Spraying assembly line information management system

Abstract

The invention relates to the technical field of spraying assembly lines, and discloses a spraying assembly line information management system which comprises a coating assembly line digital platform, an automatic sand blasting process information management system and a putty polishing process information management system. Through the design of the automatic sand blasting process information management system, the putty polishing process information management system, the primer / floating coat automatic spraying process information management system and the finishing coat automatic spraying process information management system, accurate monitoring and management in the vehicle production process are achieved, and information exchange among all the processes is smoother; in addition, the information exchange efficiency is improved, the production efficiency and the product quality are improved, meanwhile, through application of the digital twin technology, real-time optimization of the production process and rapid problem positioning are achieved, resource waste and the error rate are reduced, real-time monitoring and data collection and analysis of the production process are achieved, and the production efficiency and the product quality are improved. And the automation degree and efficiency of the sand blasting and spraying procedures are greatly improved.

Description

Technical Field

[0001] The present invention relates to the technical field of spraying production lines, and specifically to an information management system for a spraying production line. Background Art

[0002] A spraying production line, also known as a painting production line, is a production line tool specifically used for covering a protective layer or a decorative layer on the surfaces of metals and non-metals. It is mainly used for the painting operations of single-piece or small-batch workpieces, and is applicable to the spray painting and spray coating treatments of the surfaces of workpieces.

[0003] Currently, there are some problems with spraying production lines, such as low process efficiency, serious information silo phenomenon, lack of unified data management and real-time monitoring systems, resulting in difficulties in timely discovering and solving problems during the production process. The present invention realizes the real-time monitoring and data analysis of the production process by establishing a centralized information management system, significantly improving the working efficiency and quality control level of the spraying production line. Summary of the Invention

[0004] The purpose of the present invention is to provide an information management system for a spraying production line to solve the problems raised in the above background art.

[0005] To achieve the above purpose, the present invention provides the following technical solution: An information management system for a spraying production line includes a digital platform for a painting production line, an information management system for an automatic sandblasting process, an information management system for a putty grinding process, an information management system for an automatic primer / midcoat spraying process, an information management system for an automatic topcoat spraying process, and a on-site monitoring room. The digital platform for the painting production line consists of 1 server and 11 on-site MES workstations, and the PLC, data management workstation, and server of the spraying production line are built based on an industrial Ethernet and are all connected through an Ethernet; Among them, the server is used for data storage, data query, and analysis. At the same time, this server is also a server for WEB access, and data query, analysis, visualization, and digital twin display can also be completed by accessing this server through the web method; The on-site MES workstations are responsible for on-site data collection, on-site signal collection, and anti-error traceability verification work with a scanning gun; The on-site monitoring room monitors the production status of the production line through a digital twin system.

[0006] Preferably, the information management system for the automatic sandblasting process includes a vehicle type identification module for the sandblasting process, a sandblasting production management module, a sandblasting data collection module, a digital twin monitoring module for the sandblasting process, a data analysis module for the sandblasting process, and a production kanban module.

[0007] Preferably, the vehicle type identification module of the sandblasting process is signal-connected to the sandblasting production management module, the sandblasting production management module is signal-connected to the sandblasting data acquisition module, the sandblasting data acquisition module is signal-connected to the digital twin monitoring module and the data analysis module of the sandblasting process, and the data analysis module of the sandblasting process is signal-connected to the production board module.

[0008] Preferably, the information management system for the putty sanding process includes a sanding process flow monitoring module, a vehicle type identification module for the sanding process, a production management module for the sanding process, a data acquisition module for the sanding process, a sanding quality management module, a sanding energy consumption monitoring module, a digital twin monitoring module for the sanding process, and a data analysis module for the sanding process.

[0009] Preferably, the sanding process flow monitoring module is signal-connected to the vehicle type identification module of the sanding process, the vehicle type identification module of the sanding process is signal-connected to the production management module of the sanding process, the production management module of the sanding process is signal-connected to the data acquisition module of the sanding process, the data acquisition module of the sanding process is signal-connected to the sanding quality management module, the sanding quality management module is signal-connected to the sanding energy consumption monitoring module, and the sanding energy consumption monitoring module is signal-connected to the digital twin monitoring module of the sandblasting process and the data analysis module of the sanding process.

