Automobile part production line management tracing system and method

Abstract

The invention discloses an automobile part production line management traceability system and method. The system comprises a production information acquisition module, a production data acquisition module, a production data processing module, a production data traceability module and a production data display module. Part information and production scheduling information are acquired through the production information acquisition module; the production data acquisition module is used for acquiring production equipment data and product data; the production data processing module is used for processing data acquired by all parties according to requirements and storing the data in a database; through the production data tracing module, the whole-process machining data of workpieces are stored by taking a single workpiece as a unit, and the machining data of a production line are stored by taking a shift as a unit; the production data display module is used for displaying real-time information of production line equipment, historical statistics of production line information and checking and exporting of various production reports and traceability files; according to the method, a series of processing and storage are carried out on various production data through the tracing process, if the data need to be connected with other systems for uploading subsequently, an interface is directly created to upload the data, and the system has good expandability.

Description

Technical Field

[0001] The present invention relates to the technical field of production process tracing, and in particular to a system and method for tracing the management of an automobile parts production line. Background Art

[0002] The rapid expansion and development of the automotive parts industry in recent years has also put forward higher requirements for the digital capabilities of various parts manufacturers. One important point is the traceability of production parts. Many companies have begun to propose digital upgrades and introduce automated production lines. The informatization and transparency of production lines are becoming more and more important.

[0003] However, many current production data of automobile parts production lines are not collected in real time, or the collected data is not fully and reasonably used. When unqualified parts appear on the production line, it is impossible to quickly know the specific unqualified parameters. The real-time status of production line equipment is also difficult to know, and it is impossible to analyze and judge the alarm conditions of each device, which will waste more time to solve the problem. Managers are also unable to know the real-time production status of the production line in real time, resulting in a waste of manpower and time in tracing problems and optimizing production.

[0004] The existing technology has also conducted some research on the information traceability of workpieces, but the process production information lacks changes in equipment-related parameters. Only the test results or process parameters are not detailed enough to make further judgments and optimizations; it is impossible to determine the circulation of the workpiece during the entire process of traceability; it is impossible to quickly find specific production information based on the engraved code or other unique information. Management personnel cannot quickly find the corresponding parameter data of the problem parts, or it takes a lot of time to confirm.

[0005] Therefore, a production line management and tracing system and method for automobile parts are needed to solve the above problems. Taking an automobile brake caliper bracket automatic production line as an example, a production line management and tracing system and method are proposed. Summary of the invention

[0006] In view of the problems existing in the prior art, the present invention provides an automobile parts production line management and tracing system and method.

[0007] The technical solution of the present invention is as follows:

[0008] An automobile parts production line management and tracing system includes a production information acquisition module, a production data collection module, a production data processing module, a production data tracing module and a production data display module;

[0009] Through the production information acquisition module, parts information and production scheduling information are acquired;

[0010] Through the production data acquisition module, production equipment data and product data are obtained;

[0011] Through the production data processing module, the data obtained by each party is processed according to the needs and stored in the database;

[0012] Through the production data tracing module, the whole process processing data of the workpiece is saved in units of a single workpiece, and the processing data of the production line is saved in units of a shift, so as to facilitate the subsequent tracing and viewing;

[0013] The production data display module is used to display real-time information of production line equipment, historical statistics of production line information, and the viewing and export of various production reports and traceability files.

[0014] Furthermore, the production information acquisition module acquires part information by acquiring the qualified inspection range of the parts before production, which is consistent with the setting of the inspection equipment in the production line, and imports the qualified inspection range of the product by importing Excel from the system;

[0015] The production line includes a testing device. Before product production, the qualified range of specific testing production data (such as upper beam torque) will be imported. The system collects the test results of the testing device and also imports the qualified range data of production into the system. When displaying, the unqualified items of specific unqualified parts can be determined based on the collected test results and the pre-acquired qualified range.

[0016] The production scheduling information includes: planned rhythm entry, daily production plan acquisition and employee login; employees log in to the system through the front-end to enter the planned rhythm of the product for the day in the information entry interface, and the Java back-end system obtains employee information and planned rhythm and stores them in the database; the Java back-end system obtains the production plan for the day from the management system through http requests and stores it in the database.

