Intelligent assembly and error-proofing method for transmission rocker arm angle

Abstract

The invention relates to an assembling method of transmission parts, in particular to an intelligent assembling and mistake-proofing method for a transmission rocker arm angle, and aims to solve the problems that the operation burden is large, the assembling efficiency is low, and effective mistake-proofing measures are lacked due to the fact that no uniform angle guiding tool exists in the assembling of the existing transmission rocker arm angle. And an existing engine production management system integrated with the MES and the TCM is low in automation degree, weak in real-time performance and poor in flexibility. According to the intelligent assembly and error-proofing method for the transmission rocker arm angle, a transmission rocker arm database in a TCM is established, the corresponding relation of production stations, structural data items and structural data values is systematically managed, and the process of process development and data transmission is optimized.

Description

Technical Field

[0001] The invention relates to an assembly method of a transmission component, and in particular to an intelligent assembly and error-proofing method for a transmission rocker arm angle. Background Art

[0002] At present, in the production and assembly process of heavy truck transmissions, customers have an increasing demand for personalized products, especially in the angle adjustment of the transmission rocker arm. The transmission rocker arm needs to be assembled at a personalized angle according to the transmission assembly agreement of different customers, which leads to multiple problems in the assembly process.

[0003] First, there are many types of transmission assembly protocols, which means that assemblers need to frequently adjust the rocker arm angle according to different customer requirements during operation. Since there is no unified angle guidance tool, assemblers can only rely on manually reading the angle information in the customer's requirement file and then manually adjusting the installation angle of the rocker arm, which not only increases the operating burden of assemblers, but also leads to low assembly efficiency.

[0004] Secondly, the process of manually reading and adjusting the angle information is prone to errors. Since the entire operation process is completely dependent on the manual operation and judgment of the assembly workers, the accuracy of the angle adjustment cannot be effectively guaranteed and errors are prone to occur. In addition, there is a lack of effective error-proofing measures in the subsequent processes, and the accuracy of all assembly steps cannot be ensured, which may result in the final performance of the product not meeting the standards or meeting customer requirements.

[0005] Chinese patent CN117114617A discloses an engine production management system that integrates MES (Manufacturing Execution System) and TCM (Technology Configuration Management). It integrates and synchronizes the process files generated by TCM with the work instruction files issued by MES through SOA (Service-Oriented Architecture) technology, ensuring that each process in production can be operated according to the latest and synchronized process files, solving the information inconsistency and island problems caused by the traditional independent use of these two systems. However, it still has the following shortcomings: Although information synchronization and process file management are integrated between MES and TCM, the system still relies on operators to manually review work instructions, perform assembly tasks, and make adjustments through process changes and error reporting mechanisms. This means that the system has a low degree of automation and still requires a lot of manual operation, resulting in low assembly efficiency. In addition, the system's response speed depends on the workers' operational feedback, and its real-time performance is poor, making it impossible to make real-time adjustments or feedback during the assembly process. In addition, although the system achieves synchronization and updating of process files through SOA, the flexibility of the entire system is poor, especially in the actual assembly process, where process changes need to be verified and approved, resulting in a slow update of process files and difficulty in adapting to rapidly changing production needs. Summary of the invention

[0006] The purpose of the present invention is to solve the problems that the existing transmission rocker arm angle assembly has no unified angle guidance tool, which not only has a heavy operating burden and low assembly efficiency, but also lacks effective error prevention measures resulting in low assembly accuracy, as well as the shortcomings of the existing engine production management system integrating MES and TCM, such as low degree of automation, weak real-time performance and poor flexibility, and to provide an intelligent assembly and error prevention method for the transmission rocker arm angle.

