An intelligent hanging system for a garment production line

Abstract

The application relates to an intelligent hanging system for a garment production line, comprising a main track and a plurality of workstations, wherein a workstation support track is arranged above each workstation, a push rod and a clothes hanger are arranged on the main track, the push rod can push the clothes hanger on the main track to run to transport the in-process raw materials, semi-finished products and finished products, and the intelligent hanging system further comprises a data acquisition module, which is used for acquiring actual working time when a certain worker completes a certain process and real-time production state data; a worker process efficiency prediction module, which is used for obtaining worker process efficiency according to the actual working time; a process flow arrangement module, which is used for obtaining an optimal process arrangement scheme of the clothes to be produced; and a clothes hanger transportation route scheduling control module, which is used for completing dynamic scheduling of the clothes hanger transportation route. The application has the advantages that the process arrangement scheme can be arranged more efficiently, the arrangement quality of the process arrangement scheme can be improved, and the waiting phenomenon in the production process can be reduced or even eliminated.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of pipeline automation, and in particular to an intelligent hanging system for a garment production pipeline. BACKGROUND

[0002] In the garment production field, a hanging system is often used for single-piece flow production. One production line usually includes a main rail and multiple workstations. A push rod installed on the main rail pushes the hanger to run on the main rail, so that the hanger can enter the corresponding workstations for working. The specific structure of the hanging system can be referred to, for example, a Chinese invention patent No. ZL201711057596.9 (authorized public number CN107555114B) discloses a hanging system.

[0003] Although the hanging system has advantages such as high efficiency and intelligence, the garment production field has characteristics such as fast product update, various styles, many types of fabrics, and large changes in process structure. Therefore, the same production line needs to be constantly switched between different garment styles. For this reason, the process arrangement scheme of each different garment style needs to be programmed, which leads to the following problems in the actual application of the existing hanging system:

[0004] Firstly, before a new garment style is put into production, experienced production technicians need to manually arrange the production line process flow of the garment style on paper or with the help of computer excel software, combining with their working experience. Through manual arrangement of the production line process arrangement scheme of the hanging system, on the one hand, there is a high requirement for the experience and arrangement level of the technicians, and the quality of the work is difficult to guarantee. On the other hand, it takes 30-50 minutes to initially arrange each style, and sometimes the technicians need to adjust the process arrangement scheme of the in-process style again, which is time-consuming and inefficient. Moreover, manual arrangement of the process arrangement scheme not only has the problem of low work efficiency, but also the quality of the work is difficult to guarantee. In the same garment factory, even if the same experienced technician does the process arrangement work, some styles will have good arrangement results, and some styles will have poor arrangement results. For garment factories, it takes several years to cultivate experienced technicians and production line leaders. These phenomena are common management pain points in the garment manufacturing industry that urgently need to be solved by new technologies and new schemes.

[0005] Secondly, in the process of arranging the arrangement scheme, the process route, the employee process efficiency, the standard working hours, the workstation resources and other data need to be determined. However, the data of the employee process efficiency is often estimated by experience or impression, and the accuracy is relatively low, so that when the product is put into the hanging system for actual production, the production rhythm of different processes is unbalanced, and the waiting phenomenon such as congestion or stop waiting for materials occurs in the station. At this time, the on-site management personnel of the production line has to dynamically adjust the process arrangement scheme of the in-process product again. Such manual process arrangement work and dynamic adjustment process after going on the production line are repeated, and almost every garment production line and every style may encounter it. It is time-consuming and laborious to handle, and the actual production rhythm is often difficult to stabilize. This is the largest work content of the on-site management work of the production line leader.

[0006] Therefore, the existing intelligent hanging system for garment production line needs to be further improved. SUMMARY

[0007] The technical problem to be solved by the present application is to provide an intelligent hanging system for a garment production line which can efficiently and high-quality complete the process arrangement scheme of different garment styles and dynamically adjust the process arrangement scheme according to the real-time production state.

[0008] The technical scheme adopted by the present application to solve the above technical problem is that the intelligent hanging system for a garment production line comprises a main track, a plurality of workstations arranged below the main track, a workstation support track capable of communicating with the main track arranged above each workstation, a plurality of hanging devices arranged on the main track, and a hanger and a push rod, wherein the push rod can drive the hanger on the main track to run in a specified direction on the main track under the driving of a driving mechanism, and the hanger can enter and exit the workstation support track; the hanger is used to transport in-process raw materials, semi-finished products and finished products in the garment production process, and the intelligent hanging system further comprises:

[0009] a data acquisition module for acquiring the actual working time of a certain employee completing a certain process and simultaneously acquiring real-time production state data at the current time; the real-time production state data at the current time comprises real-time position information of the hanger of the in-process raw materials, semi-finished products and finished products in the garment production process on the main track and the workstation support track;

[0010] an employee process efficiency prediction module for predicting the work efficiency of a certain employee completing a certain process according to the actual working time of the employee completing the process acquired by the data acquisition module to obtain the employee process efficiency;

[0011] The process flow arrangement module is used for inputting process flow data and process preferred sequence data of the clothes to be produced, and obtaining an optimal process arrangement scheme of the clothes to be produced according to the input process flow data and process preferred sequence data of the clothes to be produced, workstation resource information, employee resource information and employee process efficiency.