[0010] Preferably, both the information management system for the primer / intermediate coat automatic spraying process and the information management system for the topcoat automatic spraying process include a spraying process flow monitoring module, a vehicle type identification module for the spraying process, a production management module for the spraying process, a spraying data acquisition module, a spraying process quality management module, a digital twin monitoring module for the spraying process, and a data analysis module for the spraying process.

[0011] Preferably, the spraying process flow monitoring module is signal-connected to the vehicle type identification module of the spraying process, the vehicle type identification module of the spraying process is signal-connected to the production management module of the spraying process, the production management module of the spraying process is signal-connected to the spraying data acquisition module, the spraying data acquisition module is signal-connected to the spraying process quality management module, and the spraying process quality management module is signal-connected to the digital twin monitoring module and the data analysis module of the spraying process.

[0012] The present invention provides a spraying production line information management system, which has the following beneficial effects: (1) Through the design of the automatic sandblasting process information management system, putty grinding process information management system, primer / intermediate coat automatic spraying process information management system, and topcoat automatic spraying process information management system, the present invention realizes precise monitoring and management during the vehicle production process, making the information exchange between various processes smoother. In addition, the information exchange efficiency is improved, enhancing production efficiency and product quality. Meanwhile, through the application of digital twin technology, real-time optimization of the production process and rapid problem positioning are achieved, reducing resource waste and error rates, enabling real-time monitoring, data collection, and analysis of the production process, and greatly enhancing the automation degree and efficiency of the sandblasting and spraying processes.

[0013] (2) The present invention uses the digital twin system to track and record operations, the working status of main equipment, production quality data, material conditions, and quality problems on the production line during the entire automated production process; the production information is accurately and timely fed back to production management personnel at all levels in a digital and graphical manner, and the production information is presented to the central control room in the form of a management dashboard to ensure that the operating status of production activities is within monitoring. Brief Description of the Drawings

[0014] Figure 1 It is the overall block diagram of an information management system for a spraying production line of the present invention; Figure 2 It is the block diagram of the automatic sandblasting process information management system of the present invention; Figure 3 It is the block diagram of the putty grinding process information management system of the present invention; Figure 4 It is the block diagram of the primer / intermediate coat automatic spraying process information management system and the topcoat automatic spraying process information management system of the present invention; Figure 5 It is the analysis diagram of the equipment OEE of the present invention; Figure 6 It is the digital twin monitoring dashboard diagram of the present invention. Detailed Embodiments

[0015] Next, the technical solutions in the embodiments of the present invention will be clearly and completely described in conjunction with the accompanying drawings in the embodiments of the present invention. Obviously, the described embodiments are only a part of the embodiments of the present invention, rather than all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those of ordinary skill in the art without creative efforts shall fall within the protection scope of the present invention.

[0016] Examples of the embodiments are shown in the accompanying drawings, where the same or similar reference numerals throughout denote the same or similar elements or elements having the same or similar functions. The embodiments described below by reference to the accompanying drawings are exemplary and are intended to explain the present invention and should not be construed as limiting the present invention.