[0007] In order to solve the deficiencies of the above-mentioned prior art, the present invention provides the following technical solutions:

[0008] A method for intelligent assembly and error prevention of a transmission rocker arm angle, which is special in that it includes the following steps:

[0009] Step 1: Establish a transmission rocker arm database in TCM, wherein the transmission rocker arm database includes at least one production station, each production station includes an assembly station and an error-proofing station, each production station includes at least one structured data item, and each structured data item includes at least one structured data value;

[0010] Step 2: In the PLM (Product Lifecycle Management), the user requirements are converted into structured user requirements, and transmitted to the TCM; the structured user requirements include a correspondence between structured data items and structured data values;

[0011] Step 3, TCM matches the production station correspondence in the transmission rocker arm database according to the structured user requirements, and transmits the structured user requirements and the production station correspondence to MES. MES allocates the production task to the corresponding assembly station and error-proofing station according to the structured user requirements and the production station correspondence, and transmits the structured user requirements and the production station correspondence to AMES (Assembly Manufacturing Execution System); the production station correspondence includes the correspondence between the production station and the structured data item;

[0012] Step 4: AMES sends instructions to the equipment PLC (Programmable Logic Controller) according to the correspondence between the structured user requirements and the production stations, and writes the structured data values ​​in the structured user requirements into the RFID (Radio Frequency Identification) chip of the equipment to be assembled;

[0013] Step 5, when the equipment to be assembled arrives at the assembly station of the production station in the production station correspondence relationship, the equipment PLC reads the structured data value in the RFID chip of the equipment to be assembled through the RFID reader according to the instruction, and decodes the structured data value into a specific write value according to the instruction and the protocol between the equipment PLC and AMES, and then controls the auxiliary assembly equipment according to the instruction to guide the operator to perform assembly;

[0014] Step 6: When the equipment to be assembled reaches the error-proofing station of the production station in the production station correspondence, the equipment PLC controls the auxiliary measuring equipment to measure the structured actual value of the structured data item according to the instruction;

[0015] Step 7: The equipment PLC reads the structured data value in the RFID chip of the equipment to be assembled again, and compares the structured data value with the structured actual value to see if they are consistent. If so, the assembly is qualified and the assembly is completed; otherwise, the operator is prompted to make manual adjustments and then returns to step 6.

[0016] Furthermore, in step 5, the auxiliary assembly equipment is one of a laser emitting device, AR glasses, an AR display device, a digital projector, and a robotic arm.

[0017] Furthermore, in step 5, controlling the auxiliary assembly equipment according to the instruction to guide the operator to perform assembly is specifically as follows:

[0018] The equipment PLC controls the laser emitting device to emit specific laser lines according to instructions, guiding the operators to perform assembly.

[0019] Furthermore, in step 6, the auxiliary measurement device is one of a 3D camera, a laser ranging sensor, an angle sensor, an inductive sensor, and a capacitive sensor.

[0020] Furthermore, in step 6, the device PLC controls the auxiliary measuring device to measure the structured actual value of the structured data item according to the instruction, specifically:

[0021] The equipment PLC controls the 3D camera to take pictures of the structured data items in the corresponding relationship of the production stations according to the instructions, and calculates the structured actual values ​​of the structured data items through the calculation unit built into the equipment PLC or the 3D camera.

[0022] Further, in step 4, the instructions include data reading instructions, data decoding instructions, execution assembly control instructions and error-proofing verification control instructions;

[0023] In step 5, the equipment PLC reads the structured data value in the RFID chip of the equipment to be assembled through the RFID reader according to the data reading instruction, and decodes the structured data value into a specific write value according to the data decoding instruction and the protocol between the equipment PLC and AMES, and then controls the auxiliary assembly equipment according to the execution assembly control instruction to guide the operator to perform assembly;

[0024] In step 6, the device PLC controls the auxiliary measurement device to measure the structured actual value of the structured data item according to the error-proofing verification control instruction.

[0025] Compared with the prior art, the present invention has the following beneficial effects:

[0026] (1) The present invention provides an intelligent assembly and error prevention method for a transmission rocker arm angle, which systematically manages the correspondence between production stations, structured data items and structured data values ​​by establishing a transmission rocker arm database in TCM, thereby optimizing the process development and data transmission process.

[0027] (2) The present invention automatically transmits structured data between different systems and combines it with the error-proofing verification of a 3D camera, thereby reducing the complexity and error rate of manual operations.

[0028] (3) The present invention realizes the automatic control and error-proofing of the assembly process through the cooperation of RFID and PLC, thereby improving the overall assembly efficiency and accuracy. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] Figure 1 A schematic diagram of the relationship between PLM, TCM, MES, AMES, and equipment PLC in modern manufacturing enterprises;

[0030] Figure 2 It is a flow chart of an embodiment of a method for intelligent assembly and error prevention of a transmission rocker arm angle according to the present invention;

[0031] Figure 3 Schematic diagram of the structure of the transmission rocker arm database in step 1 of the embodiment of the present invention.