[0012] The hanger transportation route scheduling control module is used for completing dynamic scheduling of the hanger transportation route according to the main track, configuration information of different workstations, the optimal process arrangement scheme of the clothes to be produced and real-time production state data collected by the data acquisition module.

[0013] Further, the employee process efficiency prediction module obtains the employee process efficiency by the following steps.

[0014] Step 1-1, a sequence of actual working time of a certain employee engaged in a certain process is recorded as X[n], wherein n is a discrete time index, n = 1, 2, 3, …, N-1, and a discrete Fourier transform is performed on X[n] to obtain frequency domain data X[k]:

[0015]

[0016] X[k] represents the transformed complex frequency domain data, k represents a discrete frequency domain frequency index, and takes a value of 0 to N-1, e j2πkn represents a complex exponential base function, and j represents an imaginary unit;

[0017] Step 1-2, a frequency band with the highest frequency in the frequency domain data X[k] is taken as k max :

[0018]

[0019] Subsequently, k max is converted as follows to obtain CT:

[0020]

[0021] CT max represents an actual working time consumed by the employee when actually engaged in the process for a long time;

[0022] Step 1-3, the process efficiency EF of the employee is calculated:

[0023] EF = SAM / CT

[0024] Wherein SAM is a standard working time value of the process.

[0025] The actual working time of an employee completing a certain process in the workstation is collected by the data collection module, and the employee process efficiency EF is calculated by combining the collected actual working time through the employee process efficiency prediction module, which is the quantitative data of the employee in a long-time working scenario. On the one hand, the employee process efficiency EF of the employee no longer needs to be evaluated by relying on manual work, and on the other hand, compared with the employee process efficiency EF obtained by relying on experience or impression in the past, the accuracy is greatly improved, and reliable data sources are provided for the subsequent process flow arrangement module to output the optimal process arrangement scheme of the garment to be produced.

[0026] Further, the process flow arrangement module obtains the optimal process arrangement scheme of the garment to be produced by the following steps:

[0027] Step 2-1, according to the process flow data and process preferred sequence data of the garment to be produced, a directed and weightless connected graph G{V i} is established, and all possible process flow tables are generated by traversing the directed and weightless connected graph G{V i} and the set is denoted as U;

[0028] Step 2-2, extracting a process flow table scheme L i from the process flow table set U, i∈U, obtaining a local optimal solution by means of operational optimization solution; then adjusting the distribution of employees and workstations according to the local optimal solution, combining the workstation resource information, the employee resource information and the employee process efficiency EF, and saving the local optimal solution of this round;

[0029] Step 2-3, traversing the process flow table set U, and performing the local optimal solution of the next process flow table scheme L i according to step 2-2, until the traversal of the process flow table set U is completed;

[0030] Step 2-4, comparing the local optimal solutions of all process flow table schemes L i , and selecting the feasible solution with the global minimum value of the objective function, so as to obtain the optimal process arrangement scheme of the garment to be produced, and then outputting the optimal process arrangement scheme of the garment to be produced.

[0031] The optimal process arrangement scheme under the current resource condition is automatically arranged by the process flow arrangement module, which can obtain the optimal process arrangement scheme without relying on experienced technical personnel, improve the overall production efficiency, and also can predict the possible waiting phenomenon in advance. Through the local adjustment of the process flow arrangement module, the production process is more smoothly, and the on-site management workload of technical personnel is reduced.

[0032] Further, the step 2-2 obtains a certain process flow table scheme L iLocal optimal solution:

[0033] Step a: Create the process flow table scheme L i Sum the standard working hours (SAM) of all processes involved and divide by the number of employees (N) involved in scheduling that process to obtain the reference value for the actual working hours in this round of calculation:

[0034]

[0035] SAM i This represents the standard time value corresponding to the i-th single operation, and m is the process flow table scheme L. i The number of all processes involved;

[0036] Step b, in the current process flow table scheme L i Based on the employee's process efficiency EF, the processes are grouped and merged using operations research optimization, and then assigned to employees, thus making the process flow table scheme L... i The actual working hours should be as close as possible to the above-mentioned reference values ​​for actual working hours. The specific method is as follows:

[0037] Calculate the objective function value (CV) for each possible process arrangement scheme. The objective function is defined as follows:

[0038]

[0039] Where μ represents the average actual working time of the merged processes, M represents the total number of merged processes, and X... i σ is the sum of the standard working hours of the i-th merged process, and σ is the standard deviation of the actual working hours of the merged process;

[0040] Step c: Calculate the solution with the minimum objective function value (CV) in the above set:

[0041] H i =Min{CV i}

[0042] Where H i Scheme L representing process flow table i The local optimal solution.

