Production line output performance index evaluation method based on code scanning data

Abstract

The invention discloses a production line output performance index evaluation method based on code scanning data, and relates to the technical field of data processing, and the method comprises the steps: firstly, obtaining the position information of production line equipment and a production line output performance standard index according to a factory layout map and a product production plan, and deploying code scanning equipment and a sensor; and constructing a digital space coordinate system and labeling related information. Secondly, code scanning equipment is used for collecting code scanning data in real time, and the code scanning data used for evaluation are accurately obtained through the processes of verification, validity judgment, multi-round code scanning comparison and the like; meanwhile, information such as equipment temperature is collected by means of various sensors. And then, evaluating code scanning data to obtain a production line output performance index, comparing the production line output performance index with a standard index, locking an abnormal production line and equipment, tracing operation information of the corresponding equipment, pushing a visual alarm, and assisting personnel in judging an abnormal reason. According to the method, abnormal data are effectively filtered, equipment is monitored in real time, and the production line performance evaluation accuracy and management efficiency are improved.

Description

Technical Field

[0001] The present invention relates to the technical field of data processing, and more particularly to a method for evaluating production line output performance indicators based on scanned code data. Background Art

[0002] In the manufacturing industry, production line efficiency is one of the important indicators to measure factory productivity. To monitor the production line status in real time and optimize the production process, enterprises usually rely on data collection and analysis systems. Among them, two-dimensional code or bar code scanning, as a mature technology, is widely used in fields such as product tracking, inventory management, and quality control. By automatically reading this encoded information through a scanning head, accurate data recording can be achieved for each link on the production line.

[0003] The existing methods for evaluating production line output performance indicators based on scanned code data cannot effectively filter abnormal data, such as data that does not meet the conditions or duplicate scans, and also lack the ability to monitor the running status of equipment in real time, making it difficult to determine the cause of a failure in a timely manner and respond to the failure. Therefore, a method for evaluating production line output performance indicators based on scanned code data is needed to solve the above problems. Summary of the Invention

[0004] To solve the above technical problems, a method for evaluating production line output performance indicators based on scanned code data is provided. This technical solution solves the problems in the above background art that the existing methods for evaluating production line output performance indicators based on scanned code data cannot effectively filter abnormal data, such as data that does not meet the conditions or duplicate scans, and also lack the ability to monitor the running status of equipment in real time, making it difficult to determine the cause of a failure in a timely manner and respond to the failure.

[0005] To achieve the above object, the technical solution adopted by the present invention is as follows:

[0006] A method for evaluating production line output performance indicators based on scanned code data, comprising:

[0007] S1. Obtain the factory layout diagram and the product production plan from within the factory, then obtain the production line equipment location information from the factory layout diagram, and obtain the production line output performance standard indicators from the product production plan. According to the production line equipment location information, deploy scanning devices and sensors;

[0008] S2. Use the scanning devices to obtain in real time the scanned code data for evaluating the production line output performance indicators. At the same time, collect the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information in real time through the deployed sensors and the built-in sensors of the production line equipment. Then evaluate the scanned code data to obtain the production line output performance indicators for different production lines;

[0009] S3. Compare the production line output performance indicators of different production lines with the corresponding production line output performance standard indicators, obtain the information of abnormal production lines where the production line output performance indicators are lower than the production line output performance standard indicators, determine the abnormal equipment information based on the abnormal production line information, trace the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information corresponding to the abnormal equipment, and evaluate the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information corresponding to the abnormal equipment to obtain the cause of the abnormality.

[0010] In an alternative embodiment, the obtaining of the production line equipment position information from the factory layout diagram specifically includes:

[0011] Based on the factory layout diagram, obtain the workshop structure information and area information. The workshop structure information includes equipment physical position information, passage information, and power source point information. The area information includes assembly area information and quality inspection area information;

[0012] Determine the power source point position information based on the power source point information, and construct a digital space coordinate system with any power source point position information as the origin;

[0013] Determine the production line equipment position information in the digital space coordinate system according to the equipment physical position information and passage information. At the same time, label the production line equipment in the digital space coordinate system with equipment IDs and area tags based on the production line equipment position information and area information.