[0017] A preferred embodiment of an information management system for a spraying production line provided by the present invention is as Figure 1-6 shown: An information management system for a spraying production line includes a digital platform for the painting production line, an information management system for the automatic sandblasting process, an information management system for the putty grinding process, an information management system for the automatic spraying process of the primer / intermediate coat, an information management system for the automatic spraying process of the topcoat, and a on-site monitoring room. The digital platform for the painting production line consists of 1 server and 11 on-site MES workstations, and PLCs, data management workstations, and servers for constructing the spraying production line are based on the industrial Ethernet and are all connected through the Ethernet; Among them, the server is used for data storage, data query and analysis. At the same time, this server is also a server for WEB access. Data query and analysis, visualization, and digital twin display can also be completed by accessing this server through the web method; The on-site MES workstations are responsible for on-site data collection, on-site signal collection, and anti-error traceability verification work for the scanning gun verification; The on-site monitoring room monitors the production status of the production line through the digital twin system; the visual screen can display the layout structure diagram of the automatic painting production line and the current production order; display the status of each device (in operation, waiting, and faulty), and can also display the real-time production dynamics, and realize the statistics and analysis of production data in various ways such as pie charts, bar charts, line charts, or statistical tables; Establish a digital model of the entire production line (virtual production line), including the visual display of the workshop process environment (temperature, humidity), equipment, vehicle bodies, etc.; Support the display of relevant information such as the real-time status, working conditions, faults, OEE, etc. of the equipment in the workshop in a three-dimensional layout manner; The digital twin system of this project is implemented in a WEB manner, and the three-dimensional model of the equipment receives on-site equipment signals in real time through the browser. The movement of the digital twin system model runs synchronously with the on-site equipment according to the on-site equipment signals; The digital model of the entire production line (virtual production line) realizes digital twin through real-time interaction with the on-site equipment according to the equipment signals; The digital twin system can import models, define the kinematic attributes of the equipment, and realize equipment process planning, robot sandblasting process planning, robot spraying process planning, model-signal binding of the equipment, virtual simulation of the digital model of the entire production line, and virtual commissioning of the digital model of the entire production line without programming through the configuration method; The digital twin system is implemented in a WEB manner to display the digital twin system on the PC side, mobile device side, and mobile phone side; The digital twin system can be easily embedded into the existing information management system of the enterprise and seamlessly connected to the existing information system of the enterprise; the digital twin system of this project can be easily embedded into the third-party information management system and seamlessly connected to the third-party WEB-based information system.

[0018] Truly reproduce the production scene and operation status of the production line, understand the production details of the equipment, and monitor the production and equipment operation status in real time. Integrate with the production site control system to synchronously display production data in the twin system. It includes production reports, quality data, product traceability, data analysis charts, monitoring center dashboards, etc.

[0019] Monitoring of the operation parameters of the automated painting production line equipment: When clicking on a specific equipment model in the digital twin system, the model highlights the feedback point, and the operation parameter information of the equipment pops up.

[0020] Analysis of specific equipment charts of the automated painting production line: When clicking on a specific model in the digital twin system, the model highlights the feedback point, and the monitoring cover page of the equipment operation parameters pops up, showing the chart analysis of the equipment data, including OEE analysis, production volume analysis, downtime analysis, alarm analysis, etc., providing a basis for management decision-making on equipment.