[0043] Furthermore, the intelligent suspension system assigns each process to the corresponding workstation and employee for production based on the above-mentioned optimal process arrangement scheme. At the same time, it combines the current employee process efficiency and real-time production status data to determine whether there will be waiting in the current production process. If there will be waiting, the process arrangement module will be run again to make local adjustments to the optimal process arrangement scheme.

[0044] Further, the data acquisition module is configured to acquire event state information and time information corresponding to the event state information, wherein the event state information comprises request for entering the station, success of entering the station, request for entering the work area, entering the work area, confirmation of completion, request for leaving the station, and success of leaving the station, so that the data acquisition module obtains the actual working duration of a worker for completing a process according to the event state information and the time information corresponding to the event state information.

[0045] Further, each workstation is provided with a workstation control module, the in-station card reader and the in-station actuator corresponding to the in-station end of the branch track of each workstation are in communication connection with the corresponding workstation control module, the out-station card reader and the out-station actuator corresponding to the out-station end of the branch track of each workstation are in communication connection with the corresponding workstation control module, and each workstation is provided with a photoelectric sensor for acquiring whether the hanger successfully enters the station, a work area card reader, an entering work area actuator, and a completion button. Through the in-station card reader, the photoelectric sensor, the work area card reader, the completion button, and the out-station card reader, the data acquisition module can acquire the actual working duration of a worker for completing a process and the real-time production state data at the current time.

[0046] Further, each push rod and hanger is provided with an electronic tag with a unique ID code for identification by the in-station card reader and the out-station card reader, the in-station end of each workstation branch track is provided with a rotating in-station swing head, the in-station swing head is in driving connection with the in-station actuator, and the in-station actuator can drive the in-station swing head to rotate so as to communicate the in-station end of the workstation branch track with the main track, and the out-station end of the workstation branch track is provided with a rotating out-station swing head, the out-station swing head is in driving connection with the out-station actuator, and the out-station actuator can drive the out-station swing head to rotate so as to communicate the out-station end of the workstation branch track with the main track.

[0047] Further, each workstation is divided into a piece-hanging station, an ordinary station, an all-purpose worker station, a storage station, a rework station, and a quality inspection station according to the function attributes, the hanger transportation route scheduling control module transports the hangers to the corresponding attribute workstations according to the optimal process arrangement scheme, so as to complete the processes of cutting, binding, hanging, entering, processing, leaving, quality inspection, and packaging of the garments to be produced, and according to the quality inspection result, the hanger transportation route scheduling control module can control the hangers to be transported to the original workstations for repair or to the designated workstations for repair.

[0048] Further, the entering priority of the common station is higher than that of the all-round station, and the entering priority of the all-round station is higher than that of the reserve station; each station can be set to only allow specific hangers to enter; in the case that there are at least two workers in the same process, one of the workers is set as the main process worker, and the hangers preferentially enter the station where the main process worker is located; in the case that there are at least two stations in the same process, if the number of hangers in each station is greater than a preset value, the station where the worker has a higher process efficiency has a higher priority, and if the number of hangers in each station is less than or equal to the preset value, the stations are evenly distributed in turn. Wherein each station can be set to only allow specific hangers to enter, for example, hangers with specific color codes or specific ID codes.

[0049] Compared with the prior art, the application has the advantages that: the actual working time of a worker when completing a process is collected by the data collection module, the worker process efficiency of the worker when completing the process is predicted by the worker process efficiency prediction module, the optimal process arrangement scheme of the garment to be produced is obtained by the process flow arrangement module, and the dynamic scheduling of the hanger transportation route can be completed by the hanger transportation route scheduling control module, so that the arrangement efficiency of the process arrangement scheme can be improved, the arrangement quality of the process arrangement scheme can be improved, the waiting phenomenon in the production process can be reduced or even eliminated, and the hanger transportation route scheduling control module can dynamically adjust the process arrangement scheme in real time according to the real-time production state data collected by the data collection module, so that the efficiency of the entire garment production process can be further improved, and the output efficiency of the entire production line under the same resource condition is improved. BRIEF DESCRIPTION OF DRAWINGS

[0050] Figure 1 It is a hardware structure schematic diagram of the intelligent hanging system in the embodiment of the application;

[0051] Figure 2 It is a software function module schematic diagram of the intelligent hanging system in the embodiment of the application;

[0052] Figure 3 It is a flow schematic diagram of the worker process efficiency prediction module in the embodiment of the application;

[0053] Figure 4 It is a flow schematic diagram of the process flow arrangement module in the embodiment of the application. DETAILED DESCRIPTION

[0054] The application will be further described in detail below in combination with specific embodiments.

