Informationized and automatic data-driven flexible production management and control system

Abstract

The invention discloses an informatization and automation data-driven flexible production management and control system, and belongs to the technical field of automation. According to the invention, the whole system can be split into a plurality of subsystems or micro-services according to services, the subsystems have load balance, the flow is taken as an entry point, the stability of the micro-services is guaranteed from multiple dimensions such as flow limiting, flow shaping, fusing degradation, system load protection and hot spot protection, and the service performance of the micro-services is improved. The method is suitable for the production characteristics and production modes of multiple types, multiple batches and small batches of products in the spacecraft production process, and solves the problems that the production preparation process is tedious, the preparation time is long, the production efficiency is low, errors are prone to occurring and the like due to the fact that the types of the products change many in the production process. And the production efficiency and quality of production and processing links of unmanned aerial vehicle metal structure products, star net structure products and power supply case products are improved.

Description

Technical Field

[0001] The present invention relates to an information-based, automated data-driven flexible production control system, belonging to the technical field of automation. Background Art

[0002] With the diversification of market demand, technological advancement, pursuit of production efficiency and requirements of sustainable development, the development and application of an information-based, automated data-driven flexible production control system has been promoted.

[0003] The diversity and personalized changes in the market have led to the traditional large-scale, single production model no longer being able to meet market demand. The flexible production control system can quickly adapt to changes in product types and quantities to meet the market's demand for multi-variety, small-batch production. In order to reduce costs and increase efficiency and improve market competitiveness, enterprises need to continuously optimize production processes and improve production efficiency. The flexible production control system improves overall production efficiency by reducing non-value-added activities in the production process and making rational use of the environment and resources.

[0004] For the single-piece, small-batch, and multi-variety production model, it is common that the production line needs to frequently change tools, adjust equipment, and reconfigure the production process. Compared with the large-batch production model, the single-piece, small-batch, and multi-variety production model requires more time to complete production preparations. Frequent product changes may lead to more human-induced quality problems in the production process. There are also many hidden dangers in inventory management. Inventory management and logistics are very complicated, resulting in increased inventory costs. Due to the wide variety of products, production planning and manual scheduling are particularly complex, requiring more sophisticated management and coordination to ensure a smooth production process. Finally, the single-piece, small-batch production model will lead to the inability of equipment to continue to operate in the optimal state, low equipment utilization, increased labor costs, and reduced production efficiency. Summary of the invention

[0005] The technical problem solved by the present invention is: to overcome the shortcomings of the prior art and provide an information-based, automated data-driven flexible production control system that is suitable for the production characteristics and production mode of multiple types, multiple batches, and small batches of products in the spacecraft production process. It solves the problems of complicated production preparation process, long preparation time, low production efficiency, and easy errors caused by the large number of product types in the production process, and improves the production efficiency and quality of the production and processing links of UAV metal structure products, star network structure products, and power chassis products.

[0006] The technical solution of the present invention is: an information-based, automated data-driven flexible production control system, including: The production planning management subsystem obtains the production plan, production work order and process information from the upstream workshop intelligent execution control platform MES system, screens specific processes, generates process step plans, and sends them to the production preparation subsystem and scheduling management subsystem; The production preparation subsystem checks the preparation status of production materials and tools according to the process step plan and corresponding process information sent by the production planning management subsystem through the shelf information unit, CNC program management subsystem, tool management subsystem, and equipment management subsystem, and gives status identification. When all preparations are completed, it sends a ready instruction to the scheduling management subsystem; The scheduling management subsystem performs scheduling according to the ready-to-go instruction; the scheduling includes: combining the process step plan, checking whether the production materials and tools required for production execution are in the production ready state through the shelf information unit, the CNC program management subsystem, the tool management subsystem, and the equipment management subsystem, and when the production is ready, scheduling is performed in accordance with the priority order and the planned completion time of the process step plan, and the process plan is distributed to the corresponding equipment that can produce the product according to the product category; The NC program management subsystem is integrated with the external equipment data acquisition and monitoring IOT system to obtain NC program files, collect NC machine tool data information, NC program information, tool information, and issue the program files to the NC machine tool; it supports manual creation of program folders and uploading of NC program files and direct acquisition of program files in the machine tool; The shelf information unit includes a loading station, a robot, and a buffer. The loading station is the starting point of the material entry line. Operators or robots use the loading station to load and unload materials and to pick and place materials. The buffer is located next to the CNC machine tool and is used to temporarily store the blanks to be processed by the machine tool and the finished parts that have been processed. The machine tool and loading station information is collected through OPC UA to obtain material information, material completeness status, machine tool status, and machine tool execution CNC program and status information, and these statuses are confirmed and verified in the production preparation subsystem. When the completeness status is confirmed, the production task, material, CNC program, tool and equipment information are sent to the scheduling management subsystem. The tool management subsystem is used to store tool information lists for query and maintenance; obtain tool list information, tool numbers, and tool types in the machine tool through OPC UA and display them in the tool management subsystem; support operators to create new tools and synchronize tools to the machine tool; integrate with the tool setting instrument to obtain tool detection data and synchronize it to the tool list in the tool management subsystem; The equipment management subsystem is used to store the information list of all processing equipment and provide query and maintenance for operators; it is integrated with the production planning management subsystem and the scheduling management subsystem to send the equipment type to the scheduling management subsystem for the production tasks and CNC programs to be issued after scheduling; The equipment data collection subsystem is used to collect the status data and operation data of each production equipment in real time and send it to the kanban subsystem for display; The kanban subsystem is integrated with the production planning management subsystem, the equipment data acquisition subsystem, the shelf information unit and the scheduling management subsystem. It is used to display the production task information in the production planning management subsystem, the equipment status and equipment information in the equipment data acquisition subsystem, the material information and status of the shelf information unit, and the current scheduling tasks and processing program information in the scheduling management subsystem, and to show the overall status of the production line, production plan monitoring and production line video to the operators.

[0007] Furthermore, the production plan management subsystem stores historical production plans and production work orders, and creates corresponding process step plans based on existing production plans and production work orders, and binds corresponding materials, CNC programs, tools and clamping step diagrams.

