Production line system

Abstract

The application discloses a production line system, comprising: a transmission main line with transmission positions, work areas and a control module; the types of the work areas include at least two types, there are at least one group of adjacent two work areas, the number of the preceding work area is greater than the number of the subsequent work area, each of the work areas has a plurality of stations arranged in sequence along the transmission direction on one side of the corresponding transmission position, the first station of each of the work areas has at least one transmission position with no station arranged on the side as the distribution position of the work area, the last station of each of the work areas has at least one transmission position with no station arranged on the side leading to the next work area as the distribution position of the next work area; the control module preferentially distributes the products to be processed to the distribution position of the work area with the idle station according to the processing sequence, and then dynamically distributes the products to be processed of the corresponding distribution position to the corresponding idle station according to the idle state of each station in the work area. The application can improve the production efficiency.

Description

Technical Field

[0001] This invention relates to the technical field of production line systems, and more particularly to a production line system that can improve efficiency. Background Technology

[0002] In existing technologies, production line systems typically use serially configured transmission positions, with a processing station located on one side of each transmission position.

[0003] Taking air conditioner production as an example, vacuuming and refrigerant charging are crucial steps in ensuring air conditioner performance. In traditional methods, this part of the production line system has approximately 30 transmission stations. The first 1-2 transmission stations are for allocating the vacuuming area, followed by 19 transmission stations with 19 vacuuming stations arranged on one side. The next few transmission stations are for allocating the refrigerant charging area, and the next few transmission stations have approximately 7-8 charging stations arranged on one side. A PLC for control sequentially distributes the air conditioning system to each station through these transmission stations. After processing, each station moves on to the next work area.

[0004] The above-mentioned work is usually done by independent stations. Each station determines whether the products to be processed at its corresponding allocation position can be released to the next transmission position or need to enter its own station based on its idle status. For stations of the same type, the stations on the front of the transmission position have more processed materials, while the stations on the back of the transmission position have less processed materials. Moreover, after the processed materials at the front stations are completed, they will block the operation of processed materials at subsequent stations, resulting in low efficiency and waste of resources.

[0005] Therefore, how to provide a highly efficient production line system is a technical problem to be solved. Summary of the Invention

[0006] To address the technical problem of low efficiency in existing production line systems, the production line system of this invention is proposed.

[0007] The production line system proposed in this invention includes:

[0008] The main transmission line has multiple transmission bits;

[0009] The work area includes at least two kinds of work area which need to be processed in sequence, each work area has at least one, and there is at least one set of adjacent two kinds of work area, the number of the previous work area is greater than the number of the subsequent work area, each work area has a plurality of stations arranged in sequence on one side of the corresponding transmission position in the transmission direction, and each work area has at least one transmission position with no station on the side before the first station as the distribution position of the work area, and each work area has at least one transmission position with no station on the side after the last station as the distribution position of the next work area;

[0010] The control module preferentially distributes the products to be processed to the corresponding distribution position of the work area with idle station based on the processing sequence, and then dynamically distributes the products to be processed in the corresponding distribution position to the corresponding idle station according to the idle state of each station in the work area.

[0011] Further, the control module establishes a data structure and / or configuration register corresponding to each work area and its distribution position in units of work area, the station reads the value in the corresponding data structure and / or register to release the product to be processed to the next transmission position, or to release the product to be processed to the station for processing, and modifies the value in the corresponding data structure and / or register according to the current state of the station, and the control module determines the idle work area and station according to the value in the data structure and / or register and performs distribution.

[0012] Further, when there are multiple work areas of the same kind, the elements in the data structure corresponding to the work area also include the distribution position of the next work area of the same kind, and / or the corresponding register is configured for the distribution position of the next work area of the same kind.

[0013] Further, for the same kind of work area, the control module allocates the idle station according to the principle of proximity.

[0014] Further, for the subsequent work area which interfaces with multiple previous work areas, the control module preferentially allocates the distribution position for the product to be processed located upstream in the transmission direction.

[0015] Further, the data structure is an array or a table.

[0016] Further, the state of the distribution position is an identification code corresponding to the empty state, or an identification code of the station or distribution position to which the product to be processed is allocated.

[0017] Further, the state of the station is an identification code corresponding to the empty state, the processing state, the discharging state, and the discharging completion state.

