equipment and the C1 equipment, and the buffer inventory between the B2 equipment and the C2 equipment is 0, the C1 equipment stops.

[0076] In this preferred solution, the time loss caused by equipment failure is eliminated through a cache mechanism, so that parallel production lines can all produce at the optimal operating rhythm, eliminating time loss to the greatest extent and ensuring stable output of automated production lines.

[0077] Preferably, the method further comprises: performing cache control between different automated production lines, as follows:

[0078] If the C1 equipment on the automated production line 1 stops abnormally, the B1 equipment will replenish the standard work-in-progress between the B1 equipment and the C1 equipment to the maximum value, and the excess products will flow into the buffer stock;

[0079] If the buffer stock has not reached the maximum value and is greater than 0, determine whether the buffer stock between B2 equipment and C2 equipment on automated production line 2 is 0. If it is 0, the excess products are transferred to B2 equipment for use. If the buffer stock between B2 equipment and C2 equipment is greater than 0, the standard work-in-progress between B1 equipment and C1 equipment is replenished.

[0080] If the buffer stock reaches the maximum value, determine whether the buffer stock between B2 equipment and C2 equipment on automated production line 2 is the maximum value. If it does not reach the maximum value, the excess products are transferred to the B2 equipment for use. If the buffer stock between B2 equipment and C2 equipment is the maximum value, the B1 equipment is shut down.

[0081] In this preferred solution, the time loss caused by equipment failure is eliminated through a cache mechanism, so that parallel production lines can all produce at the optimal operating rhythm, eliminating time loss to the greatest extent and ensuring stable output of automated production lines.

[0082] The beneficial effects of the present invention are:

[0083] The present invention provides an intelligent control method for material blocking between processes, which can eliminate equipment failure, unstable quality and time loss caused by material blocking to the maximum extent through intelligent means such as automated production line rhythm design, dynamic rhythm control, rhythm self-compensation, abnormal self-repair and dynamic cache design, so as to achieve the purpose of improving the OEE level of equipment and stabilizing output. The present invention has low investment, is easy to standardize, and is convenient for large-scale promotion. BRIEF DESCRIPTION OF THE DRAWINGS

[0084] Figure 1 Layout diagram of existing automated production lines and equipment;

[0085] Figure 2 A flow chart of an intelligent control method for material blocking between processes provided by an embodiment of the present invention. DETAILED DESCRIPTION

[0086] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments and the accompanying drawings. Here, the illustrative embodiments of the present invention and their descriptions are used to explain the present invention, but are not intended to limit the present invention.

[0087] It should be noted that the term "one embodiment" or "embodiment" of the present invention refers to a specific feature, structure or characteristic that can be included in at least one implementation of the present invention. The term "in one embodiment" that appears in different places in this specification does not refer to the same embodiment, nor is it a separate or selective embodiment that is mutually exclusive with other embodiments.

[0088] It should be emphasized here that the step marks mentioned below are not intended to limit the order of the steps, but it should be understood that the steps can be executed in the order mentioned in the embodiment, or in a different order from the embodiment, or several steps can be executed simultaneously.

[0089] There are two existing automated production lines, Line 1 and Line 2. The two production lines are identical and are arranged side by side. For example, each production line is configured with four processes, ABCD, in sequence. Each process has one device. The specific production line and equipment layout are as follows: Figure 1 shown.

[0090] For the above-mentioned automated production line, this embodiment provides an intelligent control method for material blocking between processes, see Figure 2 The specific implementation process is as follows:

[0091] 1. Beat design:

[0092] The D1 equipment demand output cycle of automated production line 1 is T, and the historical abnormal downtime rate is LY D1 %, historical defect rate is LL D1 %, then the designed beat range of D1 equipment is ,

[0093] Among them, the historical abnormal downtime rate is the unplanned downtime rate of D1 equipment within a certain period, such as within 3 months. It mainly includes downtime caused by equipment failure, model change, insufficient pallets, shortage of raw materials, abnormal quality, abnormal process tooling, etc. The calculation formula is: LY D1% = abnormal downtime of D1 equipment / (production calendar time-planned downtime of D1 equipment). The historical defect rate is the defect rate of D1 equipment products within a certain period, such as within 3 months. The calculation formula is: LL D1 % = number of defective products of D1 equipment / total output of D1 equipment;

[0094] The output cycle required by C1 equipment is the fastest design cycle of D1 equipment, that is, ,