[0008] Furthermore, according to the urgency of production, the operator edits and modifies the priority of the scheduling plan in the scheduling management subsystem according to the preset logical rules for modifying the scheduling priority, and adjusts the corresponding production priority.

[0009] Furthermore, during the production preparation process, when some materials are complete, the scheduling management subsystem allows the task to enter the scheduling queue and start processing and production. Subsequently, when the material of the product is out of material and before the processing and production is stopped, the operator is reminded to replenish the material. If the operator fails to replenish the material in time, the production task will enter a suspended state due to material shortage; if and only if the operator has completed the replenishment, the production of the currently suspended task will be continued; the scheduling management subsystem manually adjusts the production order or terminates the production task according to the priority of the production task.

[0010] Furthermore, each subsystem is implemented using microservices.

[0011] Furthermore, the CNC program management subsystem packages the acquired or imported CNC programs, creates folders based on the principle of one machine tool, one product, and one set of programs, bundles the main program and multiple subprograms and puts them into a folder to form a set of CNC programs, and pushes the CNC programs to the designated CNC machine tool.

[0012] Furthermore, a card reader is set at the entrance and exit of the loading station. When the pallet loaded with parts is entering or leaving the warehouse, the label information is read by the card reader to complete the binding and unbinding operations of the pallet and the part information; a card reader is installed at the end of the robot, and the robot verifies the pallet part information when taking and placing the pallet, thereby completing the management of the part processing completion status information.

[0013] Furthermore, the loading station includes an operating end and a robot end; the operating end is used to place the blanks that need to be processed online, and to identify and bind the pallet through a unique identifier; after clamping is completed, the pallet and the material are sent to the robot end; the loading station sends status information, pallet binding information, material information and loading port information, and issues instructions to the robot; after receiving the instructions, the robot moves to the loading port on the robot end to grab the material; at the same time, the storage location of the material in the cache is allocated and sent to the robot; the robot receives the cache location information and places the material at the designated location of the cache; for the processed materials, the shelf information unit sends the location information of the finished material in the cache to the robot, and the robot grabs the corresponding material; the shelf information unit sends the loading station port position information to the robot, the robot places the pallet and the material at the loading station port, and the operator moves the pallet and the material to the loading port position to complete the material out of the warehouse.

[0014] Furthermore, the cache is provided with four layers of shelves, which are used to store materials of different sizes; the materials include ordinary materials, extra-high materials, extra-wide materials, and extra-high and extra-wide materials; wherein, Ordinary materials can be stored in any storage location; Super-high materials can be stored anywhere between the first and fourth layers of the buffer warehouse shelves; There should be no material on the left or right sides of the extra-wide material to place the material; Extra-high and extra-wide materials should be stored between the first and fourth layers of the buffer warehouse, and no other materials should be placed on the left and right sides.

[0015] Furthermore, when the materials are put into storage, the algorithm rules for considering the location according to the process, processing equipment, storage quantity, and material specifications include: When entering the warehouse, if the material is ordinary and not super-high or super-wide, you only need to determine the location of the machine tool and place the ordinary material in any empty space in the buffer closest to the machine tool; If it is an oversized material, determine the position of the machine tool and place the oversized material in any empty space on the first and fourth layers of the buffer shelf closest to the machine tool. If there is no empty space on the first and fourth layers of the buffer shelf closest to the machine tool, place the oversized material in any empty space on the first and fourth layers of the adjacent buffer shelves on both sides. If the material is extra-wide, determine the location of the machine tool and place the extra-wide material in the buffer closest to the machine tool. When placing the material, determine whether there are materials on the adjacent sides. If there are no adjacent materials, place the extra-wide material in the empty space in the middle column. If there are no empty spaces in the buffer closest to the machine tool, place the material in the middle column of the adjacent shelves according to the principle of proximity, and leave no materials on the left and right sides. If the material is super-high or super-wide, determine the position of the machine tool and place the super-high or super-wide material on the first or fourth layer of the buffer closest to the machine tool. When placing the material, determine whether there are materials on the adjacent sides. If there are no adjacent materials, place the super-high or super-wide material in the empty space in the middle column of the first or fourth layer of the shelf. If there are no empty spaces in the buffer closest to the machine tool according to the principle of material placement, then according to the principle of proximity, place the material in the middle column of the first or fourth layer of the adjacent shelf with no materials on the left and right sides.

[0016] The advantages of the present invention compared with the prior art are: (1) The present invention realizes that the entire system can be split into several subsystems or microservices according to the business, and there is load balancing between the subsystems. Taking traffic as the entry point, the stability of microservices is guaranteed from multiple dimensions such as current limiting, traffic shaping, fuse degradation, system load protection, and hotspot protection; (2) The present invention classifies the shelves in the cache (dividing them into four specifications: ordinary materials, extra-high materials, extra-wide materials, and extra-high and extra-wide materials), processes them by logical operations and algorithms, and combines them with placement restriction rules to achieve the effect of storing materials of different specifications in the cache; (3) The present invention is integrated with a tool setting instrument and a machine tool to obtain tool monitoring data from the tool setting instrument to synchronize the tool list data, and then sends the tool list information to the machine tool, thereby achieving real-time transmission and synchronization of tool information, ensuring that the tool information in the tool setting instrument, the tool management subsystem and the machine tool remains consistent; (4) The present invention locates different coordinate points through a set of process folders plus vise positions. The Java built-in tool class parses the CNC program, fills in dynamic value data according to different vise positions stored in the database, and converts the CNC program into a file stream through the OPC UA protocol and transmits it to the machine tool, thereby achieving the effect of tracking the material processing process and quality one by one, as well as information traceability. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Various other advantages and benefits will become apparent to those of ordinary skill in the art by reading the detailed description of the preferred embodiments below. The accompanying drawings are only for the purpose of illustrating the preferred embodiments and are not to be considered as limiting the present invention. Moreover, the same reference symbols are used throughout the accompanying drawings to represent the same components. In the accompanying drawings: Figure 1 It is a schematic diagram of the principle of the present invention; Figure 2 Schematic diagram of the microservice architecture of the present invention. DETAILED DESCRIPTION

[0018] In order to better understand the above technical scheme, the technical scheme of the present invention is described in detail below through the accompanying drawings and specific embodiments. It should be understood that the embodiments of the present invention and the specific features in the embodiments are detailed descriptions of the technical scheme of the present invention, rather than limitations on the technical scheme of the present invention. In the absence of conflict, the embodiments of the present invention and the technical features in the embodiments can be combined with each other.