[0021] Electronic dashboard of the automated painting production line: The display form is a hovering GUI interface, used to display information such as the current production task and status, planned production volume, and actual production volume. The automatic sandblasting process information management system includes a sandblasting process vehicle type identification module, a sandblasting production management module, a sandblasting data collection module, a sandblasting process digital twin monitoring module, a sandblasting process data analysis module, and a production dashboard module; Sandblasting process vehicle type identification module: Used to identify the vehicle body by integrating vehicle type identification technology, manually pick the vehicle body identification QR code sign, scan the code at the workstation to identify the vehicle body, and the system automatically retrieves the sandblasting process flow and executes it. If the identification fails, an alarm is immediately issued, and the operator needs to re-enter the vehicle body identification QR code to ensure the accuracy of each vehicle's information; Sandblasting production management module: Used to display the current production plan number, vehicle body type, sandblasting start time, process execution personnel information, current beat, and team production volume at the sandblasting station, and to track and adjust the production process in real time to meet the special needs of different vehicle types; Sandblasting data collection module: Used to continuously collect various parameters of the sandblasting operation (such as environmental data: temperature, humidity; material data: sandblasting parameters; production data: sandblasting pressure, sandblasting coordinates, production time; energy consumption data: power consumption, power consumption; equipment status: on, off, idle, alarm), ensuring the consistency and traceability of the spraying quality; Sandblasting process digital twin monitoring module: It is used to monitor the sandblasting system, overhead crane dynamic gantry system, automatic sandblasting device, shot supply system, and vehicle body moving and fixing device in this process. In the 3D scene model of this station, the current vehicle body position, sandblasting robot position and actions can be viewed in real time, and the production scene in the sandblasting room in the real field. At the same time, information such as production parameters, energy consumption parameters, and environmental parameters is displayed; Sandblasting process data analysis module: Analyze the collected data in real time and generate visual analysis charts, such as material usage, production rhythm, alarm information statistics, etc., to realize production monitoring, quality monitoring, equipment status monitoring, equipment alarm monitoring, environmental monitoring, energy consumption monitoring, and safety monitoring of the sandblasting process; Production dashboard module: Provide real-time production status and key performance indicators (KPIs), and display the production efficiency and completion status of each station through a large screen; The putty grinding process information management system includes a grinding process flow monitoring module, a grinding process vehicle model identification module, a grinding process production management module, a grinding process data collection module, a grinding quality management module, a grinding energy consumption monitoring module, a grinding process digital twin monitoring module, and a grinding process data analysis module; Grinding process flow monitoring module: Through the production line monitoring system, understand the current production status of each automatic station on the production line, the position and estimated arrival time of the vehicle body to reach this station, the estimated completion time of the vehicle body at this station, and the production status of the next process, etc.; Grinding process vehicle model identification module: Manually pick up the vehicle body identification QR code sign, scan the code at the station scanning location to identify the vehicle body, and the system compares with the production plan to confirm the production plan information to be executed. If the identification fails, the system will alarm, and the operator needs to re-enter the vehicle body identification QR code manually. The system automatically retrieves the putty grinding process flow corresponding to the plan and executes it; Grinding process production management module: Display the production plan number, vehicle body model, sandblasting start time, process execution personnel information, current rhythm, team output currently being executed at the sandblasting station, the current production status of this station: automatic / manual, and the current status of the grinding robot: scanning / grinding / detecting; Grinding process data collection module: Collect key data during the grinding process, including environmental data: temperature, humidity; material data: putty parameters, putty application plan, information of the program being executed; production data: grinding position; manual detection data: putty thickness; energy consumption data: power consumption, power consumption; equipment status: on, off, idle, alarm; alarm information: personnel intrusion alarm, environmental over-standard alarm, equipment failure alarm, electrical fault alarm, etc.; Grinding quality management module: Manually detect data, compare it with the detection standard to judge the detection result, and at the same time record the process plan and quality report used in production, generate a vehicle body surface quality report, and putty application plan information: Polishing energy consumption monitoring module: Monitor the voltage, current and power energy consumption of the production line. Alarm when the consumption exceeds the predetermined value. Analyze the trend of periodic energy consumption: Digital twin monitoring module for the polishing process: In the 3D scene model of this station, real-time display the current position of the vehicle body, the displacement and actions of the polishing robot, and truly reproduce the production scene of the polishing operation in the actual site. At the same time, display the production parameter information: Data analysis module for the polishing process: The system automatically counts production data, such as material usage, quality inspection, production rhythm, alarm information statistics, etc., and conducts chart analysis on the data to achieve production monitoring, quality monitoring, equipment monitoring, environmental monitoring, and energy consumption monitoring of the polishing process: Both the primer / intermediate coat automatic spraying process information management system and the topcoat automatic spraying process information management system include a spraying process flow monitoring module, a spraying process vehicle model identification module, a spraying process production management module, a spraying data collection module, a spraying process quality management module, a spraying process digital twin monitoring module, and a spraying process data analysis module; Spraying process flow monitoring module: Responsible for tracking the current production plan number, vehicle body model information, spraying start time, and process execution personnel information at the spraying station; Spraying process vehicle model identification module: Manually pick up the vehicle body identification QR code sign, scan the code at the station to identify the vehicle body model, and the system automatically retrieves the process flow and parameters of this model and executes them; Spraying process production management module: Manage the current production status of the station, automatic / manual operation mode, record key operator information, spraying volume, and spray gun operation status during spraying; Spraying data collection module: Collect key data during spraying, including environmental data: painting temperature / humidity, drying temperature / humidity, painting duration, drying duration; material data: paint parameters, coating consumption, automatic cleaning time; manual touch-up painting: touch-up start time, touch-up end time; quality inspection: manual quality inspection, and the inspection results are manually entered into the information system; production data: spraying position, spraying pressure; manual detection data: coating thickness; energy consumption data: current, voltage, power; fuel supply system status: on, off, idle, alarm; alarm information: personnel intrusion alarm, environmental over-standard alarm, equipment failure alarm, electrical fault alarm, etc.; Spraying process quality management module: Manually detect the coating thickness, compare it with the preset standard, evaluate the coating quality, record the results of each spraying, ensure that the coating meets the design requirements, form a coating quality report, and detail the data of each coating link to provide a basis for subsequent quality improvement; Digital twin monitoring module for spraying process: establish a digital model of this process (virtual spraying), including a visual display of the spraying process environment (temperature, humidity), equipment, materials, tools, etc.; display the real-time status, working conditions, faults, OEE and other related information of the equipment in the spraying room in a three-dimensional layout; the three-dimensional model of the equipment receives the on-site equipment signal in real time through the browser, and the movement of the digital twin system model is driven by the on-site PLC and runs synchronously with the on-site equipment; realize the digital twin monitoring system, and view the current vehicle position, the displacement and movement of the reciprocating spraying equipment and the spray gun in real time in the three-dimensional scene of this spraying process, truly reproduce the production scene of the spraying site, and display the production parameter information at the same time.