[0095] The historical abnormal downtime rate is LY C1 %, historical defect rate is LL C1 %, then the design C1 equipment beat range is:

[0096] ,

[0097] The historical abnormal downtime rate is the unplanned downtime rate of C1 equipment within a certain period, such as within 3 months. The calculation formula is: LY C1 % = C1 equipment abnormal downtime / (production calendar time - C1 equipment planned downtime); the historical defect rate is the defect rate of C1 equipment products within a certain period, such as within 3 months, and its calculation formula is: LL C1 % = number of defective products of C1 equipment / total output of C1 equipment;

[0098] The design beat ranges of the same B1 and A1 equipment are:

[0099] and

[0100] ≥ .

[0101] Among them, D1 equipment has the largest design cycle and the slowest maximum design speed, C1 equipment is second, and A1 equipment is the smallest and has the fastest maximum design speed. Within the design cycle range of each equipment, the product quality level is within the standard requirements.

[0102] The same method is used to design the design rhythm of the A2, B2, C2, and D2 equipment of the automated production line 2.

[0103] 2. Regulate the dynamic speed of equipment and logistics lines as follows:

[0104] When the D1 equipment starts to operate normally for the first time, the initial beat is the demand output beat T, and then the beat is adjusted every minute. How to adjust is related to the abnormal downtime rate and defect rate of the equipment from the beginning of operation to the current moment. The theoretical operation beat is: ,

[0105] Y D1 %,L D1% are the abnormal downtime rate and product defect rate of D1 equipment from the first start of operation to the current moment;

[0106] The abnormal downtime rate and product defect rate are calculated as follows:

[0107] Y D1 % = abnormal downtime of D1 equipment / (time period from the first start of operation to this moment - planned downtime of D1 equipment),

[0108] L D1 %=Number of defective products of D1 equipment / Total output of D1 equipment.

[0109] When the C1 device starts to operate normally for the first time, the initial demand rhythm is the theoretical operating rhythm of the D1 device , and then adjust the rhythm every minute. How to adjust is related to the abnormal downtime rate and defect rate of the equipment from the beginning of operation to the current moment. The theoretical operating rhythm of C1 equipment is: ,

[0110] Y C1 %,L C1 % are the abnormal downtime rate and product defect rate of C1 equipment from the first start of operation to the present moment.

[0111] The B1 and A1 devices are deduced in sequence, and the theoretical operating rhythms are: and .

[0112] Y B1 %,Y A1 % and L B1 %,L A1 % are the abnormal downtime rate and product defect rate of B1 equipment and A1 equipment from the first start of operation to the present moment.

[0113] The theoretical operating cycle of the D1 equipment is adjusted in real time according to the required output cycle T and the abnormal downtime rate and defect rate of the equipment. The C1, B1, and A1 equipment are dynamically adjusted in sequence to recover the production loss. The abnormal downtime rate and product defect rate of all the above equipment are updated in real time, and if the theoretical operating cycle is greater than the fastest design cycle, it will operate at the maximum design cycle. The fastest design cycle here refers to the minimum value of the above design cycle range.

[0114] The same method is used to design the theoretical operating rhythm of the A2, B2, C2, and D2 equipment of the automated production line 2.

[0115] 3. Beat self-compensation, as follows:

[0116] The theoretical operating cycle of each device is dynamically adjusted as the abnormal downtime rate of the device and the defective rate of the product change. Taking D1 equipment as an example, if the fastest design cycle ≤Theoretical operation rhythm , then there is a beat difference of: CT D1理论 -CT D1设计 , if the fastest design cycle CT D1设计 >Theoretical operation rhythm CT D1理论 , then the fastest design cycle CT D1设计 The beat operates, and there is an upper beat difference of CT D1设计 -CT D1理论， The total time of the upper beat difference in a single minute is 60*[(CT D1设计 -CT D1理论 ) / CT D1设计 ], when the beat adjustment is performed every minute, the total beat difference time in the previous single minute is accumulated and calculated, and the accumulated calculation is publicized as: . Where i is the i-th single minute with an upper beat difference, a i is the total beat difference time in the single minute with the upper beat difference of the ith one, and its formula is 60*[(CT D1i设计 -CT D1i理论 ) / CT D1i设计 ], and at the same time, in a single minute without an upper beat difference, use the total time of the lower beat difference of this minute 60*[(CT D1理论 -CT D1设计 ) / CT D1理论 ]Compensate for the total beat difference time. The total cumulative beat difference time after compensation is , where j is the jth single minute with a lower beat difference, b j is the total beat difference time in the jth minute with the next beat difference, and its formula is 60*[(CT D1j理论 -CT D1j设计 ) / CT D1j理论 ], if after a single minute compensation If it still has not returned to zero, compensation will be performed within the next single minute with a beat difference, and so on, until the compensation is completed.