[0018] Further, the production area is two, and the number of pre-sequencing work area is two, and the number of post-sequencing work area is one.

[0019] Further, the distribution bit of the first and second pre-sequencing work area is one, and adjacent to the transmission bit corresponding to the first station of the corresponding work area, and the distribution bit of the second pre-sequencing work area is adjacent to the transmission bit corresponding to the last station of the corresponding pre-sequencing work area, and the two distribution bits of the post-sequencing work area are adjacent to the work bit corresponding to the first station of the post-sequencing work area.

[0020] Further, the production line system is a vacuum and filling production line system, the pre-sequencing work area is a vacuum area, the post-sequencing work area is a refrigerant filling area, and the product to be processed is an air conditioning system.

[0021] The application reduces the waiting time of the product to be processed on the production line by dynamically allocating stations, and the optimized allocation strategy of the control module ensures the full use of the stations, reduces the waste of energy and materials, and improves the transparency of the production process through real-time data acquisition and monitoring, which facilitates quality control and fault diagnosis. The system can adjust the test plan according to real-time data, and improve the response ability to unexpected situations. BRIEF DESCRIPTION OF DRAWINGS

[0022] The application will be described in detail below in conjunction with the embodiments and drawings, in which:

[0023] Figure 1 is a layout schematic diagram of the production line of an embodiment of the application.

[0024] Figure 2 is a data change process schematic diagram of the prior art for allocating one material.

[0025] Figure 3 is a data change process schematic diagram of the prior art for allocating three materials.

[0026] Figure 4 is a data change process schematic diagram of the application for allocating one material.

[0027] Figure 5 is a data change process schematic diagram of the application for allocating three materials.

[0028] BRIEF DESCRIPTION OF DRAWINGS

[0029] 1, first vacuum area; 2, second vacuum area; 3, refrigerant filling area; 4, transmission main line; 11, distribution bit; 12, vacuum station; 31, first filling distribution bit; 32, second filling distribution bit; 33, refrigerant filling station. DETAILED DESCRIPTION

[0030] In order to make the technical problems, technical solutions and beneficial effects of the present application clearer, the present application will be further described in detail below in conjunction with the accompanying drawings and examples. It should be understood that the specific examples described herein are only intended to explain the present application and not to limit the present application.

[0031] Thus, one feature indicated in the specification will be used to illustrate one feature of one embodiment of the present application, rather than implying that every embodiment of the present application must have the illustrated feature. In addition, it should be noted that the specification describes many features. Although certain features can be combined together to show possible system designs, these features can also be used in other combinations that are not explicitly described. Thus, unless otherwise stated, the described combinations are not intended to be limiting.

[0032] The production line system of the present application comprises a transmission main line, work areas and a control module.

[0033] The transmission main line has a plurality of transmission positions.

[0034] The types of work areas are divided according to processing procedures, and the types of work areas of the present application include at least two types that need to be processed sequentially.

[0035] For example, taking lens processing as an example, the types of work areas can be divided into rough cutting work area, primary cleaning work area, polishing work area, and secondary cleaning work area. For example, taking vacuumizing and refrigerant filling of air conditioning system as an example, the types of work areas can be divided into vacuumizing work area and refrigerant filling work area.

[0036] Each type of work area has at least one, and there is at least one set of adjacent two types of work areas, the number of the preceding work area is greater than the number of the subsequent work area.

[0037] Taking lens processing as an example, the number of rough cutting work area, primary cleaning work area, polishing work area, and secondary cleaning work area is 1, 2, 2, and 1 respectively. Then the lens processing production line has a set of adjacent two types of work areas, which are polishing work area and secondary cleaning work area, and their numbers satisfy that the number of polishing work area is greater than the number of secondary cleaning work area.

[0038] Taking vacuumizing and refrigerant filling of air conditioning system as an example, two vacuumizing areas can be set to correspond to one refrigerant filling area, so there is at least one set of adjacent two types of work areas, the number of the preceding work area is greater than the number of the subsequent work area. Usually, this case is because the processing time of the station of the preceding work area is greater than the processing time of the station of the subsequent work area, so the number of the preceding work area is greater than the number of the subsequent work area, which can effectively improve the production efficiency.