[0022] When in use, when the factory information management system issues a new production line plan, the automatic painting line information system automatically receives the production plan and makes additions, deletions and adjustments based on the actual production situation. When the car body is on the line, it can automatically identify the car body and compare it with the production plan to confirm the production plan; the production plan information currently executed by the production line can be synchronously fed back to the factory information management system. The production plan is mainly entered into the system manually. The order execution sequence is based on the planned production time of the order. The order sequence can be adjusted according to the actual situation on site. This system can realize emergency order insertion; The automated painting line information system tracks the flow of car bodies in the production line in real time, collects the production plan, output, production teams, car body information, current workstation information, executed process formula information and quality inspection information of the painting line. When the information is abnormal, the system automatically alarms and displays it prominently on the dashboard; The production line receives the process method issued by the factory information management system and updates the production line process library. At the same time, it also edits the production line process under authorization, records the production line process method, and prints a report for the operator's reference; The device then monitors: Device status monitoring: monitors the on, off, idle, and alarm status of devices.

[0023] Equipment alarm monitoring: Collect alarm information, including alarm type, alarm release, duration, and perform alarm statistics and alarm frequency analysis.

[0024] Equipment management, tooling management, tool management, and auxiliary equipment management: record information such as equipment usage, loss, and utilization efficiency, including paint material quotas and equipment consumables replacement.

[0025] Secondly, energy consumption monitoring: Monitor the current, voltage, power and gas consumption of the production line, realize real-time display of energy consumption and alarm when exceeding the preset value, and realize periodic energy consumption trend analysis.

[0026] Then monitor the production status: Overall production situation monitoring: Based on the scanning data of each up and down line point, it shows the online quantity, in-line quantity, offline quantity of the current shift and the corresponding product details in real time.

[0027] Real-time data monitoring: Integrate the real-time display of product queues on the spraying production line and the display of quality inspection information to achieve the monitoring of the entire spraying production line. Through the monitoring interface, the current product production situation on the spraying production line can be seen.

[0028] Equipment failure information monitoring: Query the occurrence of equipment failures. The failure information comes from the failure codes collected by the on-site equipment PLC and the failure buttons pressed by the operators. The system will automatically record the information such as the workstations and times when the failures occur.

[0029] Equipment processing time collection: The equipment PLC communicates directly with the server to feedback the equipment processing time, and the actual processing cycle time is recorded separately for each single equipment by the equipment PLC and uploaded to the server.

[0030] Equipment OEE analysis: Calculate the overall equipment effectiveness (OEE) of each workstation and generate charts.

[0031] OEE = Availability × Performance Efficiency × Quality Rate × 100%. Through the analysis of each sub-item of the OEE model, it can accurately reflect how the equipment efficiency is, how much loss there is in which production link, and propose improvement work to achieve the purpose of improving production efficiency.