[0017] Furthermore, the production information data collection module includes the collection of production equipment data and product data;

[0018] The objects of data collection include PLC, machining center and detection device; PLC and machining center adopt OPC communication protocol, the equipment end acts as OPC server, and Java back-end system acts as OPC client to process the data obtained through real-time subscription through production data processing module and then store it into database; the detection device will save the detection result in the form of txt in the specified path each time, and the system will access the shared txt file through the local area network, obtain the detection result and save it in the database.

[0019] The on-site machining center, production line control PLC, broaching machine control PLC and detection device host are connected to the industrial computer server host through network cables and switches; the collection of the machining center and PLC uses the OPC communication mentioned below. The collected equipment serves as a server to publish some point data, and the industrial computer server serves as a client to subscribe to the required data in real time. The main purpose here is to collect production equipment data; the detection device comes with a host. After confirmation by the equipment provider, the fixed files in the fixed location folder of the detection device host computer are copied to the industrial computer server to obtain the latest test results. The main purpose here is to collect product test data.

[0020] Furthermore, in the production data processing module:

[0021] For the data used to display monitoring in real time, the corresponding fields in the database table are directly updated; the data displayed in real time is mainly obtained through OPC subscription. When the data changes, the device will send this data. After the server system receives it, the system executes the corresponding SQL statement to update it in the database.

[0022] For data used for workpiece or production report traceability, historical preservation is required, and data is continuously added and saved with time in the corresponding table of the database; the data saved with time is mainly to save the workpiece inspection result data in the database table, and the execution time is also saved in the table when saving. During subsequent shifts, the statistical time of daily data is determined according to this saved time.

[0023] The PLC control trigger signal data is used to confirm the time when the workpiece enters and exits the production link, and is used to bind the relevant data to the workpiece according to the time of entry and exit, and save it in the database; OPC subscribes to some Boolean trigger signals (such as: loading and unloading of the lathe is completed). When the loading and unloading of the lathe is completed, the system backend receives the point of loading and unloading completion of the lathe and changes it to true. The time when this signal is received represents the time when the previous workpiece completed the lathe processing and left the lathe, and the time when the next workpiece starts the lathe processing and enters the lathe, which are updated in their respective fields. When loading begins, each workpiece will create a row of time data belonging to that workpiece in the database, and as the processing progresses, the workpiece continues to move, and this time data is also continuously filled.

[0024] For statistical report data that needs to be queried by date and time, the received data is counted based on time units and saved in the database. The statistics include: test result statistics, production statistics, CPK statistics and OEE statistics.

[0025] The inspection result statistics is to retrieve the saved workpiece inspection results from the database and display them on the page.

[0026] Production statistics are calculated on a daily basis based on the time the data is saved.

[0027] CPK is the process capability index: it mainly calculates the CPK of six data of workpiece inspection (upper and lower beam torque; left and right pin hole diameter; left and right slide slot size)

[0028] The calculation formula of CPK is:

[0029]

[0030] Cpk=Cp×(1-Ca)

[0031] USL is the upper specification limit, LSL is the lower specification limit, is the mean value, δ is the standard deviation, and n is the number of samples; taking classes as units, the corresponding data is taken out and calculated according to the time range of each class.

[0032] OEE is the overall equipment effectiveness: OEE = availability * performance index * quality index;

[0033] Availability = operation time / planned processing time, where the operation time is obtained through data collection, which collects the time when the production line starts automation, and the planned processing time is fixed as the time of one shift;

[0034] Performance index = ideal cycle time / actual cycle time, where the ideal cycle time is confirmed by the customer before production and imported into the system, and the actual cycle time = operation time / total output;

[0035] Quality index = good products / total output, where the number of good products and the total output can be obtained by collecting and storing the inspection results of the workpieces.

[0036] Furthermore, in the production data tracing module, the data tracing module obtains and processes the equipment data of each production link from the database in units of workpieces, and generates a PDF document including various production parameters of the workpiece.

[0037] Furthermore, the production data display module includes: a real-time monitoring unit and a historical statistical reporting unit; the real-time monitoring unit displays the real-time operating status of the equipment of the production line, the processing information and alarm status of the production line; the historical statistical reporting unit includes historical statistics of workpiece data, historical statistics of the overall equipment information and processing information of the production line.