[0039] Each work area has multiple stations arranged in sequence along the conveying direction on one side of the corresponding conveying position. For example, a rough cutting work area has two rough cutting stations arranged one-to-one corresponding to two conveying positions respectively, and a primary cleaning work area has five primary cleaning stations arranged one-to-one corresponding to five conveying positions respectively. For another example, a vacuum pumping work area has four vacuum pumping stations arranged one-to-one corresponding to four conveying positions respectively. A refrigerant filling work area has four filling stations arranged one-to-one corresponding to four conveying positions respectively.

[0040] The first station of each work area has at least one conveying position with no station arranged on the side as the distribution position of the work area, and the last station of each work area has at least one conveying position with no station arranged on the side leading to the next work area and as the distribution position of the next work area.

[0041] For example, the first 1-2 conveying positions of the first vacuum pumping work area can be the distribution position of the first vacuum pumping work area. The first 1-2 conveying positions of the second vacuum pumping work area can be the distribution position of the second vacuum pumping work area, and the distribution position of the second vacuum pumping work area is not the conveying position corresponding to the vacuum pumping station of the first vacuum pumping work area. The conveying position of the last vacuum pumping station of the first vacuum pumping work area can lead to the distribution position of the refrigerant filling work area in addition to the distribution position of the second vacuum pumping work area, that is, the conveying position of the last vacuum pumping station of the first vacuum pumping work area has two branches, one leading to the second vacuum pumping work area and the other leading to the refrigerant filling work area. For the second vacuum pumping work area, the conveying position corresponding to the last station of the second vacuum pumping work area can only lead to another distribution position of the refrigerant filling work area.

[0042] The control module preferentially allocates the products to be processed to the distribution position of the work area with an idle station based on the processing sequence, and dynamically allocates the products to be processed at the corresponding distribution position to the corresponding idle station according to the idle state of each station in the work area.

[0043] The present application divides the work area with relatively short time consumption and large number of stations into multiple work areas, each of which is connected to the work area of the next type, and improves the production efficiency of the production line through dynamic allocation.

[0044] In an embodiment, the control module establishes the data structure and / or configuration register corresponding to each work area and its distribution position in units of work area, each station reads the value in the corresponding data structure and / or register to release the product to be processed to the next conveying position or to the station for processing, and modifies the value of the corresponding data structure and / or register according to the current state of the station, and the control module determines the idle work area and station according to the value in the data structure and / or register and performs allocation.

[0045] For example, the control module can establish three arrays according to two vacuumizing areas and one refrigerant filling area. When an air conditioner system currently located at the distribution position of the first vacuumizing area is to be distributed to the first station of the second vacuumizing area, the first value of the first array can be modified to write the identification code corresponding to the distribution position of the second vacuumizing area, so that the distribution position of the first vacuumizing area releases the air conditioner system to the transmission position corresponding to the first station of the first vacuumizing area. After the release, the first value of the first array is changed to 0, and the second value of the first array is changed to the identification code corresponding to the distribution position of the second vacuumizing area (modified by the PLC). The operation is sequentially performed until the air conditioner system reaches the distribution position of the second vacuumizing area. At this time, the value of the element of the array corresponding to the distribution position is exactly the identification code of the distribution position. Then, the control module starts to select an idle station of the second vacuumizing area for distribution.

[0046] In the above manner, the management of each station is very transparent and less prone to errors.

[0047] In a further embodiment, when there are multiple work areas of the same type, the element in the data structure corresponding to the work area further contains the distribution position of the next work area of the same type, and / or the corresponding register is configured for the distribution position of the next work area of the same type. By associating the distribution position of the next work area of the same type with the previous work area, the distribution of the stations of the work area of the same type is facilitated.

[0048] In an embodiment, for the same type of work area, the control module distributes the idle stations according to the nearest principle. For example, if there are idle vacuum stations in the first vacuumizing area and the second vacuumizing area, the idle vacuum stations in the first vacuumizing area are preferentially distributed. For example, if there are two idle vacuum stations in the first vacuumizing area, the nearest idle vacuum station is selected for distribution according to the distance from the distribution position of the first vacuumizing area, so as to improve the production efficiency.