[0019] The following is a further detailed description of an information-based, automated data-driven flexible production control system provided by an embodiment of the present invention in conjunction with the accompanying drawings. The specific implementation method may include: The flexible production control system is the brain of the entire production line and production unit. It needs to be integrated with the upstream and downstream MES systems, IOT systems, integrated databases, and data domain exchange approval systems to obtain production task information from the upstream MES system. It also has functions such as production preparation management, scheduling management, CNC program management, material in and out of the warehouse management, tool management, equipment management, hardware equipment data collection and display, and overall dashboard. The flexible production control system adopts a microservice architecture with front-end and back-end separation, splitting product functions into several microservices for load balancing.

[0020] The technical solution of the present invention is: to achieve the above purpose, an information-based, automated data-driven flexible production control system is invented, such as Figure 1 , including the following steps: 1) Platform construction ① Overall architecture The system is based on Spring Boot, Spring Cloud & Alibaba, Vue, and Element's front-end and back-end separated microservices for rapid back-end development.

[0021] ② If Figure 2 , the entire system is divided into several subsystems or microservices according to the business. Each subsystem can deploy multiple applications, and load balancing is used between multiple applications. Combined with the service registration center Nacos, all services are registered in the registration center, and load balancing is also achieved by using certain strategies through the services registered in the registration center. Use the circuit breaker hystrix to handle timeouts and errors during service calls in a timely manner to prevent the paralysis of the entire system due to problems with one of the services. By using Sentinel's flow control component for distributed service architecture, it takes traffic as the entry point to help developers ensure the stability of microservices from multiple dimensions such as current limiting, traffic shaping, circuit breaking and degradation, system load protection, and hotspot protection.

[0022] Advantages of the architecture: Perform master-slave and cluster deployment at key nodes to prevent single point failures.

[0023] ③ Realize service calls within the system by using AIP gateway calls, synchronous calls, asynchronous calls, and authority verification between services.

[0024] 2) Production planning management ①Integrate with the MES system, integrated interface database and data domain exchange approval system to obtain production plans, production work orders and process information from upstream systems.

[0025] ② Create a process step plan based on the production plan and work order information, and follow the principle that one process (step) corresponds to one set of procedures, one set of tools, one clamping, and one set of materials.

[0026] ③ The flexible production control system can create corresponding process and step plans based on existing production plans and production work orders, and bind corresponding materials, CNC programs, tools, and clamping step diagrams, etc.

[0027] 3) Production preparation According to the process step information and technological information, the preparation status of materials, tools, pallets, equipment, CNC programs, etc. is automatically checked and status identification is given.

[0028] ① The flexible production control system is integrated with the IOT system. After the process approval is completed in the IOT system, the CNC program is sent to the control system.

[0029] ② The flexible production control system is integrated with the in-line cache library to view the material list information on the production preparation page, including the material completeness (complete, partially complete, incomplete), required quantity, complete quantity, how much has been prepared in the library, the number of missing materials, product name, process number, material code, specification, version and other information.

[0030] ③ The flexible production control system is integrated with the machine tool tool library to view the completeness of tools and other resources on the production preparation page, including tool completeness, tool number, tool name, diameter, length, type, required quantity, complete quantity, shortage quantity, etc.

[0031] ④ Manually determine whether materials, tools, equipment, and procedures are ready and in production status before scheduling. When scheduling, specify which type of equipment to use for production. The management and control system issues programs based on the equipment specified in the schedule (whoever calls for materials first gets them first).

[0032] ⑤ When the scheduling task is about to be executed, the flexible production control system will once again confirm whether the materials, tools, and equipment are ready for production, and the control system will send the CNC program to the machine tool that can produce this type of product.

[0033] ⑥ Before sending the NC program, the system automatically checks the number of dynamic values ​​of the vise in each pallet, and how many dynamic values ​​are bound to the pallet, and how many "#{}" are corresponding to the NC program, and compares them impromptu. If the number is consistent, the NC program is sent to the machine tool.

[0034] ⑦ Timing of sending the program to the machine tool: When the process task scheduling is completed, the program of the task with the highest priority and the closest planned completion time will be sent to the corresponding machine tool, and it also has the manual sending function.

[0035] 4) Schedule management The system obtains the complete set status information of the required materials through the shelf information unit, obtains the tool preparation status through the tool management module, and obtains whether the equipment is under maintenance through the equipment management module. Combined with the process plan information, it checks whether the various materials, CNC programs, machine tools, tools and pallets required for production execution are in production readiness.

[0036] ① On the premise that production preparations are complete, the system automatically schedules the processes and steps according to their priority order and planned completion time, forming a visual interface.

[0037] ② Distribute the process plan to the corresponding equipment that can produce the product according to the product category.

[0038] ③ Machine tools of the same type can all receive product CNC programs issued by the flexible production control system.

[0039] ④In addition, you can also manually adjust the production time of the process task, the start and end time of the process task, and insert orders.

[0040] ⑤ Operators can edit and modify the priority of the schedule plan in the schedule management module, and adjust the corresponding production priority according to the urgency of production. The system has built-in logical rules for scheduling priority modification, such as: production tasks that are already in production execution cannot have their priorities adjusted.