[0038] A method for managing and tracing an automobile parts production line comprises the following steps:

[0039] 1) Before starting production, the production information acquisition module obtains the corresponding data and stores the data in the database;

[0040] 2) The product is loaded and enters the production line for processing. The production data acquisition module and the production data processing module begin to collect and save various data;

[0041] 3) After the product is processed and tested, the production data acquisition module and the production data processing module obtain and save the product test results;

[0042] 4) When the product is offline, the data traceability module obtains and processes the equipment data of each production link from the database based on the workpiece, and generates a PDF document including various production parameters of the workpiece;

[0043] 5) The production data display module displays product test results and traceability documents.

[0044] The beneficial effects of the present invention are as follows:

[0045] 1) The present invention designs an automobile parts production line management and tracing system, which can realize real-time monitoring of production conditions, production information entry, production information tracing and production-related report query;

[0046] 2) The present invention designs a method for tracing the entire process of workpiece production, which realizes the record and preservation of production information from scheduling and loading to inspection and packaging. The system can query the production information of the corresponding workpiece code in real time to facilitate tracing; by downloading the PDF file, the various data of the workpiece can be clearly seen, and unqualified data will also be marked accordingly to facilitate the rapid identification of unqualified data items, thereby facilitating timely adjustment and optimization of production.

[0047] 3) The present invention performs a series of processing and storage on various production data through the tracing process. If it is necessary to connect with other systems and upload them later, it only needs to directly create an interface to upload the data. The system has good scalability. BRIEF DESCRIPTION OF THE DRAWINGS

[0048] Figure 1 It is a schematic diagram of the system of the present invention;

[0049] Figure 2 It is a schematic diagram of obtaining production information of the present invention;

[0050] Figure 3 It is a schematic diagram of OPC subscription processing of the present invention;

[0051] Figure 4 The following is a flowchart of the acquisition, collection and processing of the traceability data of the present invention;

[0052] Figure 5 is a flow chart of the present invention;

[0053] Figure 6 Generate a schematic diagram for the data of the present invention. DETAILED DESCRIPTION

[0054] The present invention is further described below in conjunction with the accompanying drawings and embodiments.

[0055] like Figure 1 As shown, an automobile parts production line management and tracing system includes a production information acquisition module, a production data collection module, a production data processing module, a production data tracing module and a production data display module; the system is composed of Vue3 as the system front-end framework, Springboot as the system back-end framework and Mysql database.

[0056] The production information acquisition module includes the acquisition of parts information and production scheduling information; the acquisition of parts information mainly involves obtaining the qualified inspection range of parts before production, which is consistent with the settings of the inspection equipment in the production line, and is achieved by importing Excel from the system. The production scheduling related information mainly includes: planned rhythm entry, daily production plan acquisition and employee login. Employees log in to the system through the front-end and enter the planned rhythm of the product for the day in the information entry interface. The Java back-end system obtains employee information and planned rhythm and stores them in the database. The Java back-end system obtains the production plan for the day from the management system through http requests and stores it in the database. Figure 2 shown.

[0057] The production information data acquisition module includes the collection of production equipment data and product data. The collection objects include production line PLC, lathe PLC, machining center CNC system and detection device; among them, PLC and CNC system adopt OPC communication protocol, the equipment end acts as OPC server, and the system acts as OPC client to subscribe to data in seconds. For the production line PLC, the main information obtained includes the flow signal of the production line (the lathe starts loading and unloading, the machining center starts loading and unloading, etc.). In addition, the scanning content of the loading batch code during loading is also stored in the production line PLC and obtained. As an OPC client, the Java back-end system processes the real-time subscription data through the data processing module and stores it in the database. The detection device has its own server, which saves the detection results in the form of txt in the specified path each time. The system accesses the shared txt file through the local area network, obtains the detection results and saves them in the database, such as Figure 3 shown.