[0049] In an embodiment, for the subsequent work area that interfaces multiple previous work areas, the control module preferentially distributes the to-be-processed product located at the distribution position of a previous work area upstream in the transmission direction.

[0050] Still taking two vacuumizing areas and one refrigerant filling area as an example, the refrigerant filling area has two distribution positions, one for receiving the air conditioner system that has been vacuumized by the first vacuumizing area, referred to as the first distribution position for convenience of description, and the other for receiving the air conditioner system that has been vacuumized by the second vacuumizing area, referred to as the second distribution position. When there are air conditioner systems to be distributed at the first and second distribution positions, the control module preferentially distributes the air conditioner system at the first distribution position to the refrigerant filling area, so as to avoid the blockage of the transmission line of the first vacuumizing area and improve the production efficiency.

[0051] In one embodiment, the data structure is an array or a table. An array is preferred for ease of operation. In one embodiment, the control module records the state of each station in the form of a corresponding register, but the program control within the control module uses an array or other data format to read and store the values of the registers.

[0052] In one embodiment, the identification code corresponding to the empty state, or the identification code of the station or distribution position to which the product to be processed is assigned.

[0053] For example, when there is no product to be processed in the current distribution position, the state of the distribution position can be 0, and when there is a product to be processed in the current distribution position that needs to be assigned to the first station, the state of the distribution position can be 1.

[0054] By managing the state of the distribution position, the status of each working position on the production line is very transparent, facilitating management and distribution by the controller.

[0055] In one embodiment, the identification code corresponding to the empty state, or the identification code of the station or distribution position to which the product to be processed is assigned.

[0056] By managing the state of each station, the status of each working position on the production line is very transparent, facilitating management and distribution by the controller.

[0057] In a specific embodiment, the production area is divided into two, and the number of pre-sequencing work areas is two, and the number of post-sequencing work areas is one. One side of the first transfer position of the post-sequencing work area needs to be docked with the station, and the other side needs to be docked with the transfer position of the subsequent station. The other two sides can be set as distribution positions to dock the processed products to be processed from the two pre-sequencing work areas. Therefore, this number of matching relationship is one of the highest matching degrees between the pre-sequencing work area and the post-sequencing work area. Of course, the multiple distribution areas of the post-sequencing work area can be installed on a disc to realize docking with the first transfer position of the post-sequencing work area, to realize docking between multiple pre-sequencing work areas and multiple post-sequencing work areas, and to improve efficiency. However, compared with the two pre-sequencing work areas corresponding to one post-sequencing work area, it is easier to implement and has lower cost.

[0058] In a further embodiment based on the above embodiment, the distribution position of the first and second pre-sequencing work area is one, and is adjacent to the transfer position corresponding to the first station of the corresponding work area. The distribution position of the second pre-sequencing work area is adjacent to the transfer position corresponding to the last station of the corresponding pre-sequencing work area, and the two distribution positions of the post-sequencing work area are adjacent to the working position corresponding to the first station of the post-sequencing work area.

[0059] In other words, the allocation position of the first preceding work area is located immediately adjacent to the transmission position of its first station. The allocation position of the second preceding work area is located between the transmission positions of its first station and the last station of the first preceding work area. Simultaneously, the next transmission position after the last station of the first preceding work area discharges becomes one of the allocation positions in the subsequent work area. Similarly, the next transmission position after the last station of the second preceding work area discharges becomes another allocation position in the subsequent work area. This arrangement ensures that each work area is closely spaced, with no redundant transmission positions between them, thereby improving production efficiency.

[0060] In a specific application embodiment, the production line system of the present invention can be specifically a vacuuming and filling production line system, wherein the preceding work area is a vacuuming area, the subsequent work area is a refrigerant filling area, and the product to be processed on the production line is an air conditioning system.

[0061] The present invention will be further explained below using a vacuuming and filling production line system as a preferred specific application example.

[0062] like Figure 1 As shown, the vacuuming and filling production line system of this embodiment includes: a first vacuuming zone 1, a second vacuuming zone 2, and a refrigerant filling zone 3.