[0117] If the cycle time of a single shift has not been compensated, no compensation will be made in the next shift. The cycle time compensation logic of automated production lines 1 and 2 is the same.

[0118] In summary, the actual operating rhythm of the D1 device in the kth minute is:

[0119] ① If CT D1k设计 >T D1k理论 , then CT D1k实际 =CT D1k设计 ;

[0120] ②If CT D1k设计 ≤CT D1k理论 , and the current cumulative beat difference total time ≥ Total time of the next beat difference to be compensated in the kth single minute 60*[(CT D1k理论 -CT D1k设计 ) / CT D1k理论 ],

[0121] Then let CT D1k实际 =CT D1k设计 ;

[0122] At this time, if the equipment of the same process on the different lines has surplus beat, it will receive the beat compensation of the different lines. After compensation, the total cumulative beat difference time of the D1 equipment is the total cumulative beat difference time before compensation - the total beat difference time that needs to be compensated within the kth minute - the total beat difference time provided by the different lines within the kth minute.

[0123] ③If CT D1k设计 ≤CT D1k理论 , and the current cumulative beat difference total time <Total time of the next beat difference to be compensated in the kth single minute 60*[(CT D1k理论 -CT D1k设计 ) / CT D1k理论 ] and the current cumulative beat difference total time ,

[0124] Then the kth minute starts with CT D1k实际 =CT D1k设计 When the compensation is completed, determine whether the different line needs to provide beat compensation. If beat compensation is required, the subsequent time within the single minute will still run at the designed speed, or when the total accumulated beat difference time of the different line has just been compensated within the single minute, the actual operating beat is adjusted to the theoretical operating beat; after compensation, the total accumulated beat difference time of the D1 equipment is 0.

[0125] ④If CT D1k设计 ≤CT D1k理论 ,and , no self-compensation is performed, and it is determined whether the different line needs to provide beat compensation. If beat compensation is required, it will run at the design speed within that single minute, or when the total accumulated beat difference time of the different line has just been compensated within that single minute, the actual operating beat is adjusted to the theoretical operating beat.

[0126] The same method is used to compensate C1 equipment, B1 equipment and A1 equipment. Each process equipment has an impact on each other. The impact of A on B equipment will be reflected in LYB1%, the impact of B on C will be reflected in LYC1%, and so on.

[0127] The same method is used to compensate the A2, B2, C2, and D2 devices of the automated production line 2.

[0128] 4. Carry out compensation for off-line supply as follows:

[0129] When the device self-compensation is not completed, the total time of the current accumulated beat difference When the equipment with the same process on the other production line has surplus rhythm, interactive rhythm compensation is performed between the equipment with the same process on automated production lines 1 and 2.

[0130] The surplus beat refers to the total time of the current cumulative beat difference of the equipment in the same process of another production line. , and the fastest design cycle is less than or equal to the theoretical operating cycle.

[0131] For example, if the off-line D2 device can provide beat compensation in the kth single minute, that is, CT D2k设计 ≤CT D2k理论 , and the total accumulated beat difference time of D2 device is 0, then the different line supply compensation is performed as follows:

[0132] 4-1. D2 equipment can provide compensation for different supply lines in a single minute:

[0133] If the total accumulated beat difference time of the D1 device after self-compensation is ≥ the total beat difference time of the D2 device compensated in the kth single minute, then CT D2k实际 =CT D2k设计 ;

[0134] Then the total time of the next beat difference of the different-line supply compensation in the kth single minute = 60*[(CT D2k理论 -CT D2k设计 ) / CT D2k理论 ];

[0135] If the total accumulated beat difference time of the D1 device after self-compensation is less than the total beat difference time of the D2 device during the entire k-th minute compensation, and the total accumulated beat difference time of the D1 device after self-compensation is ≠ 0,

[0136] Then the total beat difference time that needs to be compensated for the off-line in the kth single minute = the total accumulated beat difference time of the D1 equipment after self-compensation, and the D2 equipment operates at the fastest designed beat in the first half of the k single minutes, and resumes operation at the theoretical beat after the off-line supply compensation is completed.