[0032] The reference numerals are explained as follows: 6 - production station; 7 - structured data item; 8 - structured data value. DETAILED DESCRIPTION

[0033] The present invention is further described below in conjunction with the accompanying drawings and exemplary embodiments.

[0034] Reference Figure 1 , PLM, TCM, MES, AMES, equipment PLC, their relationship in modern manufacturing enterprises can be described as a collaborative system network, each system controls and optimizes the production and management of products at different levels and stages.

[0035] Reference Figure 1 , a transmission rocker arm angle intelligent assembly and error prevention method, comprising the following steps:

[0036] Step 1: Establish a transmission rocker arm database in TCM. The transmission rocker arm database includes at least one production station 6. Each production station 6 includes an assembly station and an error-proofing station. Each production station 6 includes at least one structured data item 7. Each structured data item 7 includes at least one structured data value 8, such as Figure 2 As shown;

[0037] Step 2: Convert the user requirements into structured user requirements in PLM and transmit them to TCM; the structured user requirements include the corresponding relationship between structured data items 7 and structured data values ​​8;

[0038] Step 3: TCM matches the production station correspondence in the transmission rocker arm database according to the structured user requirements, and transmits the structured user requirements and the production station correspondence to MES; MES allocates the production task to the corresponding assembly station and error-proofing station according to the structured user requirements and the production station correspondence, and transmits the structured user requirements and the production station correspondence to AMES;

[0039] The production station correspondence relationship includes the correspondence relationship between the production station 6 and the structured data item 7;

[0040] Step 4: AMES issues instructions to the equipment PLC according to the correspondence between the structured user requirements and the production stations, and writes the structured data value 8 in the structured user requirements into the RFID chip of the equipment to be assembled; the instructions include data reading instructions, data decoding instructions, execution assembly control instructions and error-proofing verification control instructions:

[0041] Step 5, when the equipment to be assembled arrives at the assembly station of production station 6 in the production station correspondence relationship, the equipment PLC reads the structured data value 8 in the RFID chip of the equipment to be assembled through the RFID reader according to the data reading instruction, and decodes the structured data value 8 into a specific write value according to the data decoding instruction and the protocol between the equipment PLC and AMES, and then controls the auxiliary assembly equipment according to the execution assembly control instruction to guide the operator to perform assembly; MES interacts with the equipment PLC through AMES to obtain the execution status of the assembly station;

[0042] In this embodiment, the auxiliary assembly equipment is a laser emitting device, and the equipment PLC controls the laser emitting device to emit a specific laser line according to the instruction to guide the operator to perform assembly; in other embodiments, the auxiliary assembly equipment can also be AR (augmented reality) glasses, AR display equipment, digital projector, robotic arm, etc.;

[0043] Step 6: When the equipment to be assembled reaches the error-proofing station of production station 6 in the production station correspondence, the equipment PLC controls the auxiliary measurement equipment to measure the structured actual value of structured data item 7 according to the error-proofing verification control instruction; MES interacts with the equipment PLC through AMES to obtain the structured actual value;

[0044] In this embodiment, the auxiliary measuring device is a 3D camera. The device PLC controls the 3D camera to take pictures of the structured data item 7 in the corresponding relationship of the production station according to the error-proofing verification control instruction, and calculates the structured actual value of the structured data item 7 through the calculation unit built into the device PLC or the 3D camera; in other embodiments, the auxiliary measuring device can also use a laser distance sensor, an angle sensor, an inductive or capacitive sensor, etc.;

[0045] Step 7, the equipment PLC reads the structured data value 8 in the RFID chip of the equipment to be assembled again, and compares the structured data value 8 with the structured actual value to see if they are consistent. If so, the assembly is qualified and the assembly is completed; otherwise, the operator is prompted to make manual adjustments, and then returns to step 6;

[0046] MES interacts with the equipment PLC through AMES to obtain comparison results; MES is used to monitor and track each process link in the production process in real time to achieve traceability of the assembly process.