[0041] ⑥ The "suspend" function of the production task of the flexible production control system fully meets the "flexibility" capability. During the production preparation process, when the materials are partially complete, the system allows the task to enter the scheduling queue. Even if the materials are not completely complete, processing and production can be started. Later, when the materials of the product are about to be out of stock, the system will automatically determine the shortage of materials and automatically remind the operator to replenish the materials before stopping processing and production. If the operator does not replenish the materials in time, the production task will enter the "suspend" state when the materials are out of stock. Once the operator completes the replenishment, the system will automatically adjust and give priority to continuing the production of the currently suspended tasks. It reflects the characteristics of flexibility and does not affect the overall production operation efficiency.

[0042] ⑦ The flexible production control system supports the "priority scheduling" function. When there are very urgent production tasks in the production process, the operator can perform one-click priority scheduling, "one-click top" urgent production tasks, and give priority to production.

[0043] ⑧The flexible production control system also supports the "termination scheduling" function. In some special cases, if there is no need to continue processing a certain production task, the operator can terminate the production of the task with one click.

[0044] ⑨The flexible production control system supports the creation of new emergency orders. You can select a production task in the schedule management list (production tasks that have entered the schedule) to create an emergency order, and support the free allocation of the production quantity of the emergency order. Emergency orders have the highest priority and are not limited by priority restrictions. As long as there are emergency orders, the tasks of emergency orders will be produced first.

[0045] ⑩The flexible production control system has a visual scheduling Gantt chart. By setting the future production time, different analysis dimensions (product dimension or equipment dimension), selected equipment or production tasks, the future production trend is predicted according to the future production time (x hours), and the production schedule Gantt chart and list for the next x hours are generated. Automatic scheduling can be automatically adjusted according to the equipment type, completion time and quantity of the production task, etc.

[0046] 5) NC program management Through OPC UA communication, the flexible production control system interacts with the CNC machine tool to collect machine tool data information, CNC program information, and tool information from the Siemens system, and automatically send the CNC program to the machine tool.

[0047] ①Integrate with the IOT system and obtain the program files in the IOT system.

[0048] ② In the flexible production control system, process personnel can "package" the acquired or imported CNC programs. Based on the principle of one machine tool, one product, and one set of programs, after creating a folder, they can bundle the main program and multiple sub-programs and put them into a folder to form a set of CNC programs.

[0049] ③Program transmission and push function: the system automatically calls the corresponding processing program and pushes the program directly to the specified machine tool, without the need to manually drag the CNC program from the shared folder to the machine tool folder on the machine tool.

[0050] ④After the CNC program is transmitted to the machine tool, the machine tool automatically starts running the CNC program.

[0051] ⑤ When the equipment fails due to an unexpected malfunction, the system also has the function of resuming program breakpoints.

[0052] ⑥ Delete machine tool files through FTP communication and delete unnecessary test programs through the Recycle Bin.

[0053] ⑦ Machine tool file management: transmit file streams through OPC UA, obtain parsed files, and display the CNC programs stored in each folder of the machine tool on the system page, so that operators can check the machine tool program version and other information in time.

[0054] ⑧Each program folder corresponds to multiple clamping materials (vice positions), and each vise position corresponds to multiple dynamic value data. The operator can arbitrarily bind the vise position to the existing empty space on the pallet; and set the dynamic value of the same vise position on different pallets. The NC program sets a fixed variable (#{}). When the NC program is executed, the flexible production control system automatically assigns the dynamic value on the pallet to the fixed variable (#{}) in the NC program. One pallet is bound to multiple materials and can execute multiple NC programs.

[0055] 6) Information integration based on shelves, loading stations, and caches The flexible production control system integrates with loading stations, buffer warehouses, robots, and machine tools to achieve full-process management and monitoring of the production line. The loading station is the starting point for materials to enter the line. Operators and robots use the loading station to load and unload materials and pick and place materials. The buffer warehouse is located next to the machine tool and is used to temporarily store the blanks to be processed by the machine tool and the finished parts that have been processed. The control system drives the robot to pick up and place the pallet in the designated buffer warehouse according to the processing tasks of different parts.

[0056] RFID When binding materials on pallets, RFID radio frequency identification technology is used to achieve contactless identification, improve efficiency, and increase the accuracy of verification. An RFID radio frequency card is fixed on the pallet as the pallet ID, and an RFID reader is set at the entrance and exit of the loading station. When the part pallet is in and out of the warehouse, the label information is read by the card reader, and the binding and unbinding operations of the pallet and part information can be completed with the help of the operating terminal system. An RFID card reader is installed at the end of the robot, and the robot verifies the pallet part information when picking up and placing the pallet, and the auxiliary warehouse information management module completes the management of the part processing completion status information.

[0057] Loading station integration ① The operator places the blanks that need to be processed on the loading station operation end, operates through the warehousing management page of the flexible production control system, performs RFID identification and binds the pallet with a unique identifier.

[0058] ②After clamping is completed, the pallet and materials are sent to the robot end through the loading button.

[0059] ③ Use the barcode scanner to automatically fill in and send back data such as material coding and production plan number. After selecting the pallet type, scan and read the RFID to complete the pallet binding, ensuring the uniqueness of the pallet and logistics, and preventing problems such as wrong materials from being loaded.

[0060] ④The flexible production control system collects information such as the status of the loading station, pallet binding information, material information, and loading port, and issues instructions to the robot.

[0061] ⑤After receiving the command, the robot moves to the loading port at the robot end of the loading station to grab the material.

[0062] ⑥At the same time, the management and control system automatically allocates the storage location of materials in the cache and sends them to the robot through algorithms and specified principles.

[0063] ⑦ The robot receives the cache location information and places the material in the designated location of the cache.

[0064] ⑧ For processed materials, the management and control system sends the location information of the finished materials in the cache to the robot, and the robot grabs the corresponding materials.

[0065] ⑨The control system continues to send the loading port location information to the robot. The robot places the pallet and materials at the loading port. The operator moves the pallet and materials to the loading port position by pressing buttons to complete the material delivery.

[0066] Cache library management System cache library management module. The cache library is used to temporarily store the blanks to be processed by the machine tool and the finished parts that have been processed. The control system drives the robot to pick up and put the pallet into the designated cache location according to the processing tasks of different parts. There are 4 in-line cache libraries with a total of 144 locations.