[0063] These three zones are arranged along the main transmission line 4, which is divided into two: the first vacuum zone 1 is located on the right side of the main transmission line, the second vacuum zone 2 is partially located on the right side of the main transmission line and partially on the left side, and the refrigerant filling zone 3 is located on the left side. The transmission position corresponding to the first station in the refrigerant filling zone 3 and the transmission position corresponding to the very first station in the first vacuum zone are located on the same straight line perpendicular to the transmission direction of the main transmission line, connected by a transmission position, which is the first filling distribution position 31 of the refrigerant filling zone 3. The lower ends of the two main transmission lines are connected by a transmission position, making the entire main transmission line U-shaped. That is, the two parts of the second vacuum zone 2 are connected to form a production line segment by the transmission position located at the bottom of the U-shaped main transmission line. The transmission position corresponding to the first station in the refrigerant filling zone 3 and the transmission position corresponding to the last station in the second vacuuming zone are located on the same straight line along the transmission direction of the main transmission line. They are connected by a transmission position, which is the second filling allocation position 32 of the refrigerant filling zone 3. The allocation priority of the first filling allocation position 31 is higher than that of the second filling allocation position 32.

[0064] In this embodiment, through the above layout, the areas are regionalized according to different functions, small-scale allocation management is performed, and correlation is performed through the last process of the previous work area and the starting process of the next work area, so as to achieve allocation management of the entire layout.

[0065] Eight vacuum stations 12 and four filling stations are deployed on the above production line, each station is equipped with automatic equipment and sensors. The eight vacuum stations 12 are evenly divided into the first and second vacuum areas 2. Each vacuum station 12 is responsible for the vacuum operation of the air conditioning system entering the station. The filling station is responsible for filling the refrigerant into the air conditioning system.

[0066] Each station is provided with multiple sensors to monitor the working state of each station and the production data of the air conditioning system in real time. Each station has four states, namely empty state, processing state, discharging state and discharging completion state, and the corresponding identification codes (also referred to as station state values) of the four states are 0, 88, 99 and 100. Through the transmission of the station state values, the idle condition and the discharging condition of each station are finally judged, for example, if the state value of a certain station is 100, the regional outstation action can be performed.

[0067] Each material (i.e. air conditioning system) also has a corresponding state. It is assumed that the current material is assigned a state of 4, that is, the value of the first element (corresponding to the allocation bit 11) of the array is assigned as 4, which means that the material needs to be vacuumed at the 4th station (the third station of the first vacuum area) of the first vacuum area. The material will first arrive at the position of the 1st station (allocation bit 11), and after judging that the current state is 4 (for example, the state value of the 1st station and the station number of the 1st station can be compared through PLC, the current state value of the 1st station is 4, and the station number of the 1st station is 1, so the blocking action is performed), the material is released to the transfer position corresponding to the 2nd station. Similarly, the 2nd station judges that the state value of the material is also 4, and the blocking of the 2nd station is also released, and the material arrives at the 3rd station, which is also judged and released, until the material arrives at the 4th station. The 4th station judges that the state value of the current material is the same as the station number, and then the in-station action is performed.

[0068] After the in-station is completed, the value of the corresponding element in the array is changed from 4 to 88 by the 4th station, and 88 represents the processing state.

[0069] When the process is completed, the out-station button is pressed manually, and the material is transferred back to the transfer position corresponding to the 4th station. At this time, the corresponding element in the array is changed from 88 to 99 by the 4th station. If the subsequent 4th station is in an empty state, the value of the corresponding element in the array is changed to 100, and the 4th station performs the top lifting and transplanting to lift up and output the material from the first vacuum area 1.

[0070] As for the station No. 5, it is actually the distribution site 11 of the second vacuumizing area 2. Only when the material state value is 5, the material will pass through the transmission site corresponding to the station No. 1-4 to reach the distribution site 11, and there is no in-out station action, so it is not necessary to judge. The array corresponding to the second vacuumizing area 2 has no element corresponding to the station No. 5, because there is no third vacuumizing area of the same kind after the second vacuumizing area 2.

[0071] The configuration of the embodiment will be compared with the control process of recording the state of the work area station in the form of array when each process of the prior art has only one work area.

[0072] Both of the two comparative embodiments control the operation of the production line through PLC (programmable logic controller) and monitor the station state, and data transmission is carried out through shift algorithm.

[0073] Suppose that the prior art also has 8 stations, and the specific data change process of the prior art is as shown in Figure 2 .

