An integrated production line for upright pianos

Abstract

The present invention discloses an integrated production line for upright pianos, including a production line for manufacturing upright piano accessories, tuning and assembling upright pianos; an AGV transfer device for automatically distributing or circulating upright pianos and their accessories; and a matching algorithm, which is arranged inside the AGV transfer component and is used for automatic circulation and allocation of accessories, and relates to the technical field of upright piano production lines. The high-end production line of the present invention realizes the comprehensive automation of the transfer process by adopting advanced machinery and equipment, automatic control, intelligent algorithms and other technical means, thereby greatly improving production efficiency. Compared with traditional production lines that require a large amount of manual handling, high-end production lines can reduce production delays and errors caused by human factors, making the production process smoother and more efficient.

Description

Technical Field

[0001] The invention relates to the technical field of upright piano production lines, in particular to an integrated production line for upright pianos. Background Art

[0002] An upright piano, also known as an upright piano, is a common type of piano, named for its upright structure. Compared with a grand piano, an upright piano has a more compact body, usually in a rectangular shape, suitable for placement next to a wall, so an upright piano takes up less space and is more suitable for homes and small performance venues. An upright piano usually has a warm, soft tone, suitable for indoor performances. Although it may be slightly inferior to a grand piano in terms of volume and sound quality, it can still meet the needs of beginners and home use, and many upright pianos are equipped with high-quality mechanical devices to ensure that the keyboard has a good touch, which helps performers to achieve good performance in practice and performances.

[0003] The upright piano production line is an assembly line used in factories for large-scale production of upright pianos. The traditional production lines of existing technologies have shortcomings such as outdated equipment, backward technology, unreasonable layout, high energy consumption, many safety hazards, and difficulty in adapting to changes in market demand.

[0004] Therefore, the production line of the prior art will use the MES management execution system to manage and operate the production line, thereby avoiding the technical problems existing in the old production line. For example, the patent with publication number CN112684768A discloses a method and system for automatically associating material information based on the MES system. The patent specifically discloses that "the present invention discloses a method and system for automatically associating material information based on the MES system, and the method includes the following steps: the PLC control cabinet sends a material transfer signal to the MES system; the MES system sends material transfer location information to the idle second AGV car; the second AGV car obtains the location identification code of the corresponding position; the MES system determines whether it is consistent with the material transfer location; controls the material to be transferred to the second AGV car; sends the bound material information to the second AGV car; the MES system updates and saves the information in its own database; obtains the display screen content and material identification number on the second AGV car; determines whether the material on the second AGV car is consistent with the material to be transferred; and ends the program." The technical solution achieves the "beneficial effect: not only can the full automatic association of material information be realized, reducing the workload of staff, but also the inspection of material transfer information can be realized, better meeting the use needs of the enterprise."

[0005] However, after the production line was put into operation, the way in which the AGV equipment and the MES execution system responded was not comprehensive enough. As a result, although the AGV equipment could implement the execution commands issued by the MES execution system, the MES execution system lacked optimized positioning of the AGV equipment, which made the AGV equipment prone to deviation. In addition, the AGV equipment lacked effective support equipment and suffered excessive wear and tear during operation. Summary of the invention

[0006] The purpose of the present invention is to provide an integrated production line for upright pianos, which optimizes the layout of the production line, reduces energy consumption, improves production efficiency and product quality, enhances the corporate image, and creates a clean and comfortable production environment by introducing new equipment, technology and processes, thereby enhancing the market competitiveness of the enterprise and solving the problems raised in the above background technology.

[0007] To achieve the above-mentioned purpose, the present invention provides the following technical solutions: an integrated production line for upright pianos, comprising a production line for manufacturing upright piano accessories and tuning and assembling upright pianos; an AGV transfer device for automatically distributing or circulating upright pianos and their accessories; and a matching algorithm, which is arranged inside the AGV transfer component and is used for automatic circulation and allocation of accessories.

[0008] As a further solution of the present invention: the production line includes an incoming material line, a card back line, a sub-assembly line and a complete assembly line. The incoming material line provides and inspects raw materials for the production line, the card back line provides for the production and assembly of piano frames and back panels through a card back machine, the sub-assembly line provides for the connection and assembly of strings and pianos through a hammer machine, and the complete assembly line provides for the overall assembly of the piano and its factory use.