[0067] Operators can intuitively see the display diagram of 144 storage locations, and the status information of each cache location is also clearly displayed (empty location, empty pallet, blank, semi-finished product, finished product, abnormal part, in progress).

[0068] In and out warehouse management: Through the intuitive display of the cache location map of 144 warehouse locations, operators can choose to enter and exit a single product, or to centrally dispatch goods and dispatch goods by product type. The system also realizes the centralized in and out warehouse function. This simplifies the operation steps of operators and greatly improves the efficiency of in and out warehouse.

[0069] Material storage algorithm: The flexible production control system supports the storage of common materials, extra-high materials, extra-wide materials, and extra-high and extra-wide materials in the buffer warehouse. It locates the coordinates of the machine tool that is closest to the current production and processing and can store materials. According to the storage rules of materials in the buffer warehouse: ① Ordinary materials can be stored in any storage location; ②Super-high materials can be stored anywhere on the first and fourth layers of the buffer warehouse shelves; ③ There should be no materials on the left and right sides of the extra-wide materials for material placement; ④ Extra-high and extra-wide materials can only be stored in the middle position between the first and fourth layers of the buffer warehouse, and no other materials can be placed on the left and right sides.

[0070] Optimal path algorithm: For products with short processing time and high frequency, in order to make the processing more efficient, the location algorithm rules are considered according to the process, processing equipment, storage quantity, material specifications, etc. when entering the warehouse.

[0071] ① When entering the warehouse, if it is ordinary material, you only need to determine the location of the machine tool and place the ordinary material in any empty space in the cache closest to the machine tool; ② If it is an ultra-high material, determine the position of the machine tool and place the ultra-high material in any empty space on the first and fourth layers of the buffer shelf closest to the machine tool. If there is no empty space on the first and fourth layers of the buffer shelf closest to the machine tool, place the ultra-high material in any empty space on the first and fourth layers of the adjacent buffers on both sides; ③ If the material is extra-wide, determine the location of the machine tool and place the extra-wide material in the buffer closest to the machine tool. When placing the material, determine whether there are materials on the adjacent sides. If there are no adjacent materials, place the extra-wide material in the empty space in the middle column. If there are no empty spaces in the buffer closest to the machine tool, place the material in the middle column of the adjacent shelves according to the principle of proximity, and leave no materials on the left and right sides. ④ If the material is super-high or super-wide, determine the position of the machine tool and place the super-high or super-wide material on the first or fourth layer of the buffer closest to the machine tool. When placing it, determine whether there are materials on the adjacent sides. If there are no adjacent materials, place the super-high or super-wide material in the empty space in the middle column of the first or fourth layer of the shelf; if there is no empty space in the buffer closest to the machine tool according to the principle of material placement, then according to the principle of proximity, place the material in the middle column of the first or fourth layer of the adjacent shelf with no materials on the left and right sides.

[0072] Material taking algorithm: When picking materials, the best choice is the storage location closest to the machine tool, and the material is placed in accordance with the characteristics of the material (normal / extra high / extra wide / extra high and extra wide). If there is no vacant storage location at the optimal distance, extend to the adjacent left and right shelves.

[0073] Design even distribution: The purpose of even distribution is to ensure that there is a reserved space for materials of all specifications. According to the scheduling plan, filtering and screening, if there are only extra-high / extra-wide / extra-high and extra-wide material plans, there is no need to consider the storage of ordinary materials. If there are only ordinary / extra-high / extra-wide materials, there is no need to consider the storage of extra-high and extra-wide materials. Only when there is a material specification different from the previous one and it is in the unexecuted or executed state, the algorithm will cover the even distribution rules for the material.

[0074] Materials Management By obtaining material information from the upstream MES system, including material code, delivery order number, material type, quantity and other information, edit and add material specification information to confirm whether the material is large or small. At the same time, based on the delivery order number and other information, the refill function is realized. The operator does not need to re-fill in the material information for refilling. If the material is from the same batch and has the same material code, the operator can directly click the refill button to complete the refilling.

[0075] Stock location record query The management and control system displays detailed information for each storage location in the cache, including storage location status (empty location, empty pallet, blank, semi-finished product, finished product, abnormal part, in progress), material name, material in-stock time, and other information.

[0076] 7) Tool management Tool Management Module It has the function of viewing tool inventory information. Currently, the equipment can obtain the tool library list. The management and control system directly obtains the tool list in the equipment. The tool list entry information includes: location (which position on which machine tool), tool name, tool number, tool category, tool life, number of workpieces, target value, warning value, tool specification, whether there is tool compensation, etc. It realizes the display of tool lists in tool libraries of all equipment, and at the same time, it provides information such as tool number, tool name, tool model, tool manufacturer, quantity, and whether it is intact. Tool administrators can fill in and maintain tool information on the tool management page.

[0077] At the same time, the flexible production control system is integrated with the tool setting instrument. After the tool setting instrument detects the tool, the system automatically obtains the tool detection list in the tool setting instrument, synchronizes it with the tool list of the machine tool, and displays the tool information in the flexible production control system.

[0078] Tool life management Display tool life information. The system can calculate the tool usage time based on the execution time of the CNC program or the number of pieces processed by the tool. The management and control system is responsible for collecting, displaying, and prompting tool change. Users can set tool life and configure the target value of tool use (for example, when the tool life reaches 80%, prompt tool change).

[0079] At the same time, the control system has the function of tool information statistics. For example, if there are 120 knives in a unit, how many Φ10 knives are there and which tool position on which machine tool? How many Φ12 knives are there and which position on which machine tool? For different knives, the monthly consumption is statistically analyzed, that is, the frequency of use and replacement, which is used to guide the subsequent stocking of tools.

[0080] 8) Equipment Management Equipment ledger management When the device is connected, it supports the device basic information management and matching function, and manages the basic information of each device, mainly including the basic information of the device itself and the management information of the device after entering the factory, and has the functions of adding, deleting, updating and viewing the history of the device ledger.