[0137] 4-2. D2 equipment performs self-compensation in the first half of the t1 time within a single minute, and can provide compensation for the supply of different lines in the second half of the t2 time:

[0138] If the total accumulated beat difference time of the D1 device after self-compensation is ≥ the total beat difference time compensated by the D2 device during the second half of the kth single minute, then CT D2k实际 =CTD2k设计 ;

[0139] Then the total time of the next beat difference of the D2 equipment supply compensation in the kth single minute = t2*[(CT D2k理论 -CT D2k设计 ) / CT D2k理论 ];

[0140] If the total accumulated beat difference time after self-compensation of the D1 device is less than the total beat difference time of the D2 device in the second half of the kth minute t2 time compensation, and the total accumulated beat difference time after self-compensation of the D1 device is ≠ 0,

[0141] Then the total beat difference time of the D2 device that needs to be compensated by the different line supply in the second half t2 of the kth single minute = the total accumulated beat difference time of the D1 device after self-compensation, and the D2 device in the first half t2 of the kth single minute 2前 Time runs at the fastest design rhythm, and after the compensation of different line supply is completed, t 2后 Time returns to its theoretical rhythm.

[0142] It should be noted that the products produced by self-compensation and different-line compensation are adjusted with the equipment of the next process and the same process on different lines through buffer inventory.

[0143] 5. Minor abnormality self-repair, as follows:

[0144] If a small abnormality occurs in a single process, such as material jamming, the equipment will automatically trigger an alarm and cause shutdown. At this time, the equipment can identify the corresponding mechanism according to the alarm point and automatically reset the mechanism. If the abnormality is eliminated, the equipment will operate normally. If a small abnormality occurs in multiple stations, the equipment will automatically reset the entire equipment. If the abnormality is eliminated, the equipment will operate normally. Automatic repairs are performed for small abnormalities to minimize equipment downtime.

[0145] 6. Cache design:

[0146] While ensuring the normal operation of dynamic rhythm, rhythm compensation, and off-line supply compensation, a buffer stock (WIP) is established between every two processes. The buffer stock is set up in a separate area, which is different from the work-in-progress SWIP flowing on the assembly line.

[0147] Taking the buffer stock setting between processes B1 and C1 as an example, the maximum buffer stock is calculated as:

[0148] Maximum buffer stock = t / (CT B1设计 -0)-the number of SWIP in process,

[0149] Where t is the minimum downtime of the equipment, which is generally 5 minutes. In the formula, 0 means that the C1 equipment is down and the B1 equipment is running. In this way, there is a beat difference between the B1 equipment and the C1 equipment, so there is inventory, CTB1设计 It is the maximum design beat of the B1 device.

[0150] When the SWIP between the B1 and C1 equipment reaches the maximum value, the excess products flow into the buffer storage area. When the SWIP drops to the lower water level (SWIP maximum value * 20%), the products in the buffer storage area automatically flow into the buffer storage area to replenish the SWIP.

[0151] If the B1 device on the automated production line 1 stops abnormally, the C1 device has consumed the SWIP and buffer inventory between the B1 and C1 devices, or the buffer inventory between the B2 and C2 devices has reached the maximum value and the cache between the B1 and C1 devices has not reached the maximum value, the C1 device receives the output of the B2 device on the automated production line 2 and the supply of the buffer inventory between the B2 and C2 devices; if the C1 device has consumed the SWIP and buffer inventory between the B1 and C1 devices, and the buffer inventory between the B2 and C2 devices is 0, the C1 device stops, which is a non-abnormal shutdown. When the SWIP and buffer inventory between the B1 and C1 devices or the buffer inventory between the B2 and C2 devices is not 0, the non-abnormal shutdown is lifted and the equipment automatically resumes operation.

[0152] If the C1 device on the automated production line 1 stops abnormally, the B1 device will replenish the SWIP between the B1 device and the C1 device to the maximum value, and the excess products will flow into the buffer inventory area;

[0153] If the buffer inventory area has not reached the maximum value and is greater than 0, determine whether the buffer area between the B2 device and the C2 device on the automated production line 2 is 0. If it is 0, the excess products are immediately transferred to the B2 device for use. If the buffer area between the B2 device and the C2 device is greater than 0, the SWIP between the B1 device and the C1 device is supplemented.