[0055] As Figure 1As shown, the intelligent hanging system for the garment production line in the embodiment comprises a main track 20 and a plurality of workstations arranged below the main track 20, each of the workstations is provided with a workstation branch track 30 capable of communicating with the main track 20, a plurality of hanging devices are arranged on the main track 20, the hanging devices comprise a push rod 21 and a clothes hanger 22, the push rod 21 can drive the clothes hanger 22 on the main track 20 to run in a specified direction on the main track 20 under the driving of a driving mechanism, and the clothes hanger 22 can enter and exit the workstation branch track 30; the clothes hanger 22 is used to transport the in-process raw materials, semi-finished products and finished products in the garment production process. The main track 20 is provided with a transmission chain, the transmission chain is connected with the driving mechanism, the push rod 21 and the clothes hanger 22 are hung on the transmission chain, the driving mechanism drives the transmission chain to run in a specified direction on the main track 20, so as to drive the push rod 21 to move along the main track 20 through the transmission chain. In addition, the intelligent hanging system for the garment production line in the embodiment further comprises a central control host, the driving mechanism is connected with the central control host and controlled by the central control host.

[0056] Each workstation is internally provided with a workstation control module 7, which is in communication connection with the central control host and can exchange data with the central control host, and can also receive control signals from the central control host; the main track 20 on the front side of the entry end of each workstation branch track 30 is provided with an entry card reader 1, and the entry end of each workstation branch track 30 is provided with an entry execution mechanism, and the entry card reader 1 and the entry execution mechanism are in communication connection with the corresponding workstation control module 7, and the exit end of each workstation branch track 30 is provided with an exit card reader 6 and an exit execution mechanism, and the exit card reader 6 and the exit execution mechanism are also in communication connection with the corresponding workstation control module 7, and each workstation is internally provided with a photoelectric sensor 2 for collecting whether the hanger 22 successfully enters the station, and each workstation is also provided with a work area card reader 4, an entry work area execution mechanism 3 and a completion button 5. The above-mentioned entry card reader 1, photoelectric sensor 2, work area card reader 4, completion button 5 and exit card reader 6 jointly constitute a data collection module for collecting the internal working state information of the workstation; the data collection module can collect the actual working time of an employee completing a certain process in the workstation and the real-time production state data at the current time. Each push rod 21 and hanger 22 is provided with an electronic tag with a unique ID code for identification by the entry card reader 1 and the exit card reader 6, and the entry end of each workstation branch track 30 is provided with a rotating entry swing head, which is in driving connection with the entry execution mechanism, and the entry execution mechanism can drive the entry swing head to rotate so as to communicate the entry end of the workstation branch track 30 with the main track 20, and the exit end of the workstation branch track 30 is provided with a rotating exit swing head, which is in driving connection with the exit execution mechanism, and the exit execution mechanism can drive the exit swing head to rotate so as to communicate the exit end of the workstation branch track 30 with the main track 20. When the hanger 22 enters the workstation, whether it is the ID code required for processing in the current workstation is read by the entry card reader 1, if yes, the hanger 22 is allowed to enter the workstation, and the time is recorded as the entry time, and when the hanger 22 that has entered passes through the photoelectric sensor 2, the time is recorded as the successful entry time; when the required hanger 22 enters the work area, the entry work area execution mechanism 3 is controlled by the workstation control module 7 to make the hanger 22 enter, and the time is recorded as the entry time of the work area; when the processing of the cloth on the hanger 22 is completed, the employee strikes the completion button 5 to send the hanger 22 into the outstation queue, and at the same time, the workstation control module 7 is informed to control the entry work area execution mechanism 3 to put a new hanger 22 into the work area, and the time is recorded as the completion time of the hanger 22 in the process, and also as the entry time of the new hanger 22 into the work area; when the hanger 22 exits, the exit card reader 6 continuously reads the ID code and constantly requests the central control host to run the exit, and when the central control host informs that the hanger 22 is allowed to exit through the workstation control module 7, the workstation control module 7 controls the exit execution mechanism to release the hanger 22, and the time is recorded as the time when the hanger 22 leaves the work area.

[0057] In addition, the intelligent hanging system in the embodiment further includes the following functional modules, as shown in Figure 2

[0058] The data acquisition module is configured to acquire the actual working duration of an employee to complete a work procedure and acquire real-time production state data at the current time. The real-time production state data at the current time includes the real-time position information of the garment hangers 22 of the work-in-process materials, semi-finished products and finished products on the main track 20 and the work station branch track 30 in the garment production process. The entry card reader 1, the photoelectric sensor 2, the work area card reader 4, the completion button 5 and the exit card reader 6 in all work stations jointly constitute the above-described data acquisition module.

[0059] The employee work procedure efficiency prediction module is configured to predict the work efficiency of the employee to complete the work procedure according to the actual working duration of the employee to complete the work procedure acquired by the data acquisition module, so as to obtain the employee work procedure efficiency.

[0060] The work procedure flow arrangement module is configured to input the process flow data and the work procedure preferred sequence data of the garment to be produced, and obtain the optimal work procedure arrangement scheme of the garment to be produced according to the input process flow data and work procedure preferred sequence data of the garment to be produced, the work station resource information, the employee resource information and the employee work procedure efficiency.

[0061] The garment hanger transportation route scheduling control module is configured to complete the dynamic scheduling of the garment hanger transportation route according to the main track 20, the configuration information of different work stations, the optimal work procedure arrangement scheme of the garment to be produced and the real-time production state data acquired by the data acquisition module.