[0058] The production data processing module mainly processes the data obtained by all parties and stores them in the database. For data used to display monitoring in real time (current operating status of equipment, current location of equipment, etc.), there is no need for historical tracing of such data, so the corresponding fields in the database table are directly updated. For data that need to be used for workpiece or production report tracing in the future (equipment torque, remaining life of equipment tool, test results), such data needs to be saved historically, and the corresponding table in the database is continuously added and saved with time. Another type of data is some control trigger signals of the production line PLC (the lathe starts loading and unloading, the machining center starts loading and unloading). The value of this type of signal is Bool. These signals are mainly used to confirm the time when the workpiece enters and exits the production link, so as to facilitate the subsequent binding of relevant data with the workpiece according to the time of entry and exit. The system saves various types of data in the MySQL database through OPC subscription, front-end and back-end interaction, etc. For some statistical report data that need to be queried by date and time (production information, equipment alarm status, qualified rate), the received data is accumulated or calculated accordingly according to time, and the total is saved in the database.

[0059] The real-time data storage of the device is as follows

[0060]

[0061] The device historical data is stored as shown in the following table

[0062]

[0063] Single-shift data storage is as follows

[0064]

[0065] The production data traceability module uses workpieces as units, obtains and processes the equipment and other data of each production link from the database, and generates a PDF document including various production parameters of the workpiece. When a batch of products is full, the batch code is printed as a spot label and shipped to the next production link together with the finished product.

[0066] The production data display module includes: real-time monitoring unit and historical statistical report unit. The real-time monitoring unit mainly displays the real-time operation status of the equipment of the production line (position, torque, mode, start-up time), the processing information of the production line (current shift, completion degree, qualified rate) and alarm status. The historical statistical report unit includes the historical statistics of workpiece data (test parameter history, fluctuation curve of various data), the historical statistics of the overall equipment information and processing information of the production line (historical equipment utilization, historical alarm records, historical production qualified rate, historical spot labels and workpiece codes).

[0067] Example:

[0068] For a single workpiece, the entire production process includes the following steps: loading, broaching, machining center processing, cleaning, testing, marking, and offline. The traceable parameters include: loading batch, unloading batch, operator shift, online time, offline time, broaching torque, broach life, machining center speed feed, machining center tool life, test results, and marking code.

[0069] like Figure 4 As shown, a method for managing and tracing an automobile parts production line comprises the following steps:

[0070] Step 1: Before starting production, the production information acquisition module obtains the corresponding data and stores the data in the database;

[0071] Step 2: Load product raw materials and obtain loading batches;

[0072] Step 3: Enter the broaching machine processing, and the data acquisition and processing module starts to collect and save various data;

[0073] Step 4: After the product is processed on the broaching machine, it enters the machining center for processing. The data acquisition and processing module begins to collect and save various data.

[0074] Step 5: After the product is processed in the machining center, it enters the air blowing cleaning;

[0075] Step 6: After the product is cleaned by air blowing, it is tested, and the data acquisition and processing module obtains and saves the product test results;

[0076] Step 7: After the product is marked and shipped, the data traceability module obtains and processes the equipment and other data of each production link from the database based on the workpiece, and generates a PDF document including various production parameters of the workpiece. When the product is full, the batch code is printed as a spot label and shipped to the next production link together with the finished product;

[0077] Step 8: The system display page shows the product test results and traceability documents.

[0078] The relevant data of a workpiece is one row in the database table, among which the two torques (upper and lower beam torques) only store the time of entering and leaving the equipment. The historical torque and other data required to draw curves are in another table and will be retrieved and processed separately when generating PDF.

[0079] The operating shift personnel information is obtained through employee input.

[0080] The loading batch is obtained from the production line PLC. The barcode scanner scans the QR code on the loading frame to save the batch data in the PLC. The system obtains the loading batch information through OPC subscription.

[0081] The unloading batches are counted by the system. According to the production scheduling data obtained from the management system, a batch is composed of a certain quantity and the name is date + batch number (20240801001). When the batch quantity is reached, the batch number is increased by one (20240801002) to indicate that the following workpieces are the next batch. When a batch is full, the system will send a command to the printer through socket communication to print the unloading batch code.

[0082] The online time and offline time are determined by the two control signals of the loading conveyor belt starting to load and the unloading conveyor belt completing unloading.