[0009] As a further solution of the present invention: the AGV transfer equipment includes an AGV truck and an AGV forklift, the interior of the production line is laid with tracks for the AGV truck, the AGV forklift is used for picking up upright pianos or their accessories, and the AGV forklift is compatible with the AGV truck.

[0010] As a further solution of the present invention: the supporting algorithm includes a composite algorithm, which includes an MES manufacturing execution algorithm implanted in an AGV truck and an IPC vision execution algorithm implanted in an AGV forklift. The MES manufacturing execution algorithm is used for navigation, obstacle avoidance and scheduling when the AGV truck is used, and the IPC vision execution algorithm is used for identification, forking and transportation when the AGV forklift is used.

[0011] As a further solution of the present invention, it also includes an inspection line, which is arranged at the rear end of the production line and is used for factory inspection of assembled upright pianos.

[0012] As a further solution of the present invention: the MES manufacturing execution algorithm has a built-in allocation module for allocating work tasks to AGV trucks. The allocation module is used for route planning and tracking of AGV working trucks, as well as waiting and staying for loading and unloading materials. The allocation module is used for standby use and charging processing of idle AGV trucks.

[0013] As a further solution of the present invention: the IPC vision execution algorithm has a built-in recognition module to assist the AGV forklift in its work, the recognition module is used by the AGV forklift to recognize and select the piano number and the piano fork position, and the recognition module is used by the AGV forklift to recognize its position relative to the AGV truck boarding position.

[0014] As a further solution of the present invention: the IPC vision execution algorithm includes an image computing unit, a point cloud computing unit and a real-time settlement unit. The image computing unit is used by the IPC vision execution algorithm to capture pictures of piano fork holes and labels as well as AGV truck boarding points. The point cloud computing unit is used by the IPC vision execution algorithm to convert pixels in the pictures into point cloud groups with point cloud information. The real-time settlement unit is used by the IPC vision execution algorithm to recognize point clouds and analyze the positions of piano fork holes, label information and the positions of AGV truck boarding points.

[0015] As a further solution of the present invention: the AGV truck has a built-in Dijkstra algorithm for obstacle avoidance, and the Dijkstra algorithm is preset with a computing node for updating the position of the AGV truck in real time.

[0016] Compared with the prior art, the present invention has the following beneficial effects: 1. The high-end production line of this application realizes the full automation of the transfer process by adopting advanced machinery and equipment, automatic control and intelligent algorithms, thereby greatly improving production efficiency. Compared with traditional production lines that require a lot of manual handling, high-end production lines can reduce production delays and errors caused by human factors, making the production process smoother and more efficient; 2. The high-end production line of this application uses reliable automated equipment and intelligent systems. These devices have the ability to make intelligent judgments, which can reduce human errors and equipment failures, thereby ensuring the stability of the production process. In addition, high-end production lines usually have strict quality control and testing mechanisms to ensure the stability and consistency of products; 3. The high-end production line of this application is highly flexible and can be quickly adjusted according to different market demands and product characteristics. Whether it is producing different varieties of products or adjusting the production process, the high-end production line can quickly adapt to meet the diverse needs of the market; 4. The high-end production line of this application focuses on safe production. The AGV, equipment and tools used have high safety protection measures, which can effectively ensure the safety of workers and equipment. In addition, the production line is usually equipped with a safety monitoring system and an emergency shutdown device to ensure that measures can be taken quickly in the event of abnormal situations to prevent accidents; 5. The high-end production line of this application adopts advanced technology and precise control system, which can ensure that the precision and quality of the products reach a very high level. This can not only meet the market demand for high-quality products, but also improve the competitiveness and brand image of the enterprise. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 This is a flow chart of scheme 1 in an embodiment of the present invention; Figure 2 This is a flow chart of scheme 2 in an embodiment of the present invention; Figure 3 It is a schematic diagram of the AGV transfer equipment in an embodiment of the present invention. DETAILED DESCRIPTION

[0018] The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0019] In the description of the present invention, it should be noted that, for those skilled in the art, the specific meanings of the above terms in the present invention can be understood in specific situations. The following describes an embodiment of the present invention based on its overall structure.