[0062] The data acquisition module is configured to acquire event state information and time information corresponding to the event state information, wherein the event state information includes request entry, entry success, request entry into the work area, entry into the work area, confirmation of completion, request exit and exit success, so that the data acquisition module acquires the actual working duration of the employee to complete the work procedure according to the event state information and the time information corresponding to the event state information.

[0063] In the embodiment, the employee work procedure efficiency prediction module, the work procedure flow arrangement module and the garment hanger transportation route scheduling control module can be integrated on the central control host, and the computer software modules of the central control host realize the above-described functions. Specifically, as shown in Figure 3 The employee work procedure efficiency prediction module can obtain the employee work procedure efficiency through the following steps:

[0064] ​Step 1-1, the sequence of actual working time of an employee in a certain process is recorded as X[n], where n is the discrete time index, n = 1, 2, 3, …, N-1, and the discrete Fourier transform is performed to obtain frequency domain data X[k]:

[0065]

[0066] where X[k] represents the transformed complex frequency domain data, k represents the discrete frequency domain frequency index, and takes values from 0 to N-1, represents the complex exponential base function, and j represents the imaginary unit;

[0067] Step 1-2, the highest frequency band in the frequency domain data X[k] is set as k max :

[0068]

[0069] Subsequently, k max is converted as follows to obtain CT:

[0070]

[0071] where CT max represents the actual working time of the employee when the longest time is spent in the process;

[0072] Step 1-3, calculate the process efficiency EF of the employee:

[0073] EF = SAM / CT

[0074] where SAM is the standard man-hour value of the process.

[0075] The actual working time of an employee completing a certain process in the workstation is collected by the data collection module, and the employee process efficiency EF is calculated by the employee process efficiency prediction module combined with the collected actual working time. The employee process efficiency EF is the quantitative data of the employee in a long-time working scenario. On the one hand, it is no longer necessary to rely on manual evaluation of the employee process efficiency EF of the employee, and on the other hand, compared with the employee process efficiency EF estimated by experience or impression in the past, the accuracy is greatly improved, and it provides reliable data source for the subsequent process flow arrangement module to output the optimal process arrangement scheme of the garment to be produced. In addition, the employee process efficiency prediction module in the embodiment firstly extracts data according to the characteristic rules commonly used in the garment manufacturing industry, assembles the extracted tables to obtain an original table marked as W, performs data cleaning operation on the original table W to obtain a clean table marked as C, and stores the cleaned data in a rejection table marked as T. In this process, the corresponding log records, i.e. data extraction log, data assembly log and data cleaning log, are left. By comparing the data of the W, C and T tables, a data quality report of the production operation record data is obtained through statistical analysis, and then the employee process efficiency prediction module can calculate the employee process efficiency EF of the employee according to the above steps based on the actual working time in the clean table C. The employee process efficiency prediction module can also summarize the employee process efficiency EF of all employees engaged in each single process to output the employee process efficiency prediction result set of the new version, and combine the historical version data to form a complete employee process efficiency prediction result which always maintains the latest data for users to view. The complete prediction result is one of the important input data required by the subsequent process flow arrangement module to output the optimal process arrangement scheme.

[0076] In terms of the function of the process flow arrangement module, as shown in Figure 4 , the process flow arrangement module can obtain the optimal process arrangement scheme of the garment to be produced by the following steps:

[0077] Step 2-1, according to the process flow data and process preferred order data of the garment to be produced, a directed and weightless connected graph G{V i} is established, and all possible process flow tables are generated from the directed and weightless connected graph G{V i} to form a set U;

[0078] Step 2-2, extracting a process flow table scheme L i from the process flow table set U, i∈U, obtaining a local optimal solution by means of operational optimization solution; then adjusting the distribution of employees and workstations according to the local optimal solution, combining the workstation resource information, employee resource information and employee process efficiency EF, and saving the local optimal solution of this round;

[0079] Step 2-3, traverse the process flow table set U, and according to step 2-2, the next process flow table scheme L is obtained i The local optimal solution of the objective function value is obtained until the process flow table set U is traversed.

[0080] Step 2-4, compare the local optimal solutions of all process flow table schemes L i The global minimum feasible solution of the objective function value is selected, and the optimal process arrangement scheme of the garment to be produced is obtained, and then the optimal process arrangement scheme of the garment to be produced is output.

[0081] It should be noted that the operation optimization solution in step 2-2 is a common prior art, so it will not be described again. The optimal process arrangement scheme under the current resource condition is automatically arranged by the process flow arrangement module, which can obtain the optimal process arrangement scheme without relying on experienced technical personnel, improve the overall production efficiency, and also predict possible waiting phenomenon in advance. Through local adjustment by the process flow arrangement module, the production process is more smoothly, and the on-site management workload of technical personnel is reduced.