[0154] If the buffer inventory area reaches the maximum value, determine whether the buffer inventory area between B2 equipment and C2 equipment on automated production line 2 is the maximum value. If it is not the maximum value, the excess products are transferred to B2 equipment for use. If the buffer inventory area between B2 equipment and C2 equipment is the maximum value, the B1 equipment is shut down, which is a non-abnormal shutdown. When the buffer inventory between B1 equipment and C1 equipment or the buffer inventory between B2 equipment and C2 equipment is not the maximum value, the non-abnormal shutdown is lifted and the equipment automatically resumes operation.

[0155] It should be noted that the decision to start or maintain shutdown is made after re-evaluation every minute.

[0156] The above description is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field can make equivalent replacements or changes according to the technical scheme and inventive concept of the present invention within the technical scope disclosed by the present invention, which should be covered by the protection scope of the present invention.

Claims

1. An intelligent control method for material blocking between processes, characterized in that: include: Design the theoretical operation rhythm of each process equipment on the automated production line based on the required output rhythm, abnormal equipment downtime rate and defect rate; Based on the preset equipment beat range, the theoretical operating beat and the speed adjustment provided for the beat compensation of the different lines, the actual operating beat of each process equipment on the automated production line is determined, and the operating beat of each process equipment is self-compensated; For equipment that has not completed self-compensation, equipment in the same process of different automated production lines is used to perform off-line supply compensation.

2. According to claim 1, a method for intelligently controlling material blocking between processes is characterized in that: The theoretical operation rhythm of each process equipment in the designed automated production line includes: The initial beat when each process equipment on the automated production line starts normal operation for the first time is set as the demand output beat T. The beat is dynamically adjusted every minute based on the demand output beat, equipment abnormal downtime rate and defect rate to obtain the theoretical operation beat. The abnormal downtime rate and defective rate refer to the unplanned downtime rate of the equipment and the defective rate of the equipment products from the time when the equipment first started normal operation to the current moment.

3. According to claim 2, a method for intelligently controlling material blocking between processes is characterized in that: The workshop is assumed to include two identical automated production lines. Each production line is configured with four processes, ABCD, in order. Each process has one device. The devices for each process of automated production line 1 are A1, B1, C1, and D1, and the devices for each process of automated production line 2 are A2, B2, C2, and D2. The theoretical operation rhythm of each process equipment is designed as follows: When the D1 equipment starts to operate normally for the first time, the initial beat is the demand output beat T. The theoretical operation beat per minute is dynamically adjusted based on the abnormal downtime rate and defect rate of the equipment, expressed as: ; Among them, Y D1 %,L D1 % are the abnormal downtime rate and product defect rate of D1 equipment from the first start of operation to the present moment; When the C1 device starts to operate normally for the first time, the initial beat is the theoretical operating beat of the D1 device , the theoretical operation rhythm per minute is dynamically adjusted based on the abnormal downtime rate and defect rate of the equipment, expressed as: ; Among them, Y C1 %,L C1 % are the abnormal downtime rate and product defect rate of C1 equipment from the first start of operation to the present moment; When the B1 equipment starts to operate normally for the first time, the initial beat is the theoretical operating beat of the C1 equipment. The theoretical operating beat per minute is dynamically adjusted based on the abnormal downtime rate and defect rate of the equipment, expressed as: ; Among them, Y B1 %,L B1 % are the abnormal downtime rate and product defect rate of B1 equipment from the first start of operation to the present moment; When the A1 equipment starts to operate normally for the first time, the initial beat is the theoretical operating beat of the B1 equipment. The theoretical operating beat per minute is dynamically adjusted based on the abnormal downtime rate and defect rate of the equipment, expressed as: ; Among them, Y A1 %,L A1 % are the abnormal downtime rate and product defect rate of A1 equipment from the first start of operation to the present moment; Design the theoretical operating rhythm of each process equipment in the automated production line 2 in the same way.