[0032] Availability = Operating Time / Loading Time; Among them, Loading Time = Working Time - Scheduled Downtime - Downtime due to External Equipment Factors; Operating Time = Loading Time - Breakdown Downtime - Equipment Adjustment and Initialization Time (including the time used for activities such as changing product specifications and replacing tooling and fixtures) Performance Efficiency = Net Operating Rate × Speed Operating Rate; Quality Rate = Number of Qualified Products / Number of Processed Products; Finally, conduct quality management: Manually enter the equipment inspection data, compare it with the inspection standards to judge the inspection results. At the same time, record the process plans and quality reports used in production; record the quality status of the vehicle paint coating; robot processing process parameter correction information. Combine the pre-developed process parameter library (the core is the relationship between the robot processing speed and the putty grinding removal amount), correct the speed parameters in the robot processing path, so as to ensure that the putty thickness after processing reaches the prefabricated thickness value; be able to print and query the vehicle paint coating quality inspection data; the vehicle body surface quality report; the putty scraping plan information.

[0033] It should be noted that in this text, relational terms such as first and second are only used to distinguish one entity or operation from another entity or operation, and do not necessarily require or imply any actual relationship or order between these entities or operations. Moreover, the term "comprising", "including" or any other variant thereof is intended to cover non-exclusive inclusion, so that a process, method, article or device comprising a series of elements not only includes those elements, but also includes other elements not expressly listed, or elements inherent to such process, method, article or device.

[0034] Finally, it should be noted that the above are only preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some of the technical features. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A spraying line information management system, including a painting line digital platform, an automatic sandblasting process information management system, a putty grinding process information management system, a primer / midcoat automatic spraying process information management system, a topcoat automatic spraying process information management system and an on-site monitoring room, characterized in that: The digital platform of the painting line consists of 1 server and 11 on-site MES workstations. The PLC, data management workstation and server of the painting line are built based on industrial Ethernet, and all are connected via Ethernet. The server is used for data storage, data query and analysis. It is also a WEB access server. Accessing the server via the web can also complete data query and analysis, visualization, and digital twin display. The on-site MES workstation is responsible for on-site data collection, on-site signal collection, and scanner verification, error prevention, and traceability verification; The on-site monitoring room monitors the production status of the production line through a digital twin system.

2. A spraying line information management system according to claim 1, characterized in that: The automatic sandblasting process information management system includes a sandblasting process vehicle type identification module, a sandblasting production management module, a sandblasting data acquisition module, a sandblasting process digital twin monitoring module, a sandblasting process data analysis module, and a production kanban module.

3. A spraying line information management system according to claim 2, characterized in that: The sandblasting process vehicle model identification module is signal-connected to the sandblasting production management module, the sandblasting production management module is signal-connected to the sandblasting data acquisition module, the sandblasting data acquisition module is signal-connected to the sandblasting process digital twin monitoring module and the sandblasting process data analysis module, and the sandblasting process data analysis module is signal-connected to the production kanban module.

4. A spraying line information management system according to claim 1, characterized in that: The putty polishing process information management system includes a polishing process flow monitoring module, a polishing process vehicle type identification module, a polishing process production management module, a polishing process data acquisition module, a polishing quality management module, a polishing energy consumption monitoring module, a polishing process digital twin monitoring module, and a polishing process data analysis module.

5. A spraying line information management system according to claim 4, characterized in that: The polishing process flow monitoring module is signal-connected to the polishing process vehicle type identification module, the polishing process vehicle type identification module is signal-connected to the polishing process production management module, the polishing process production management module is signal-connected to the polishing process data acquisition module, the polishing process data acquisition module is signal-connected to the polishing quality management module, the polishing quality management module is signal-connected to the polishing energy consumption monitoring module, and the polishing energy consumption monitoring module is signal-connected to the sandblasting process digital twin monitoring module and the polishing process data analysis module.

6. A spraying line information management system according to claim 1, characterized in that: The primer / midcoat automatic spraying process information management system and the topcoat automatic spraying process information management system both include a spraying process flow monitoring module, a spraying process vehicle type identification module, a spraying process production management module, a spraying data acquisition module, a spraying process quality management module, a spraying process digital twin monitoring module, and a spraying process data analysis module.

7. A spraying line information management system according to claim 6, characterized in that: The spraying process flow monitoring module is signal-connected to the spraying process vehicle type identification module, the spraying process vehicle type identification module is signal-connected to the spraying process production management module, the spraying process production management module is signal-connected to the spraying data acquisition module, the spraying data acquisition module is signal-connected to the spraying process quality management module, and the spraying process quality management module is signal-connected to the spraying process digital twin monitoring module and the spraying process data analysis module.

Images