[0014] In an alternative embodiment, the obtaining of the production line output performance standard indicators from the product production plan specifically includes:

[0015] The product production plan is exported from the internal ERP system of the factory. The product production plan includes the total product production demand, available production time, and required good product rate;

[0016] Use the ratio of the available production time to the total product production demand as the tact time;

[0017] Based on the factory layout diagram, obtain the number of production lines, and use the ratio of the tact time to the number of production lines as the production line tact time;

[0018] Import the production line tact time and required good product rate into the same Excel table to obtain the production line output performance standard indicators.

[0019] In an alternative embodiment, the deployment of the barcode scanning device and sensor according to the production line equipment position information specifically includes:

[0020] Compare the factory layout diagram and the product production plan to determine the production logic sequence of the production line equipment;

[0021] Mark the material flow path in the digital space coordinate system according to the production logic sequence of the production line equipment;

[0022] Generate a production line topology diagram based on the production line equipment location information and the production logic sequence of the production line equipment in the digital space coordinate system, and embed the marked material flow path, equipment ID, and area label into the production line topology diagram;

[0023] Based on the production line topology diagram, determine the workstation entrance coordinates and material transfer point coordinates in the digital space coordinate system;

[0024] Taking the workstation entrance coordinates and the material transfer point coordinates as a reference, deploy a barcode scanning device on the Z-axis of the workstation entrance coordinates and the material transfer point coordinates;

[0025] Obtain the first production line equipment location information corresponding to the workstation entrance coordinates, and at the same time obtain the second production line equipment location information corresponding to the material transfer point coordinates. The second production line equipment location information is the location information corresponding to the two production line equipment closest to the material transfer point coordinates in the material flow path;

[0026] Based on the first production line equipment location information and the second production line equipment location information, obtain the historical material flow speed, and determine the rotation speed and initial angle of the barcode scanning device with the average value of the historical material flow speed;

[0027] Based on the production line equipment location information in the digital space coordinate system, determine the production line equipment specification information and the production line equipment production task information corresponding to the production line equipment location information;

[0028] Judge whether to deploy sensors at the production line equipment location according to the production line equipment specification information and the production line equipment production task information.

[0029] In an optional embodiment, the use of the barcode scanning device to obtain in real time the barcode scanning data for evaluating the production line output performance indicators specifically includes:

[0030] Obtain the initial barcode scanning data value Co S1 , and perform preliminary verification on Co S1 , including digit verification and regular expression verification. The barcode scanning data value includes basic barcode scanning data, process operation data, and advanced association data;

[0031] Perform validity determination on the verified Co S1 :

[0032] If the verified Co S1 is invalid, call the next barcode scanning device corresponding to Co S1 , and use the next barcode scanning device to perform multiple barcode scans to obtain the secondary barcode scanning data values Co S2 and Co S3 , and perform verification on the secondary barcode scanning data values Co S2 and CoS3 Make a comparison to determine whether the two scanned code data values are the same. If they are the same, use Co S3 as the scanned code data S for evaluating the production line output performance indicator n , if they are different, call the next scanned code device of this scanned code device to perform multiple scans until Co S2n and Co S3n when they are the same S3n as the scanned code data S for evaluating the production line output performance indicator n , if the two scanned code data values are still different when reaching the last scanned code device, exit the scanning;

[0033] If the verified Co S1 is valid, call the next scanned code device of the scanned code device corresponding to Co S1 to perform a single scan on the material to obtain the single scan data value Co S4 ;

[0034] Judge whether there are production line devices between Co S1 and Co S4 through the production line topology diagram:

[0035] If so, judge whether the scanned code data values of Co S1 and Co S4 are the same. If they are the same, it proves that there is an abnormality in the production line device and mark the abnormal device in the production line topology diagram. If they are different, it proves that the production line device is normal. Co S1 and Co S4 are both the scanned code data S corresponding to the current time point for evaluating the production line output performance indicator n ;

[0036] If not, judge whether the scanned code data values of Co S1 and Co S4 are the same. If they are the same, use Co S4 as the scanned code data S for evaluating the production line output performance indicator n , if they are different, call the next scanned code device of this scanned code device to perform multiple scans to obtain the secondary scanned code data values Co S5n and Co S6n until Co S5n and Co S6n when they are the same S6n as the scanned code data S for evaluating the production line output performance indicator n , if the two scanned code data values are still different when reaching the last scanned code device, exit the scanning.