4. The method for intelligently controlling material blocking between processes according to claim 3 is characterized in that: The method further includes designing a device beat range based on the device demand output beat, the device historical abnormal downtime rate, and the device historical defect rate, as follows: The demand output rhythm of D1 equipment is T, and the rhythm range of D1 equipment is set as: ; Among them, LY D1 % is the historical abnormal downtime rate of D1 equipment, LL D1 % is the historical defect rate of D1 equipment, The historical abnormal downtime rate and historical defect rate refer to the equipment unplanned downtime rate and equipment product defect rate within the equipment production calendar time; The demand output rhythm of C1 equipment is the fastest design rhythm of D1 equipment , the beat range of the C1 device is set to: , Among them, LY C1 % is the historical abnormal downtime rate of C1 equipment, LL C1 % is the historical defect rate of C1 equipment; The demand output rhythm of B1 equipment is the fastest design rhythm of C1 equipment , the beat range of the B1 device is set to: ； Among them, LY B1 % is the historical abnormal downtime rate of B1 equipment, LL B1 % is the historical defect rate of B1 equipment; The demand output rhythm of A1 equipment is the fastest design rhythm of B1 equipment. The rhythm range of A1 equipment is set as: ； Among them, LY A1 % is the historical abnormal downtime rate of A1 equipment, LL A1 % is the historical defect rate of A1 equipment; Design the beat range of each process equipment in automated production line 2 in the same way.

5. The method for intelligently controlling material blocking between processes according to claim 4 is characterized in that: The actual operation rhythm of each process equipment on the automated production line is determined based on the preset equipment rhythm range, the theoretical operation rhythm and the speed adjustment provided for the rhythm compensation of the different lines, and the operation rhythm of each process equipment is self-compensated, including: ① If CT D1k设计 >T D1k理论 , then CT D1k实际 =CT D1k设计 CT D1k设计 is the fastest designed beat of the k-th single-minute D1 device, which is the minimum value of the device beat range, T D1k理论 is the theoretical operating rhythm of the kth single-minute D1 device, CT D1k实际 is the actual operating rhythm of the D1 device in the kth single minute; ② If CT D1k设计 ≤CT D1k理论 , and the current cumulative beat difference total time ≥ the next beat difference total time to be compensated within the kth single minute, then CT D1k实际 =CT D1k设计 ; At this time, if the equipment of the same process in different lines has surplus beat, it will receive the beat compensation of different lines. After compensation, the total accumulated beat difference time of D1 equipment is: the total accumulated beat difference time before compensation - the total beat difference time to be compensated in the kth minute - the total beat difference time provided by the different lines in the kth minute; The current cumulative beat difference total time is expressed as: ； a i =60*[(CT D1i设计 -CT D1i理论 ) / CT D1i设计 ]; b j =60*[(CT D1j理论 -CT D1j设计 ) / CT D1j理论 ]; Among them, a i is the total beat difference time in the single minute with the upper beat difference of the ith one, b j is the total beat difference time within the jth minute with the next beat difference; The total time of the next beat difference that needs to be compensated in the kth single minute is expressed as: 60*[(CT D1k理论 -CT D1k设计 ) / CT D1k理论 ]; ③If CT D1k设计 ≤CT D1k理论 , and the current cumulative beat difference total time is less than the next beat difference total time to be compensated within the kth single minute, and the current cumulative beat difference total time is ≠ 0, Then the kth minute starts with CT D1k实际 =CT D1k设计 After the compensation is completed, determine whether the different line needs to provide beat compensation. If beat compensation is required, the subsequent time within the single minute will still operate at the fastest designed beat, or when the total cumulative beat difference time of the different line is just compensated within the single minute, the actual operation beat is adjusted to the theoretical operation beat; after compensation, the total cumulative beat difference time of the D1 equipment is 0; ④ If CT D1k设计 ≤CT D1k理论 , and the current cumulative beat difference total time = 0, then no self-compensation is performed, and it is determined whether beat compensation is required for the different line. If beat compensation is required, the fastest designed beat is operated within the single minute, or the actual operation beat is adjusted to the theoretical operation beat when the cumulative beat difference time of the different line is just compensated within the single minute; The C1 device, B1 device and A1 device are compensated in the same way; The same method is used to compensate the A2, B2, C2, and D2 devices of the automated production line 2.