[0083] The broaching machine torque and broaching tool life data are obtained by subscribing to the OPC server of the broaching machine PLC. The broaching tool torque is finally presented as a curve within a period of time. The entry and exit time is determined by the control signal obtained from the production line PLC. All the torque data during this period are taken out from the database and then the data is aligned (some curves in the traceability file constitute the data. The curve data in the traceability file includes the broaching machine broaching force curve, the machining center speed curve, the machining center torque curve, etc. These data are stored in a separate table, and the data for each second is saved. When the workpiece needs to generate a file, the data is taken out to form a curve according to the entry and exit time of the workpiece).

[0084] During the production process, the production may be suspended and then restarted. At this time, the time range for the workpiece to enter and exit the equipment will be very large, that is, a large section of the drawn curve will be 0. However, for the torque curve judgment, only the processed section is needed, so the data during this period of time must be processed (in view of the possible suspension of the production line, which makes the workpiece in and out of the time period particularly long, which will lead to unreasonable curve generation, and corresponding processing is performed).

[0085] The speed feed of the machining center and the tool life of the machining center are obtained by subscribing to the OPC server of the machining center CNC system. The processing method of the speed feed is the same as that of the broaching machine torque above.

[0086] The test results are obtained based on the trigger signal of the production line PLC. When the full test completion signal becomes true, the system obtains the most recent test result from the test device. The test device has its own server, and each time the test result is saved in the specified path in the form of txt. The system accesses the shared txt file through the local area network, obtains the test results and saves them in the database.

[0087] The marking code is sent from the production line PLC. By subscribing to the OPC server of the production line PLC, the station marking code point data is read and saved when the marking completion signal becomes true.

[0088] When the product is offline, a PDF file named with the imprint code is generated for each workpiece. The PDF content format is pre-designed in HTML format in the system. The corresponding data is obtained from the database and filled in when it is generated. The PDF is generated in a folder named with the date through the PDF conversion tool. According to the test results, the NG (unqualified) part files will be saved in a specific unqualified folder. According to the pre-acquired parameter qualified value range, the specific unqualified item data will be marked in red to facilitate the subsequent quick search for specific unqualified items.

[0089] Operation process, such as Figure 5 As shown:

[0090] Single-shift production starts with employee login. Employees log in on the big screen, and the front end transmits relevant information to the back end. The database stores the shift employee information. At the same time, the back end requests the ERP system to display and confirm the production scheduling related information on the big screen.

[0091] Table 1. Employee data storage

[0092]

[0093] The raw materials are ready to go online, the barcode scanner scans the QR code of the loading batch, and the loading batch information is obtained through the collection robot and the production line control PLC point and saved in the database.

[0094] Table 2. Data storage of loading batches

[0095]

[0096] When the workpiece raw materials begin to enter the production line, a data position belonging to the workpiece is created in the database table and prepared to be filled in. The time when the workpiece enters and each device is recorded by collecting the interactive signal points of the robot and the production line control PLC. After the workpiece leaves the device, the required equipment data is taken out from the database according to the corresponding time period and stored in the corresponding workpiece data position.

[0097] Table 3. Data storage of equipment residence time

[0098]

[0099] The workpiece enters the broaching machine for processing and collects relevant data of the broaching machine

[0100] Table 4. Storage of information such as broaching

[0101]

[0102] Table 5. Torque information storage of broaching machine

[0103]

[0104] The workpiece enters the machining center for processing and collects relevant data of the machining center

[0105] Table 6. Storage of information on machining center tools, etc.

[0106]

[0107] Table 7. Data storage of machining center speed and other data

[0108]

[0109] After the workpiece is processed, it enters the testing equipment, collects the loading and unloading signal points of the robot and the production line PLC, and when the test is completed, the full inspection equipment obtains the full inspection results and saves them in the location of the corresponding workpiece data.

[0110] Table 8. Data storage of full inspection results

[0111]

[0112] After the workpiece has completed full inspection, it enters the engraving equipment. By collecting the loading and unloading signal points of the robot and the production line PLC, the engraving code is collected and stored in the workpiece data position after the engraving is completed.

[0113] Table 9, Data storage of printed code

[0114]

[0115] Qualified workpieces will enter the unloading frame, and the back end will count the number of unloadings and assign the qualified workpieces to a unloading batch. After the workpieces are unloaded, the unloading batch code of the workpieces will also be stored in the workpiece data position.