[0020] In an embodiment of the present invention, an integrated production line for upright pianos includes a production line, the production line is used for manufacturing upright piano parts and tuning and assembling upright pianos. The specific production line includes a material supply line, a card back line, a subassembly line and a complete assembly line. The material supply line provides and inspects raw materials for the production line, the card back line provides the production and assembly of piano frames and backboards through a card back machine, the subassembly line provides the connection and assembly of strings and pianos through a string action machine, and the complete assembly line provides the overall assembly of the piano and factory use; See also Figure 1 and Figure 2 The embodiment of the present application is provided with two selectable production line modes, wherein Plan 1: The original piano production layout of the factory, in which the incoming material line includes the shell unpacking area and the piano back unpacking area for the inspection of incoming material accessories; after the inspection, the production line will transfer the incoming piano accessories to the card back line, sub-assembly line and assembly line for piano assembly. During the assembly period, the piano needs to be scraped, the sound head is touched, the sound head is repaired, the keyboard is installed, the action is installed, the primary / secondary sound head is arranged, and up to 6 times or more of the picking inspection; after the inspection, the assembled piano will be sent to The pianos are transferred to the inspection line for a general inspection, which includes the appearance repair, sound quality inspection and vibration humidification inspection of the piano. Therefore, the production and inspection sequence of the production line is plucking, action installation, keyboard installation, tuning, assembly, secondary sound head, appearance repair, sound quality and general inspection. Finally, the pianos are sent to the finished product storage area. Before they leave the factory, they are subject to another inspection for unqualified paint parts and pre-sale repair inspection, so as to prevent defective products from leaving the factory in bulk and affecting the quality of upright pianos leaving the production line. Plan 2: For the production layout after the factory improved and added AGV transfer equipment, Plan 2 follows the process flow of piano production in Plan 1 (pluck, install action, install keyboard, tune, complete assembly, secondary sound head, appearance repair, sound quality and general inspection, and finally enter the finished product storage area). In addition, the operation of AGV transfer equipment for transfer is realized between each process - that is, the piano is transported from entering the line to the appearance through AGV transfer equipment (including AGV trucks and AGV forklifts) during the operation of the equipment in the incoming material line, card back line, sub-assembly line, assembly line and inspection line. At the same time, intermediate process inspections are added in the three processes of installing action, sorting and assembly to ensure that problems are found and solved as early as possible during the piano assembly process, and finally achieve the production of high-quality pianos.

[0021] Therefore, the production line proposed in this application has the following excellent characteristics: Efficiency: The high-end production line of this application realizes the full automation of the transfer process by adopting advanced machinery and equipment, automatic control and intelligent algorithms, thereby greatly improving production efficiency. Compared with traditional production lines that require a lot of manual handling, high-end production lines can reduce production delays and errors caused by human factors, making the production process smoother and more efficient; Stability: The high-end production line of this application uses reliable automated equipment and intelligent systems. These devices have the ability to make intelligent judgments, which can reduce human errors and equipment failures, thereby ensuring the stability of the production process. In addition, high-end production lines usually have strict quality control and testing mechanisms to ensure product stability and consistency; Flexible manufacturing: The high-end production line of this application is highly flexible and can be quickly adjusted according to different market demands and product characteristics. Whether it is producing different varieties of products or adjusting the production process, the high-end production line can quickly adapt to meet the diverse needs of the market; Safety: The high-end production line of this application focuses on safe production. The AGV, equipment and tools used have high safety protection measures, which can effectively ensure the safety of workers and equipment. In addition, the production line is usually equipped with a safety monitoring system and an emergency shutdown device to ensure that measures can be taken quickly in case of abnormal situations to prevent accidents; High precision and high quality: The high-end production line of this application adopts advanced technology and precise control system, which can ensure that the precision and quality of the products reach a very high level. This can not only meet the market demand for high-quality products, but also improve the competitiveness and brand image of the enterprise.