6. The method for intelligently controlling material blocking between processes according to claim 5 is characterized in that: The said different lines provide beat compensation means that when the equipment self-compensation is not completed, that is, the current cumulative beat difference total time ≠ 0, and the equipment of the same process of the other production line has surplus beat, the equipment of the same process of the automated production lines 1 and 2 will perform interactive beat compensation; Among them, "beat surplus" means that the total time of the current cumulative beat difference of the equipment in the same process of another production line is 0, and the fastest designed beat is less than or equal to the theoretical operating beat; The beat compensation provided by the different lines specifically includes: ①. D2 equipment can provide compensation for different supply lines in a single minute: If the total accumulated beat difference time of the D1 device after self-compensation is ≥ the total beat difference time of the D2 device compensated in the kth single minute, then CT D2k实际 =CT D2k设计 ; Then the total time of the next beat difference of the different-line supply compensation in the kth single minute = 60*[(CT D2k理论 -CT D2k设计 ) / CT D2k理论 ]; If the total accumulated beat difference time of the D1 device after self-compensation is less than the total beat difference time of the D2 device during the entire k-th minute compensation, and the total accumulated beat difference time of the D1 device after self-compensation is ≠ 0, Then the total time of the next beat difference that needs to be compensated for the different lines in the kth single minute = the total accumulated beat difference time of the D1 equipment after compensation, and the D2 equipment operates at the fastest designed beat in the first half of the k single minutes, and resumes to the theoretical beat after the compensation for the different line supply is completed; ②. D2 equipment performs self-compensation in the first half t1 of a single minute, and provides compensation for the supply of different lines in the second half t2: If the total accumulated beat difference time of the D1 device after self-compensation is ≥ the total beat difference time compensated by the D2 device during the second half of the kth single minute, then CT D2k实际 =CT D2k设计 ; Then the total time of the next beat difference of the off-line D2 equipment supply compensation in the kth single minute = t2*[(CT D2k理论 -CT D2k设计 ) / CT D2k理论 ]; If the total accumulated beat difference time after self-compensation of the D1 device is less than the total beat difference time of the D2 device in the second half of the kth minute t2 time compensation, and the total accumulated beat difference time after self-compensation of the D1 device is ≠ 0, Then the total beat difference time of the D2 device that needs to be compensated by the different line supply in the second half t2 of the kth single minute = the total accumulated beat difference time of the D1 device after self-compensation, and the D2 device in the first half t2 of the kth single minute 2前 Time runs at the fastest design rhythm, and after the compensation of different line supply is completed, t 2后 Time returns to its theoretical rhythm.

7. The method for intelligently controlling material blocking between processes according to claim 5 is characterized in that: The method further includes: performing cache control between processes, as follows: Establish a buffer stock between every two processes, and the buffer stock is independent of the standard work-in-progress flowing on the automated production line; When the standard work-in-process between two devices reaches the maximum value, the excess products flow into the buffer stock. When the standard work-in-process drops to the lower water level, the buffer stock products automatically flow into the standard work-in-process.

8. The method for intelligently controlling material blocking between processes according to claim 7 is characterized in that: The method further includes: performing cache control between different automated production lines as follows: If the B1 equipment on the automated production line 1 stops abnormally, the C1 equipment has consumed the standard work-in-progress and buffer inventory between the B1 equipment and the C1 equipment, or the buffer inventory between the B2 equipment and the C2 equipment has reached the maximum value and the buffer inventory between the B1 equipment and the C1 equipment has not reached the maximum value, the C1 equipment receives the output of the B2 equipment on the automated production line 2 and the buffer inventory between the B2 equipment and the C2 equipment; if the C1 equipment has consumed the standard work-in-progress and buffer inventory between the B1 equipment and the C1 equipment, and the buffer inventory between the B2 equipment and the C2 equipment is 0, the C1 equipment stops.

9. The method for intelligently controlling material blocking between processes according to claim 7 is characterized in that: The method further includes: performing cache control between different automated production lines as follows: If the C1 equipment on the automated production line 1 stops abnormally, the B1 equipment will replenish the standard work-in-progress between the B1 equipment and the C1 equipment to the maximum value, and the excess products will flow into the buffer stock; If the buffer stock has not reached the maximum value and is greater than 0, determine whether the buffer stock between B2 equipment and C2 equipment on automated production line 2 is 0. If it is 0, the excess products are transferred to B2 equipment for use. If the buffer stock between B2 equipment and C2 equipment is greater than 0, the standard work-in-progress between B1 equipment and C1 equipment is replenished. If the buffer stock reaches the maximum value, determine whether the buffer stock between B2 equipment and C2 equipment on automated production line 2 is the maximum value. If it does not reach the maximum value, the excess products are transferred to the B2 equipment for use. If the buffer stock between B2 equipment and C2 equipment is the maximum value, the B1 equipment is shut down.

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