[0082] Regarding the specific process of step 2-2, step 2-2 obtains the local optimal solution of the process flow table scheme L i by the following steps:

[0083] Step a, sum all the standard man-hour values SAM involved in the process flow table scheme L i and divide by the number of employees participating in the process arrangement N to obtain the actual working time reference value of this round of solution:

[0084]

[0085] Where SAM i represents the standard man-hour value corresponding to the ith single process, and m is the number of all processes involved in the process flow table scheme L i .

[0086] Step b, under the current process flow table scheme L i , according to the employee process efficiency EF, the process is combined and distributed to the employees by the operation optimization solution, so that the actual working time under the process flow table scheme L i is as close as possible to the actual working time reference value, and the specific method is as follows:

[0087] Calculate the objective function value CV of each possible process arrangement scheme, and the definition of the objective function is as follows:

[0088]

[0089] wherein μ represents the mean of the actual working time length of the merged merging process, M represents the total number of the merging processes, X i is the sum of the standard working time values of the i-th merging process, and σ is the standard deviation of the actual working time length of the merging processes.

[0090] Step c, calculating the solution with the minimum objective function value CV in the above set:

[0091] H i = Min{CV i}

[0092] wherein H i represents the local optimal solution of the process flow table scheme L i .

[0093] After obtaining the local optimal solution, the work station distribution can be fine-tuned in combination with the on-site work station distribution data source. If the same employee needs to work at multiple work stations, the employee is arranged to work at adjacent work stations as much as possible, and then the optimal process arrangement scheme, index value, and log are saved.

[0094] In the specific use process of the intelligent hanging system in the embodiment, a set of optimal process arrangement scheme of the to-be-produced garment under the given resource conditions is obtained through the process flow arrangement module a few days before the production line of each new to-be-produced garment, and the optimal process arrangement scheme is converted into a processing scheme for execution after being verified to be correct. Further, the intelligent hanging system allocates each process to the corresponding work station and employee for production according to the optimal process arrangement scheme, and judges whether waiting will occur in the current production process in combination with the current employee process efficiency and real-time production state data. If waiting will occur, the process arrangement flow module is run again to locally adjust the optimal process arrangement scheme.

[0095] In this embodiment, each workstation can also be divided into piece hanging station, ordinary station, all-purpose worker station, storage station, rework station and quality inspection station according to the attribute. The rack transport route scheduling control module transports the rack 22 to the workstation with the corresponding attribute according to the optimal process arrangement scheme. The main control host can send the rack ID that needs to enter different workstations to the workstation control module 7 of the corresponding workstation in advance according to the optimal process arrangement scheme. In this way, different workstation control modules 7 only allow racks that can enter the workstation to enter the workstation when controlling the entry mechanism. Through the overall control of the main control host and all workstation control modules, the cutting, binding, piece hanging, entry, processing, exit, quality inspection and packaging of the garment to be produced can be completed. According to the quality inspection result, the rack transport route scheduling control module can control the rack 22 to be transported to the original workstation for repair or to the designated workstation for repair. The entry priority of the ordinary station is higher than that of the all-purpose worker station, and the entry priority of the all-purpose worker station is higher than that of the storage station. Each workstation can be set to allow only specific racks 22 to enter. In the case where at least two employees are processing in the same process, one of the employees is set as the main process employee, and the rack 22 enters the workstation where the main process employee is located first. In the case where there are at least two workstations in the same process, if the number of racks 22 in each workstation is greater than the preset value, the workstation with higher employee process efficiency has higher priority, and if the number of racks 22 in each workstation is less than or equal to the preset value, the workstations are evenly distributed in turn.

[0096] The specific entry rules of workstations with different attributes are as follows:

[0097] (1) Ordinary station, all-purpose worker station and storage station

[0098] The entry priority of the ordinary station is the highest, the all-purpose worker station is the second, and the storage station is the last. If all the processes are in the same workstation attribute, the rack enters the workstation of the current production line first, then the workstation of the adjacent production line, and finally the storage station. When entering the storage station, the rack enters the storage station closest to the physical path of the current workstation first.

[0099] (2) Ordinary station

[0100] If there are employees working in the ordinary station, and multiple ordinary stations are set for the same process, the racks will enter the stations in the order of the workstation allocation table. When the preset upper limit of the average entry is reached, the rack enters the workstation with fewer racks 22 first.

[0101] (3) All-purpose worker station

[0102] The all-purpose worker station has similar properties to the ordinary station, but has lower priority than the ordinary station. The rack 22 will flow to the ordinary station first. In the scenario where no storage station is set, the rack 22 enters the all-purpose worker station after the ordinary station is full.

[0103] (4) Reserve station

[0104] The reserve station does not need staff to do production work, and it is simply used as a storage location for hangers 22. When the hangers 22 in the normal station of the same process are full and no all-purpose station is set, the hangers 22 automatically enter the reserve station. When the number of hangers 22 in the normal station is less than the set capacity, if the "automatic hanger output" switch is turned on, the reserve station automatically sends hangers 22 to the normal station.