[0081] Equipment inspection function In order to ensure the normal operation of the equipment, daily inspections should be carried out to check whether all protective plates, covers and doors are operating properly, step each axis throughout the entire stroke to observe whether the operation is smooth, ensure that the limit switches of all axes are working properly and adjusted to the corresponding limit positions, check whether the guide rails have signs of scratches or excessive wear, check whether the guide rail cleaners are damaged, and touch the guide rails to check whether the lubrication is appropriate. The equipment inspection function includes the maintenance of basic information of equipment inspection items; check the inspection items on the client to generate an equipment inspection record sheet, which is automatically recorded and stored in the system; retrieve the inspection items according to the inspection items configured for the equipment.

[0082] Equipment regular maintenance function During the operation of a unit or production line, employees must cooperate with maintenance workers in inspections and repairs, keep equipment accessories and tools safe, properly lubricate equipment before the shift, pay attention to operating conditions during the shift, and clean and wipe equipment after the shift. The regular equipment maintenance function in the system includes the import and addition of equipment maintenance plans; regularly reminding relevant responsible persons to maintain the equipment according to the equipment maintenance plan; and storing equipment maintenance information as equipment history.

[0083] Equipment maintenance function The equipment maintenance function is to repair equipment failures and restore their functions. The main purpose is to standardize the maintenance process, record the maintenance content, establish equipment maintenance history, and realize the full life cycle management of the equipment. The equipment maintenance function includes equipment failure alarm; online call for equipment failure, passing the abnormality to the equipment management personnel; displaying the name of the maintenance personnel and information such as equipment status and maintenance time, etc.

[0084] Device type management The flexible production control system realizes functions such as adding new equipment types and editing equipment types. It can classify the equipment in the equipment list, and bind the equipment of this type to the production and processing, and issue the CNC program at the same time when creating the process step plan.

[0085] According to the newly created or existing type, check the devices of this type by ticking them. After saving, you can edit and delete this type.

[0086] 9) Equipment data collection and control The flexible production control system collects data from various equipment in the entire production unit, including machine tool data, loading station data, cache library data, robot data, ground rail data, camera monitoring data, etc., and performs statistics, analysis and display respectively.

[0087] CNC machine tool data collection content The information collected from CNC machine tools includes the real-time operation status of the equipment, such as power on / off signals, alarm information, spindle load, spindle speed s value, feed speed F value, feed rate, spindle rate, program operation status information, beat information, current program information, tool information, equipment processing times, processing operation time information, and coordinate values. Calculate the equipment opening probability, equipment utilization rate, equipment operation efficiency, etc.

[0088] Robot data collection content The collected information includes power on / off signals, current operating status (including end effector status), operating speed, spatial posture, alarm information, etc.

[0089] Collection method and performance The status and process data of the workshop CNC equipment and robots are collected through "real-time collection". The data collection time interval is not less than 1 second / time, the data transmission bandwidth is greater than 50Mbps / s, and the number of data collection points for a single device is not less than 100.

[0090] 10) Overall dashboard The main dashboard of production line control is divided into four parts, mainly the overall status dashboard of the production line, the equipment status dashboard of the production line, the production plan monitoring dashboard and the production line scheduling dashboard.

[0091] The first part is the overall status dashboard of the production line, which mainly displays the full-screen electronic map of the CNC milling automation unit. Below it are the operating status of the seven devices (green: running, yellow: idle, gray: shutdown, red: alarm) and the products produced by each device (marking the unique product identification). On the left side of the full-screen electronic map, the names of the seven devices, machine tool types, products being processed, products to be processed later, programs being processed, tools used, planned production, and production during the shift are displayed in a scrolling (page flipping) manner. Each device is equipped with an alarm emergency stop button. Placing the mouse above each device displays the basic information of the device and relevant data of the master control (PLC), including: the connection status between the master control and the management and control system, the connection status between the master control and the robot, the connection status between the master control and the ground rail, the master control alarm, the machine tool alarm, the robot alarm, the ground rail fault alarm, the safety door alarm, and the end fixture alarm.

[0092] The second part is the key plan monitoring dashboard, which mainly displays the completion status and production preparation status of key products of the production line. The total planned quantity, completed planned quantity, executing planned quantity, and unfinished planned quantity are displayed on the top. The completion status and production preparation status of the production line plan of key products are displayed in a scrolling manner, including product name, drawing number, model, plan number, work order number, process number, process name, planned completion time, production progress, tool set status, CNC program preparation status, and material set status. Click the production scheduling button in the upper right corner of the page to jump to the automatic scheduling and shift scheduling interface.

[0093] The third, fourth, fifth and sixth parts are production line status dashboards.

[0094] The third part shows the overall production completion rate of the production line, the planned number of products completed, the number of products completed, the cumulative number of models completed, the on-time completion rate and the actual completion rate.

[0095] The fourth part shows the overall analysis of equipment operation, unit equipment utilization, equipment operating status, real-time statistics of powered-on equipment, currently operating equipment, average operating efficiency, etc.

[0096] The fifth part shows the current inventory status, products that can be taken off the shelves, and products to be processed based on the shelf information integration unit.

[0097] The sixth part shows the Gantt chart of process planning and production scheduling.

[0098] The seventh part is the video monitoring board of the production line Integrated with the video surveillance system, it displays the overall monitoring picture of the current production line. By setting up a global video camera, it is possible to observe whether the loading station, in-line buffer, robot and ground rail system are working properly.

[0099] 11) Integration with robots The control system sends the production task information, the position of the material at the loading port, the position of the material in the buffer, the material tray RFID and other data to the robot, and the robot feeds back the material call, the machine door opening and closing status, whether to pick up materials and other data to the control system. It includes IP, signal name (online, no abnormal status, no task, task in progress, material picking / releasing completed, whether the gripper has material), data address, signal status (Y / N), the position of the material in the loading station and buffer (position number), etc.

[0100] The flexible production control system is designed to adapt to the millisecond-level communication of robots. In order to solve the problems of network delay caused by the long distance between the server and the production line, abnormal material collection, material loading errors, inaccurate machine tool position, and inability to terminate the machine tool loading program normally, the software program is innovated and broken through.