[0037] In an alternative embodiment, the temperature distribution information, vibration distribution information, and power information of the equipment during operation are collected in real time through the deployed sensors and the built-in sensors of the production line equipment, specifically including:

[0038] The deployed sensors include temperature sensors, vibration sensors, and power sensors;

[0039] The temperature sensor selects an infrared thermometer and obtains a temperature heat map with a collection unit of 1 second;

[0040] The vibration sensor uses a wireless accelerometer to monitor the bearing and gearbox with a collection unit of 1 minute and obtains a vibration spectrum diagram;

[0041] The power sensor uses a CT current transformer to monitor the real-time power of the production line equipment and obtains a power trend diagram;

[0042] Through the deployed sensors and the built-in sensors of the production line equipment, the temperature heat map, vibration spectrum diagram, and power trend diagram corresponding to each equipment are collected in real time, and the temperature heat map, vibration spectrum diagram, and power trend diagram corresponding to the same equipment are respectively stored in corresponding files to obtain the equipment temperature distribution information, equipment vibration distribution information, and equipment operation power information.

[0043] In an alternative embodiment, the evaluation of the scanned code data to obtain the production line output performance indicators of different production lines specifically includes:

[0044] Perform anti-duplication logic determination on the scanned code data S n :

[0045] Traverse the scanned code data S n , and compare the scanned code data S n one by one, delete the same scanned code data S n , and retain any one of the scanned code data S n ;

[0046] After the start of a shift on a certain production line, record the duration as T shift , continuously record the quantity of the scanned code data S n as the output N prod1 during the shift;

[0047] Set the initial successful scanning time as T S1 , and the next successful scanning time adjacent to it as T S2 , and calculate the single beat T S = T S2 - T S1 ;

[0048] Set the time threshold λ idle, used to determine whether to enter the no-load state:

[0049] When Time now -T S1 <λ idle , and N prod2 -N prod1 > 0, then the on-duty operation duration is T run = Time now -T S1 , where N prod2 is the on-duty output corresponding to T S2 ;

[0050] When and N prod2 -N prod1 = 0, then the on-duty no-load duration is T idle = Time now -T S1 , where, The mean value of the single beat, and n is the total number of scanned code data;

[0051] After the on-duty ends, through OEE time = T run / T shift , obtain the time utilization rate OEE time , and at the same time obtain the ratio of the qualified products to the total products of the on-duty output to determine the on-duty good product rate;

[0052] Obtain the ratio of the on-duty operation duration to the qualified products of the on-duty output as the on-duty beat time;

[0053] Take the on-duty beat time and the on-duty good product rate as the production line output performance indicators of this production line.

[0054] In an alternative embodiment, the determining the abnormal equipment information based on the abnormal production line information and tracing the equipment temperature distribution information, equipment vibration distribution information, and equipment operation power information corresponding to the abnormal equipment specifically includes:

[0055] Based on the abnormal production line information, obtain all the T S1 and T S2 equipment temperature distribution information, equipment vibration distribution information, and equipment operation power information within the time period;

[0056] Find the marked abnormal equipment corresponding to the abnormal production line in the production line topology diagram to obtain the abnormal equipment information, and then based on Co S1 and Co S4 scanned code data values, determine the initial successful scan time T S1 (Co S1), and the next successful code scanning time T adjacent to it in time S2 (Co S4 );

[0057] Obtain T S1 (Co S1 ) and the device temperature distribution information, device vibration distribution information, and device operating power information of abnormal devices within the time period of T S2 (Co S4 ).