[0074] In which the 1-9 of the table header represent the station No. 1-9, i.e. one distribution site and 8 stations. Each row behind the table header represents the change of each array element.

[0075] Suppose that three materials are to be distributed to the station No. 9, 8 and 7 respectively, and the data change process of the corresponding technology is as shown in Figure 3 .

[0076] It can be seen from the two tables of Figure 2 , Figure 3 that each station is sequentially connected, and the corresponding influence is that when any one station has abnormal problem, the production line will be affected.

[0077] In the embodiment, each work area is provided with an array of 5-8 sites at most. Taking the first vacuumizing area as an example, when the material is to be distributed to the second vacuumizing area, the specific data change process of the first vacuumizing area is as shown in Figure 4 .

[0078] When the embodiment needs to distribute three materials, one of which is to the second vacuumizing area, and the remaining two materials are to the station No. 5 and 4 respectively, the specific data change process is as shown in Figure 5 .

[0079] As can be seen from the table in the figure, before the material is transmitted, the state of the next station needs to be judged, and only the station corresponding to the value 0 or 88 can transmit the material to the transmission position corresponding to the next station. The embodiment divides the vacuum extraction area into multiple small areas, greatly reducing the loss probability and misplacement rate in the data transmission process. When an abnormality occurs, for example, when an abnormality occurs in the second vacuum extraction area, it will not affect the first vacuum extraction area and will only have an impact in the area, without affecting the first vacuum extraction area.

[0080] The above merely describes the preferred embodiments of the present application and is not intended to limit the present application. Any modification, equivalent replacement and improvement within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A production line system, characterized by, The application relates to a production line system, comprising: a main conveying line with multiple conveying positions; multiple work areas, the types of the work areas including at least two types of work areas that need to be processed in sequence, at least one set of two adjacent work areas having a number of preceding work areas greater than a number of subsequent work areas, each of the work areas having multiple stations arranged in sequence along a conveying direction on one side of a corresponding conveying position, each of the work areas having at least one conveying position with no station arranged on a side as an allocation position of the work area in front of a first station of the work area, and each of the work areas having at least one conveying position with no station arranged on a side as an allocation position of a next type of work area behind a last station of the work area; a control module that preferentially allocates products to be processed to corresponding allocation positions of work areas with idle stations based on a processing sequence, and dynamically allocates the products to be processed at the corresponding allocation positions to corresponding idle stations according to idle states of the stations in the work areas; the control module establishes a data structure and / or a configuration register corresponding to each work area and the allocation position of the work area, the stations read values in the corresponding data structure and / or the register to release the products to be processed to a next conveying position or to process the products to be processed at the stations, and modify the values in the corresponding data structure and / or the register according to current states of the stations, and the control module determines idle work areas and stations according to the values in the data structure and / or the register and performs allocation.

2. The production line system of claim 1, wherein, When multiple work areas of the same type exist, an element in a data structure corresponding to the work areas further comprises an allocation position of a next work area of the same type, and / or a corresponding register is configured for the allocation position of the next work area of the same type.

3. The production line system of claim 2, wherein, For a subsequent work area that is docked with multiple preceding work areas, the control module preferentially allocates products to be processed at the allocation position of a preceding work area located upstream in the conveying direction.

4. The production line system of claim 2, wherein, The data structure is an array or a table.

5. The production line system of claim 1, wherein, The state of the allocation position is an empty material state corresponding to an identification code or an identification code of a station or an allocation position to which the products to be processed are allocated.

6. The production line system of claim 1, wherein, The state of the station is an empty material state, a processing state, a discharging state, and a discharging completion state corresponding to identification codes.

7. The line system according to any one of claims 1 to 6, characterized in that The work areas are two types, and the number of preceding work areas is two and the number of subsequent work areas is one.

8. The production line system of claim 7, wherein, The allocation positions of the first and second preceding work areas are one, and adjacent to a conveying position corresponding to a first station of the corresponding work area, and the two allocation positions of the subsequent work area are both adjacent to a conveying position corresponding to a last station of a previous work area.

9. The production line system of claim 8, wherein, The production line system is a vacuum extraction and refrigerant filling production line system, the preceding work areas are vacuum extraction areas, the subsequent work area is a refrigerant filling area, and the products to be processed are air conditioning systems.

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