[0116] Table 10. Data storage of blanking batch code

[0117]

[0118] Take out the relevant data of a row to generate PDF, such as Figure 6 As shown, a, b, c, and d together constitute a PDF.

[0119] The above embodiments are only preferred embodiments of the present invention and are not limitations of the technical solutions of the present invention. Any technical solution that can be implemented on the basis of the above embodiments without creative work should be deemed to fall within the scope of protection of the patent of the present invention.

Claims

1. An automobile parts production line management and tracing system, characterized in that: It includes production information acquisition module, production data collection module, production data processing module, production data tracing module and production data display module; Through the production information acquisition module, parts information and production scheduling information are acquired; Through the production data acquisition module, production equipment data and product data are obtained; Through the production data processing module, the data obtained by each party is processed according to the needs and stored in the database; Through the production data tracing module, the whole process processing data of the workpiece is saved in units of a single workpiece, and the processing data of the production line is saved in units of a shift, so as to facilitate the subsequent tracing and viewing; The production data display module is used to display real-time information of production line equipment, historical statistics of production line information, and the viewing and export of various production reports and traceability files.

2. The automobile parts production line management and tracing system according to claim 1 is characterized in that: The production information acquisition module acquires part information by acquiring the qualified inspection range of the parts before production, which is consistent with the setting of the inspection equipment in the production line, and imports the qualified inspection range of the product by importing Excel from the system; The production scheduling information includes: planned rhythm entry, daily production plan acquisition and employee login; employees log in to the system through the front-end to enter the planned rhythm of the product for the day in the information entry interface, and the Java back-end system obtains employee information and planned rhythm and stores them in the database; the Java back-end system obtains the production plan for the day from the management system through http requests and stores it in the database.

3. The automobile parts production line management and tracing system according to claim 1 is characterized in that: The production information data collection module includes the collection of production equipment data and product data; The objects of data collection include PLC, machining center and detection device; PLC and machining center adopt OPC communication protocol, the equipment end acts as OPC server, and Java back-end system acts as OPC client to process the data obtained through real-time subscription through production data processing module and store it into database; the detection device will save the detection result in the form of txt in the specified path each time, and the system will access the shared txt file through the local area network to obtain the detection result and save it in the database.

4. The automobile parts production line management and tracing system according to claim 1 is characterized in that: In the production data processing module: For data used to display monitoring in real time, directly update the corresponding fields in the database table; For data used for workpiece or production report traceability, historical preservation is required, and data is added and saved continuously with time in the corresponding table of the database; The PLC control trigger signal data is used to confirm the time when the workpiece enters and exits the production link, and is used to bind the relevant data with the workpiece according to the entry and exit time and save it in the database; For statistical report data that needs to be queried by date and time, the received data is counted based on time units and saved in the database. The statistics include: test result statistics, production statistics, CPK statistics and OEE statistics.

5. The automobile parts production line management and tracing system according to claim 1 is characterized in that: In the production data tracing module, the data tracing module obtains and processes the equipment data of each production link from the database based on the workpiece, and generates a PDF document including various production parameters of the workpiece.

6. The automobile parts production line management and tracing system according to claim 1 is characterized in that: The production data display module includes: a real-time monitoring unit and a historical statistical reporting unit; the real-time monitoring unit displays the real-time operating status of the equipment of the production line, the processing information and alarm status of the production line; the historical statistical reporting unit includes the historical statistics of workpiece data, the overall equipment information of the production line and the historical statistics of processing information.

7. A method for tracing the management of automobile parts production line, characterized in that: The steps include: 1) Before starting production, the production information acquisition module obtains the corresponding data and stores the data in the database; 2) The product is loaded and enters the production line for processing. The production data acquisition module and the production data processing module begin to collect and save various data; 3) After the product is processed and tested, the production data acquisition module and the production data processing module obtain and save the product test results; 4) When the product is offline, the data traceability module obtains and processes the equipment data of each production link from the database based on the workpiece, and generates a PDF document including various production parameters of the workpiece; 5) The production data display module displays product test results and traceability documents.

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