[0022] Other embodiments of the present invention: AGV transfer equipment is used for automatic distribution or circulation of upright pianos and their accessories. Specifically, the AGV transfer equipment includes an AGV truck and an AGV forklift. The interior of the production line is provided with tracks for the AGV truck. The AGV forklift is used for picking up upright pianos or their accessories. The AGV forklift is adapted for use with the AGV truck. See also Figure 3 , a track route for AGV trucks to identify and move along is installed inside the factory. Under normal circumstances, the AGV truck will move along this track route to realize the circulation of pianos, reducing the time and cost of manual handling, thereby improving production efficiency. In addition, a laser radar is installed on the front of the AGV truck, so that the AGV truck can use the laser radar to identify obstacles and avoid AGV truck collisions. During production, the AGV truck can also flexibly adjust the transportation route and quantity according to production needs to adapt to production scenarios of different scales; In addition, the AGV truck compartment is equipped with an electromagnetic suction that can be compatible with the AGV forklift, so that the AGV forklift can be automatically positioned and used after being connected to the AGV truck, and the problem of the AGV equipment falling off during operation can be solved; In addition, the AGV forklift can accurately pick up the piano's fork hole through a visual solution during use. It can also be precisely assembled with the AGV truck, so that during the process of transporting the piano, there will be no transportation problems for the AGV equipment or the piano.

[0023] Other embodiments of the present invention: The supporting algorithm is set inside the AGV transfer component and is used for automatic circulation and allocation of accessories. Specifically, the supporting algorithm includes a composite algorithm, which includes an MES manufacturing execution algorithm implanted in the AGV truck and an IPC vision execution algorithm implanted in the AGV forklift. MES manufacturing execution algorithm (MES (Manufacturing Execution System) is a system used to manage and monitor the manufacturing process. It connects the enterprise's planning layer (such as ERP system) and the on-site operation layer (such as production equipment) to realize real-time data collection, production scheduling, quality management and other functions) is used for navigation, obstacle avoidance and scheduling when the AGV truck is in use. The MES manufacturing execution algorithm has a built-in allocation module for allocating AGV truck work tasks. The allocation module is used for route planning and tracking of AGV working trucks, as well as waiting and staying for loading and unloading. The allocation module is used for standby use and charging processing of idle AGV trucks, so when the AGV truck is in use The MES manufacturing execution algorithm can be used to manage working AGV trucks, and can also perform preparatory management on AGV trucks that are not working (such as charging, maintenance or idle). During the process, the MES manufacturing execution algorithm will intervene in the internal manufacturing management of working or non-working AGV trucks, read abnormal status in the AGV truck (such as abnormal alarms of the engine or motor, tire pressure, driving range, remaining fuel tank or battery, etc.), so as to prioritize the configuration of the AGV truck with the best status for work, store other AGV trucks with problems and report items to be repaired, effectively ensuring the service life of the AGV truck.

[0024] In addition, during the interaction between the AGV truck and the MES manufacturing execution algorithm, the AGV truck will work by generating the blockchain of the AGV truck, AGV forklift and piano accessories. If the hash value code of the specified AGV truck is A (a random string containing a combination of numbers and letters), the hash value code of the AGV forklift is B (a unique string like A), and the hash value code of the piano accessories is C (a unique string like A and B), then the hash value code ABC will be combined into a long hash value code string (the string has the information of ABC). Therefore, when the AGV truck interacts with the MES manufacturing execution algorithm, it will read and write the string and determine that the read and written string is ABC itself, thereby ensuring that the AGV truck, AGV forklift and piano accessories can be accurately circulated and transported after the MES manufacturing execution algorithm issues an order, avoiding errors in the circulation and transportation of AGV equipment that may lead to poor piano production.