[0101] Multithreaded sending and receiving instructions Use multi-threaded processing to optimize thread time, and check communication messages for each process to verify whether the position of the machine tool corresponds to the position, so as to implement the position return mechanism. Nest threads again in threads, add timer function, and ensure the timeliness of communication.

[0102] Double check function The flexible production control system adds the function of sending the machine number back to the robot PLC end and the robot verifies the machine number. The robot verifies whether the machine number corresponds correctly. If not, the flexible production control system records the robot's return information and leaves a log record.

[0103] Optimize signal sending timing Because the machine tool does not respond to external signals when closing the door, the flexible production control system and the robot end change the timing of sending the termination signal and send the termination signal after the retraction is completed.

[0104] Error reset mechanism If the required information is not fed back within a period of time, it will enter a timeout state and the system will push the task reset information.

[0105] "Lock" mechanism Once the system program enters a certain behavior process (warehousing, loading, retrieving, and outbound), if the feedback indicates that there is currently an executable task, other machine tool signals will be put on hold to ensure the timeliness of the current data flow and message reception and transmission.

[0106] Weighting mechanism When the system executes production tasks on the production unit, the priority of loading and retrieving tasks is higher than that of outbound and inbound tasks. When the four major process signals (inbound, loading, retrieving, outbound) are available at the same time, the system starts polling signals from the loading and unloading tasks to see if there are any executable tasks.

[0107] In the solution provided by the embodiment of the present invention, under the intelligent auxiliary wiring system and method for aerospace complex cable network products of the present invention, the wiring steps of aerospace complex cable network products are as follows: It includes display and user login interface, wiring path display area, preview area, function menu, quick operation area, data display and management area, etc. The main design goal is to highlight the main functional areas to facilitate quick application during use.

[0108] (1) Obtain production plans, production work orders and process information issued by the upstream MES system and data exchange and approval system. Create process step plans based on production task data and bind material information, CNC programs and tool information.

[0109] (2) Obtain the pallet RFID, bind it and put it into storage. According to the production plan number, work order number, process number and other data in the system, automatically select the corresponding bound materials and make pallet judgments. Determine the type of pallet (normal, extra-high, extra-wide, extra-high and extra-wide) and perform storage operations.

[0110] (3) After completing the binding action, the operator pushes the pallet material to the robot end with one click. The robot grabs the material from the loading port of the loading station and places the pallet material at the appropriate location in the cache according to the instruction information sent by the flexible production control system, completing the warehousing action.

[0111] (4) After all the conditions required for the production task are met, the production task is placed in the scheduling management queue, and the production task is automatically scheduled and the CNC program is automatically issued.

[0112] (5) After the machine tool that meets the production conditions receives the CNC program issued by the flexible production control system, it starts to automatically execute the CNC program and calls the robot to load the material. At this time, the flexible production control system sends the location information of the required material in the cache and the machine tool number to the robot, and the robot performs the loading action.

[0113] (6) After the material processing is completed, the machine tool calls for material picking. The flexible production control system sends the material picking machine tool number to the robot for verification, and the flexible production control system sends the robot the placement location of the finished product or semi-finished product in the buffer warehouse. The robot puts the corresponding material into the buffer warehouse according to the instructions of the flexible production control system to complete the material picking action.

[0114] (7) The operator selects the materials to be shipped out in the flexible production control system (they can be selected in batches or by product type). The flexible production control system sends a shipping instruction to the robot, including the information of the pallet and materials to be shipped out, the storage location of the buffer warehouse, the location information of the loading port, etc. The robot receives the instruction from the flexible production control system and executes the shipping task. After placing the materials at the corresponding loading port, the operator pushes the pallet material to the manual end with one click and completes the shipping action.

[0115] Obviously, those skilled in the art can make various changes and modifications to the present invention without departing from the spirit and scope of the present invention. Thus, if these modifications and variations of the present invention fall within the scope of the claims of the present invention and their equivalents, the present invention is also intended to include these modifications and variations.

[0116] The contents not described in detail in the specification of the present invention belong to the common knowledge of those skilled in the art.

Claims

1. An information-based, automated data-driven flexible production control system, characterized in that: include: The production planning management subsystem obtains the production plan, production work order and process information from the upstream workshop intelligent execution control platform MES system, screens specific processes, generates process step plans, and sends them to the production preparation subsystem and scheduling management subsystem; The production preparation subsystem checks the preparation status of production materials and tools according to the process step plan and corresponding process information sent by the production planning management subsystem through the shelf information unit, CNC program management subsystem, tool management subsystem, and equipment management subsystem, and gives status identification. When all preparations are completed, it sends a ready instruction to the scheduling management subsystem; The scheduling management subsystem performs scheduling according to the ready-to-go instruction; the scheduling includes: combining the process step plan, checking whether the production materials and tools required for production execution are in the production ready state through the shelf information unit, the CNC program management subsystem, the tool management subsystem, and the equipment management subsystem, and when the production is ready, scheduling is performed in accordance with the priority order and the planned completion time of the process step plan, and the process plan is distributed to the corresponding equipment that can produce the product according to the product category; The NC program management subsystem is integrated with the external equipment data acquisition and monitoring IOT system to obtain NC program files, collect NC machine tool data information, NC program information, tool information, and issue the program files to the NC machine tool; it supports manual creation of program folders and uploading of NC program files and direct acquisition of program files in the machine tool; The shelf information unit includes a loading station, a robot, and a buffer. The loading station is the starting point of the material entry line. Operators or robots use the loading station to load and unload materials and to pick and place materials. The buffer is located next to the CNC machine tool and is used to temporarily store the blanks to be processed by the machine tool and the finished parts that have been processed. The machine tool and loading station information is collected through OPC UA to obtain material information, material completeness status, machine tool status, and machine tool execution CNC program and status information, and these statuses are confirmed and verified in the production preparation subsystem. When the completeness status is confirmed, the production task, material, CNC program, tool and equipment information are sent to the scheduling management subsystem. The tool management subsystem is used to store tool information lists for query and maintenance; obtain tool list information, tool numbers, and tool types in the machine tool through OPC UA and display them in the tool management subsystem; support operators to create new tools and synchronize tools to the machine tool; integrate with the tool setting instrument to obtain tool detection data and synchronize it to the tool list in the tool management subsystem; The equipment management subsystem is used to store the information list of all processing equipment and provide query and maintenance for operators; it is integrated with the production planning management subsystem and the scheduling management subsystem to send the equipment type to the scheduling management subsystem for the production tasks and CNC programs to be issued after scheduling; The equipment data collection subsystem is used to collect the status data and operation data of each production equipment in real time and send it to the kanban subsystem for display; The kanban subsystem is integrated with the production planning management subsystem, the equipment data acquisition subsystem, the shelf information unit and the scheduling management subsystem. It is used to display the production task information in the production planning management subsystem, the equipment status and equipment information in the equipment data acquisition subsystem, the material information and status of the shelf information unit, and the current scheduling tasks and processing program information in the scheduling management subsystem, and to show the overall status of the production line, production plan monitoring and production line video to the operators.