[0105] (5) Re-work station

[0106] After a certain station is set as a re-work station, all hangers 22 that need to be re-worked due to quality inspection failure will flow to the re-work station.

[0107] (6) Special hanger setting

[0108] If a special hanger 22 is configured, such as a specific color code or ID number, etc., the work station will only enter the selected special hanger 22. If no configuration is made, all hangers 22 can enter by default.

[0109] (7) Main and auxiliary process distribution rules

[0110] Support two or more staff, the same process or a group of processes, one staff as the main process, the other staff as the auxiliary process to produce, and the hangers 22 are preferentially supplied to the work station where the staff is doing the main process.

[0111] (8) Parallel process distribution rules

[0112] If there are multiple work stations doing the same process, when the previous process is completed and exits the station, if the number of hangers 22 in the target work station is greater than the preset value, the work station with higher staff process efficiency is preferentially assigned to the staff. If it is less than or equal to the preset value, multiple work stations are then evenly distributed in rotation.

[0113] In summary, the intelligent hanging system for the garment production line provides an overall solution for garment production and manufacturing, can help the garment factory to manage the on-site management process of the production line, collect the actual working time of an employee when completing a certain process through the data acquisition module, predict the employee process efficiency of the employee when completing the process through the employee process efficiency prediction module, obtain the optimal process arrangement scheme of the garment to be produced through the process flow arrangement module, and can complete the dynamic scheduling of the clothes hanger transportation route relying on the clothes hanger transportation route scheduling control module, so as to not only improve the arrangement efficiency of the process arrangement scheme, but also improve the arrangement quality of the process arrangement scheme, and at the same time, the waiting phenomenon in the production process can be reduced or even eliminated, and the clothes hanger transportation route scheduling control module can dynamically adjust the process arrangement scheme in real time according to the real-time production state data collected by the data acquisition module, so as to further improve the efficiency of the whole garment production process, and realize the improvement of the output efficiency of the whole production line under the same resource conditions.

Claims

1. An intelligent hanging system for a garment production line, comprising a main track (20), a plurality of workstations arranged below the main track (20), each of the workstations being provided with a workstation sub-track (30) capable of communicating with the main track (20), a plurality of hanging devices arranged on the main track (20), the hanging devices comprising a push rod (21) and a hanger (22), the push rod (21) being capable of pushing the hanger (22) on the main track (20) to run in a specified direction on the main track (20) under the drive of a driving mechanism, and the hanger (22) being capable of entering and exiting the workstation sub-track (30); the hanger (22) being used to transport in-process raw materials, semi-finished products and finished products in a garment production process, characterized in that, The intelligent hanging system further comprises: a data acquisition module configured to acquire actual working time of an employee to complete a process and real-time production state data at a current time, wherein the real-time production state data at the current time comprises real-time position information of hangers (22) of semi-finished products and finished products on a main track (20) and a workstation branch track (30) in a garment production process; an employee process efficiency prediction module configured to predict working efficiency of the employee to complete the process according to the actual working time of the employee to complete the process acquired by the data acquisition module, and obtain employee process efficiency; a process flow arrangement module configured to input process flow data and process preferred sequence data of a garment to be produced, and obtain an optimal process arrangement scheme of the garment to be produced according to the input process flow data and process preferred sequence data of the garment to be produced, workstation resource information, employee resource information and employee process efficiency; a hanger transportation route scheduling control module configured to complete dynamic scheduling of a hanger transportation route according to configuration information of the main track and different workstations, the optimal process arrangement scheme of the garment to be produced, and the real-time production state data acquired by the data acquisition module; The employee process efficiency prediction module obtains the employee process efficiency through the following steps: Step 1-1, a sequence of actual working time of an employee to engage in a process is recorded as X[n], wherein n is a discrete time index, n = 1, 2, 3, …, N-1, and a discrete Fourier transform is performed on X[n] to obtain frequency domain data X[k]; where X[k] represents the transformed complex frequency domain data, k represents a discrete frequency domain frequency index, and takes a value of 0 to N-1, represents a complex exponential basis function, and j represents an imaginary unit. Step 1-2, take the highest frequency band in the frequency domain data X[k] as k max : Subsequently, k max The following conversion is performed to obtain CT: where CT max represents the actual working time length when the employee actually spends the longest time on the process for a long time; Step 1-3, the process efficiency EF of the employee is calculated as follows: EF = SAM / CT wherein SAM is a standard working time value of the process; The process flow arrangement module obtains the optimal process arrangement scheme of the garment to be produced through the following steps: Step 2-1, according to the process flow data and process preferred sequence data of the garment to be produced, a directed and unweighted connected graph G{V i} is established, and all possible process flow direction table sets U are generated by traversing the directed and unweighted connected graph G{V i}. Step 2-2, extract a process flow table scheme L in the process flow table collection U i , i∈U, the local optimal solution is obtained by means of operational optimization solution; then according to the local optimal solution, the distribution of employees and workstations is adjusted in combination with workstation resource information, employee resource information and employee process efficiency EF, and the local optimal solution of this round is saved; Step 2-3, traverse the set of process flow table U, and according to step 2-2, the next process flow table scheme L is performed i local optimum solution until the set of process flow table U is traversed. Step 2-4, compare all process flow table schemes L i the local optimal solution, and select a feasible solution with the global minimum of the objective function value, thereby obtaining the optimal process arrangement scheme of the garment to be produced, and then output the optimal process arrangement scheme of the garment to be produced; The step 2-2 gets a certain process flow table scheme L by the following steps i Local optimum solution: Step a, process flow table scheme L i All the standard man-hour values SAM involved in the process are summed up and divided by the number of employees N involved in the process arrangement to obtain the actual working time reference value for this round of solution: where SAM i represents the standard time value corresponding to the i-th lane single process, and m is the process flow table scheme L i the number of all processes involved Step b, in the current process flow table scheme L i Under the current process flow table scheme L, according to the employee process efficiency EF, the process is combined and distributed to the employees by means of operational optimization solution, so that the process flow table scheme L i The actual working time is as close as possible to the actual working time reference value, and the specific method is: a target function value CV of each possible process arrangement scheme is calculated, and the target function is defined as follows: wherein μ denotes the mean of the actual working time length of the merged merging processes, M denotes the total number of merging processes, X i is the sum of the standard working time values of the i-th merging process, and σ is the standard deviation of the actual working time length of the merging processes. Step c, a solution with the minimum target function value CV in the set is calculated: H i = Min{CV i} where H i represents the process flow table scheme L i a local optimum solution.