[0047] The present invention realizes assembly automation and error prevention mechanism through structured data transmission, PLC control, RFID data reading and 3D camera error prevention verification. The entire process is carried out around the transmission of structured data and equipment control to ensure the correct assembly of the rocker arm angle.

Claims

1. An intelligent assembly and error-proofing method for a transmission rocker arm angle, characterized in that: The steps include: Step 1: Establish a transmission rocker arm database in the TCM, wherein the transmission rocker arm database includes at least one production station (6), each production station (6) includes an assembly station and an error-proofing station, each production station (6) includes at least one structured data item (7), and each structured data item (7) includes at least one structured data value (8); Step 2: Convert the user requirements into structured user requirements in PLM and transmit them to TCM; the structured user requirements include the corresponding relationship between structured data items (7) and structured data values ​​(8); Step 3, TCM matches the production station correspondence in the transmission rocker arm database according to the structured user requirements, and transmits the structured user requirements and the production station correspondence to MES. MES allocates the production task to the corresponding assembly station and error-proofing station according to the structured user requirements and the production station correspondence, and transmits the structured user requirements and the production station correspondence to AMES; the production station correspondence includes the correspondence between the production station (6) and the structured data item (7); Step 4: AMES sends instructions to the equipment PLC according to the correspondence between the structured user requirements and the production stations, and writes the structured data value (8) in the structured user requirements into the RFID chip of the equipment to be assembled; Step 5, when the equipment to be assembled arrives at the assembly station of the production station (6) in the production station correspondence relationship, the equipment PLC reads the structured data value (8) in the RFID chip of the equipment to be assembled through the RFID reader according to the instruction, and decodes the structured data value (8) into a specific write value according to the instruction and the protocol between the equipment PLC and AMES, and then controls the auxiliary assembly equipment according to the instruction to guide the operator to perform assembly; Step 6, when the equipment to be assembled reaches the error-proofing station of the production station (6) in the production station correspondence, the equipment PLC controls the auxiliary measuring equipment to measure the structured actual value of the structured data item (7) according to the instruction; Step 7: The device PLC reads the structured data value (8) in the RFID chip of the device to be assembled again, and compares the structured data value (8) with the structured actual value to see if they are consistent. If so, the assembly is qualified and the assembly is completed; Otherwise, the operator is prompted to make manual adjustments, and then the process returns to step 6.

2. The intelligent assembly and error prevention method of the transmission rocker arm angle according to claim 1, characterized in that: In step 5, the auxiliary assembly equipment is one of a laser emitting device, AR glasses, AR display equipment, a digital projector, and a robotic arm.

3. The intelligent assembly and error prevention method of the transmission rocker arm angle according to claim 2, characterized in that: In step 5, the auxiliary assembly equipment is controlled according to the instruction to guide the operator to perform assembly, specifically: The equipment PLC controls the laser emitting device to emit specific laser lines according to instructions, guiding the operators to perform assembly.

4. The intelligent assembly and error prevention method for the transmission rocker arm angle according to claim 1, characterized in that: In step 6, the auxiliary measurement device is one of a 3D camera, a laser ranging sensor, an angle sensor, an inductive sensor, and a capacitive sensor.

5. The intelligent assembly and error prevention method of the transmission rocker arm angle according to claim 4, characterized in that: In step 6, the device PLC controls the auxiliary measuring device to measure the structured actual value of the structured data item (7) according to the instruction, specifically: The device PLC controls the 3D camera to take pictures of the structured data item (7) in the corresponding relationship of the production station according to the instruction, and calculates the structured actual value of the structured data item (7) through the calculation unit built into the device PLC or the 3D camera.

6. The intelligent assembly and error prevention method for the transmission rocker arm angle according to claim 1, characterized in that: In step 4, the instructions include data reading instructions, data decoding instructions, execution assembly control instructions and error-proofing verification control instructions; In step 5, the equipment PLC reads the structured data value (8) in the RFID chip of the equipment to be assembled through the RFID reader according to the data reading instruction, and decodes the structured data value (8) into a specific write value according to the data decoding instruction and the protocol between the equipment PLC and AMES, and then controls the auxiliary assembly equipment according to the execution assembly control instruction to guide the operator to perform assembly; In step 6, the device PLC controls the auxiliary measurement device to measure the structured actual value of the structured data item (7) according to the error-proofing verification control instruction.

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