[0025] Other embodiments of the present invention: IPC vision execution algorithm (IPC (Industrial PC) vision algorithm is usually used in the field of industrial automation and intelligent manufacturing, especially in machine vision, image processing and object recognition) is used for identification, forking and transportation when used by AGV forklift. The IPC vision execution algorithm has a built-in recognition module to assist the work of AGV forklift. The recognition module is used by AGV forklift to identify and select piano numbers and piano forking positions. The recognition module is used by AGV forklift to identify its position with the AGV truck boarding. In fact, the IPC algorithm of the prior art uses Gaussian filtering, median filtering and other technologies to reduce image noise, uses Canny, Sobel and other algorithms to extract edge information in the image, and uses Harris corner detection or Shi-Tomasi method to identify key points in the image, and then uses SIFT, SURF, ORB and other methods to describe and match image features, so as to identify objects in the image by comparing with predefined templates. The IPC vision execution algorithm of the first stage will also use convolutional neural network (CNN) to identify and classify complex objects. Its principle is to divide the image into foreground and background based on the convolutional neural network algorithm, and then expand the area according to the similarity of pixels, segment the target object, and use the optical flow method to detect the movement in the target object, and then filter out the noise background to establish a new background model, and after detecting dynamic objects, use the projection of specific light patterns to obtain the depth information of the object and reconstruct the three-dimensional scene to achieve the purpose of quality inspection (automatically detect product defects, such as scratches, deformation, color inconsistency, etc.), assembly monitoring (automatically identify parts according to the appearance to ensure that the parts are assembled correctly to avoid missing or wrong installation), robot navigation (help robots identify the environment, obstacles and target objects, and improve navigation capabilities), warehouse management (automatically identify and track inventory items to improve logistics efficiency), and safety monitoring (real-time monitoring of the production environment and detection of abnormal behavior or dangerous situations). Therefore, the IPC vision execution algorithm in this application includes an image computing unit, a point cloud computing unit, and a real-time settlement unit, wherein the image computing unit is used by the IPC vision execution algorithm to capture the piano fork holes and labels and the AGV truck boarding point pictures (i.e., to realize basic photography); The point cloud computing unit is used by the IPC vision execution algorithm to transform the pixels in the image into point cloud groups with point cloud information (i.e., the captured image is processed according to the disclosed IPC vision execution algorithm technology, following the steps of image preprocessing - feature extraction - object recognition and classification - image segmentation - motion detection - 3D reconstruction), and filter out erroneous point cloud information; Finally, the real-time settlement unit provides the IPC vision execution algorithm to recognize the point cloud and analyze the piano fork hole position, label information and AGV truck loading point position, so that the AGV forklift can smoothly and stably pick up the piano for use, and correctly identify the piano and connect it to the AGV truck; Other embodiments of the present invention: The AGV truck has a built-in Dijkstra algorithm for obstacle avoidance. The Dijkstra algorithm is preset with a computing node for updating the position of the AGV truck in real time. The AGV truck performs real-time computing node updates through the Dijkstra algorithm, that is, the Dijkstra algorithm compares the constantly changing nodes of the AGV truck with the initial nodes of the AGV truck, and then simulates the route that the next node of the AGV truck should take, thereby ensuring that the AGV truck can move correctly according to the preset program and avoiding the problem of the AGV truck running around.

[0026] The working principle of the present invention is: This application has the following two schemes Plan 1: The original piano production layout of the factory, in which the incoming material line includes the shell unpacking area and the piano back unpacking area for the inspection of incoming material accessories; after the inspection, the production line will transfer the incoming piano accessories to the card back line, sub-assembly line and assembly line for piano assembly. During the assembly period, the piano needs to be scraped, the sound head is touched, the sound head is repaired, the keyboard is installed, the action is installed, the primary / secondary sound head is arranged, and up to 6 times or more of the picking inspection; after the inspection, the assembled piano will be sent to The pianos are transferred to the inspection line for a general inspection, which includes the appearance repair, sound quality inspection and vibration humidification inspection of the piano. Therefore, the production and inspection sequence of the production line is plucking, action installation, keyboard installation, tuning, assembly, secondary sound head, appearance repair, sound quality and general inspection. Finally, the pianos are sent to the finished product storage area. Before they leave the factory, they are subject to another inspection for unqualified paint parts and pre-sale repair inspection, so as to prevent defective products from leaving the factory in bulk and affecting the quality of upright pianos leaving the production line. Plan 2: For the production layout after the factory improved and added AGV transfer equipment, Plan 2 follows the process flow of piano production in Plan 1 (pluck, install action, install keyboard, tune, complete assembly, secondary sound head, appearance repair, sound quality and general inspection, and finally enter the finished product storage area). In addition, the operation of AGV transfer equipment for transfer is realized between each process - that is, the piano is transported from entering the line to the appearance through AGV transfer equipment (including AGV trucks and AGV forklifts) during the operation of the equipment in the incoming material line, card back line, sub-assembly line, assembly line and inspection line. At the same time, intermediate process inspections are added in the three processes of installing action, sorting and assembly to ensure that problems are found and solved as early as possible during the piano assembly process, and finally achieve the production of high-quality pianos.