2. According to claim 1, an information-based, automated data-driven flexible production control system is characterized in that: The production plan management subsystem stores historical production plans and production work orders, and creates corresponding process step plans based on existing production plans and production work orders, and binds corresponding materials, CNC programs, tools and clamping step diagrams.

3. According to claim 1, an information-based, automated data-driven flexible production control system is characterized in that: According to the urgency of production, operators edit and modify the priority of the scheduling plan in the scheduling management subsystem according to the preset logical rules for scheduling priority modification, and adjust the corresponding production priority.

4. According to claim 1, an information-based, automated data-driven flexible production control system is characterized in that: During the production preparation process, when some materials are complete, the scheduling management subsystem allows the task to enter the scheduling queue and start processing and production. Subsequently, when the material of the product is out of material and before the processing and production is stopped, the operator is reminded to replenish the material. If the operator fails to replenish the material in time, the production task will enter a suspended state when the material is out of material. If and only if the operator completes the replenishment, the currently suspended task will be continued with priority. The scheduling management subsystem manually adjusts the production order or terminates the production task according to the priority of the production task.

5. The information-based, automated data-driven flexible production control system according to claim 1, characterized in that: Each subsystem is implemented using microservices.

6. The information-based, automated data-driven flexible production control system according to claim 1, characterized in that: The NC program management subsystem packages the acquired or imported NC programs, creates folders based on the principle of one machine tool, one product, and one set of programs, bundles the main program and multiple subprograms and puts them into one folder to form a set of NC programs, and pushes the NC programs to the designated NC machine tool.

7. The information-based, automated data-driven flexible production control system according to claim 1, characterized in that: A card reader is set at the entrance and exit of the loading station. When the pallet loaded with parts enters and leaves the warehouse, the label information is read by the card reader to complete the binding and unbinding operations of the pallet and the part information; a card reader is installed at the end of the robot. When the robot picks up and places the pallet, the pallet part information is checked to complete the management of the part processing completion status information.

8. The information-based, automated data-driven flexible production control system according to claim 7, characterized in that: The loading station includes an operating end and a robot end; the operating end is used to place the blanks that need to be processed online, identify them, and bind the pallet through a unique identifier; after clamping is completed, the pallet and the material are sent to the robot end; the loading station sends status information, pallet binding information, material information and loading port information, and issues instructions to the robot; after receiving the instructions, the robot moves to the loading port on the robot end to grab the material; at the same time, the storage location of the material in the cache is allocated and sent to the robot; the robot receives the cache location information and places the material at the designated location of the cache; for the processed materials, the shelf information unit sends the location information of the finished material in the cache to the robot, and the robot grabs the corresponding material; the shelf information unit sends the loading station port location information to the robot, the robot places the pallet and the material at the loading station port, and the operator moves the pallet and the material to the loading port position to complete the material out of the warehouse.

9. The information-based, automated data-driven flexible production control system according to claim 1, characterized in that: The cache is equipped with four shelves, which are used to store materials of different sizes; the materials include ordinary materials, extra-high materials, extra-wide materials, and extra-high and extra-wide materials; Ordinary materials can be stored in any storage location; Super-high materials can be stored anywhere between the first and fourth layers of the buffer warehouse shelves; There should be no material on the left or right sides of the extra-wide material to place the material; Extra-high and extra-wide materials should be stored between the first and fourth layers of the buffer warehouse, and no other materials should be placed on the left and right sides.

10. The information-based, automated data-driven flexible production control system according to claim 9, characterized in that: When the materials are put into storage, the algorithm rules for the location are considered according to the process, processing equipment, storage quantity, and material specifications, including: When entering the warehouse, if the material is ordinary and not super-high or super-wide, you only need to determine the location of the machine tool and place the ordinary material in any empty space in the buffer closest to the machine tool; If it is an oversized material, determine the position of the machine tool and place the oversized material in any empty space on the first and fourth layers of the buffer shelf closest to the machine tool. If there is no empty space on the first and fourth layers of the buffer shelf closest to the machine tool, place the oversized material in any empty space on the first and fourth layers of the adjacent buffer shelves on both sides. If the material is extra-wide, the position of the machine tool is determined, and the extra-wide material is placed in the buffer closest to the machine tool. When placing the material, determine whether there are materials on the adjacent sides. If there are no adjacent materials, the extra-wide material is placed in the empty space in the middle column; if there are no empty spaces in the buffer closest to the machine tool, the material is placed in the middle column of the adjacent shelves according to the principle of proximity, and there are no materials on both sides; If the material is super-high or super-wide, determine the position of the machine tool and place the super-high or super-wide material on the first or fourth layer of the buffer closest to the machine tool. When placing the material, determine whether there are materials on the adjacent sides. If there are no adjacent materials, place the super-high or super-wide material in the empty space in the middle column of the first or fourth layer of the shelf. If there are no empty spaces in the buffer closest to the machine tool according to the principle of material placement, then according to the principle of proximity, place the material in the middle column of the first or fourth layer of the adjacent shelf with no materials on both sides.

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