2. The intelligent hanging system for a garment production line of claim 1, wherein, The intelligent hanging system allocates each process to a corresponding workstation and employee for production according to the optimal process arrangement scheme, and judges whether a waiting phenomenon will occur in the current production process in combination with the current employee process efficiency and real-time production state data. If the waiting phenomenon will occur, the process arrangement flow module is run again to make a local adjustment to the optimal process arrangement scheme.

3. The intelligent hanging system for a garment production line of claim 1, wherein, The data acquisition module is configured to acquire event state information and time information corresponding to the event state information, wherein the event state information comprises request for entering a station, successful entry into the station, request for entering a work area, entry into the work area, confirmation of completion, request for leaving the station, and successful exit from the station, so that the data acquisition module obtains actual working time of an employee to complete a process according to the event state information and the time information corresponding to the event state information.

4. The intelligent hanging system for a garment production line of claim 3, wherein, Each workstation is provided with a workstation control module (7), the corresponding entrance card reader (1) and entrance execution mechanism on the main track (20) in front of the entrance end of each workstation branch track (30) are in communication connection with the corresponding workstation control module (7), and the corresponding exit card reader (6) and exit execution mechanism at the exit end of each workstation branch track (30) are in communication connection with the corresponding workstation control module (7), and each workstation is provided with an optical sensor (2) for collecting whether the hanger is successfully entered, and is also provided with a work area card reader (4), an entering work area execution mechanism (3) and a completion button (5).

5. The intelligent hanging system for a garment production line of claim 4, wherein, Each push rod (21) and hanger (22) is provided with an electronic tag with a unique ID code for identification by the entrance card reader (1) and exit card reader (6), and the entrance end of each workstation branch track (30) is provided with a rotating entrance swing head, the entrance swing head is drivingly connected with the entrance execution mechanism, the entrance execution mechanism can drive the entrance swing head to rotate so as to communicate the entrance end of the workstation branch track (30) with the main track (20), and the exit end of the workstation branch track (30) is provided with a rotating exit swing head, the exit swing head is drivingly connected with the exit execution mechanism, the exit execution mechanism can drive the exit swing head to rotate so as to communicate the exit end of the workstation branch track (30) with the main track (20).

6. The intelligent hanging system for a garment production line of claim 1, wherein, Each workstation is divided into a piece hanging station, an ordinary station, an all-purpose worker station, a reserve station, a rework station and a quality inspection station according to the working attributes, the hanger transportation route scheduling control module transports the hanger (22) to the corresponding attribute workstation according to the optimal process arrangement scheme, so as to complete the cutting, binding, piece hanging, entering, processing, exiting, quality inspection and packaging of the to-be-produced garment, and according to the quality inspection result, the hanger transportation route scheduling control module can control the hanger (22) to be transported to the original workstation for repair or to the designated workstation for repair.

7. The intelligent hanging system for a garment production line of claim 6, wherein, The entering priority of the ordinary station is higher than that of the all-purpose worker station, and the entering priority of the all-purpose worker station is higher than that of the reserve station; each workstation can be set to be entered only by a specific hanger (22); in the case that there are at least two workers processing in the same process, one of the workers is set as a main process worker, and the hanger enters the workstation where the main process worker is located preferentially; in the case that there are at least two workstations in the same process, if the number of hangers (22) in each workstation is greater than a preset value, the workstation with higher worker process efficiency has higher priority, and if the number of hangers (22) in each workstation is less than or equal to the preset value, the workstations are evenly distributed in turn.

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