[0027] What has been described above are only preferred specific implementations of the present invention, but the protection scope of the present invention is not limited thereto. Any technician familiar with the technical field, within the technical scope disclosed by the present invention, can make equivalent replacements or changes based on the technical solutions and inventive concepts of the present invention, which should be covered by the protection scope of the present invention.

Claims

1. An integrated production line for upright pianos, characterized in that: The invention comprises a production line for manufacturing upright piano parts and for tuning and assembling upright pianos; AGV transfer equipment, the AGV transfer equipment is used for automatic distribution or circulation of upright pianos and their accessories; and A matching algorithm is arranged inside the AGV transfer component and is used for automatic circulation and allocation of accessories.

2. The integrated production line for upright pianos according to claim 1, characterized in that: The production line includes an incoming material line, a card back line, a sub-assembly line and a complete assembly line. The incoming material line provides and inspects raw materials for the production line, the card back line produces and assembles piano frames and back panels through a card back machine, the sub-assembly line connects and assembles strings to the piano through a hammer machine, and the complete assembly line assembles the entire piano and allows it to be shipped out of the factory.

3. The integrated production line for upright pianos according to claim 2, characterized in that: The AGV transfer equipment includes an AGV truck and an AGV forklift. The interior of the production line is paved with tracks for the AGV truck. The AGV forklift is used for picking up upright pianos or their accessories. The AGV forklift is compatible with the AGV truck.

4. The integrated production line for upright pianos according to claim 3 is characterized in that: The supporting algorithm includes a composite algorithm, which includes an MES manufacturing execution algorithm implanted in an AGV truck and an IPC vision execution algorithm implanted in an AGV forklift. The MES manufacturing execution algorithm is used for navigation, obstacle avoidance and scheduling when the AGV truck is used, and the IPC vision execution algorithm is used for identification, forking and transportation when the AGV forklift is used.

5. The integrated production line for upright pianos according to claim 4, characterized in that: The invention also comprises an inspection line, which is arranged at the rear end of the production line and is used for the factory inspection of the assembled upright piano.

6. The integrated production line for upright pianos according to claim 5, characterized in that: The MES manufacturing execution algorithm has a built-in allocation module for allocating AGV truck work tasks. The allocation module is used for route planning and tracking of AGV working trucks, as well as waiting and stopping for loading and unloading materials. The allocation module is used for standby use and charging processing of idle AGV trucks.

7. The integrated production line for upright pianos according to claim 6, characterized in that: The IPC vision execution algorithm has a built-in recognition module to assist the AGV forklift in its work. The recognition module is used by the AGV forklift to identify and select the piano number and piano fork pick-up position. The recognition module is used by the AGV forklift to identify its position relative to the AGV truck boarding position.

8. The integrated production line for upright pianos according to claim 7, characterized in that: The IPC vision execution algorithm includes an image computing unit, a point cloud computing unit and a real-time settlement unit. The image computing unit allows the IPC vision execution algorithm to capture pictures of piano fork holes and labels as well as AGV truck boarding points. The point cloud computing unit allows the IPC vision execution algorithm to convert pixels in the picture into point cloud groups with point cloud information. The real-time settlement unit allows the IPC vision execution algorithm to identify point clouds and analyze the positions of piano fork holes, label information and AGV truck boarding points.

9. The integrated production line for upright pianos according to claim 8, characterized in that: The AGV truck has a built-in Dijkstra algorithm for obstacle avoidance, and the Dijkstra algorithm is preset with a computing node for updating the position of the AGV truck in real time.

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