[0058] In an alternative embodiment, evaluating the device temperature distribution information, device vibration distribution information, and device operating power information corresponding to the abnormal device to obtain the cause of the abnormality specifically includes:

[0059] According to the device temperature distribution information, device vibration distribution information, and device operating power information corresponding to the abnormal device, push the corresponding temperature heat map, vibration spectrum map, and power trend map to relevant personnel through a visualization tool for relevant personnel to judge the cause of the abnormality, and reply and record the cause of the abnormality.

[0060] Furthermore, a production line output performance index evaluation system based on code scanning data is proposed for implementing the evaluation method as described in any one of the above, including:

[0061] An acquisition module, which is used to obtain the factory layout map and product production plan from within the factory, and use a code scanning device to obtain code scanning data for evaluating the production line output performance index in real time. At the same time, it collects device temperature distribution information, device vibration distribution information, and device operating power information in real time through deployed sensors and built-in sensors of production line equipment;

[0062] A data processing module, which is used to obtain the production line equipment location information from the factory layout map, and obtain the production line output performance standard index from the product production plan, compare the production line output performance index of different production lines with the corresponding production line output performance standard index, obtain the abnormal production line information where the production line output performance index is lower than the production line output performance standard index, determine the abnormal device information based on the abnormal production line information, and trace the device temperature distribution information, device vibration distribution information, and device operating power information corresponding to the abnormal device;

[0063] A deployment module, which is used to deploy code scanning devices and sensors according to the production line equipment location information;

[0064] An evaluation module, which is used to evaluate the code scanning data to obtain the production line output performance index of different production lines, and is used to evaluate the device temperature distribution information, device vibration distribution information, and device operating power information corresponding to the abnormal device to obtain the cause of the abnormality.

[0065] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0066] A method for evaluating production line output performance indicators based on scanning code data proposed in this solution realizes accurate verification and multi-round acquisition of scanning code data through "using a scanning code device to obtain in real time the scanning code data for evaluating production line output performance indicators", effectively filters abnormal data, and uses methods such as digit verification, regular expression verification, and multi-round scanning code comparison to ensure data accuracy from the source and reduce the interference of incorrect or invalid data on the evaluation of production line output performance;

[0067] A method for evaluating production line output performance indicators based on scanning code data proposed in this solution realizes all-round and real-time monitoring of the operating status of production line equipment by deploying sensors and the built-in sensors of production line equipment to collect equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information in real time, improves the ability to monitor the operating status of equipment in real time, determines the cause of faults in a timely manner and responds to faults, and uses various types of sensors to accurately capture key operating parameters of the equipment at different acquisition frequencies to detect potential equipment fault hazards in a timely manner, providing strong support for quickly locating faults and improving the stability of the production line;

[0068] A method for evaluating production line output performance indicators based on scanning code data proposed in this solution realizes standardized comparison and rapid screening of abnormalities in production line performance by "comparing the production line output performance indicators of different production lines with the corresponding production line output performance standard indicators to obtain abnormal production line information where the production line output performance indicators are lower than the production line output performance standard indicators", can intuitively judge whether the production line output meets the standard, provides a quantitative basis for the refined management of the production line, and helps the enterprise quickly adjust production strategies to ensure production benefits. BRIEF DESCRIPTION OF THE DRAWINGS

[0069] Figure 1 It is a flowchart of a method for evaluating production line output performance indicators based on scanning code data proposed by the present invention;

[0070] Figure 2 It is a flowchart for obtaining scanning code data in the present invention;

[0071] Figure 3 It is a flowchart for deploying scanning code devices and sensors in the present invention;

[0072] Figure 4 It is a system framework diagram of a system for evaluating production line output performance indicators based on scanning code data proposed by the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0073] The following description is used to disclose the present invention so that those skilled in the art can implement the present invention. The preferred embodiments in the following description are only examples, and those skilled in the art can think of other obvious variations.

[0074] Referring to Figure 1 - Figure 4 As shown, a method for evaluating production line output performance indicators based on scanning code data includes:

[0075] S1. Obtain the factory layout diagram and product production plan from within the factory. Then, obtain the production line equipment location information from the factory layout diagram, and obtain the production line output performance standard indicators from the product production plan. According to the production line equipment location information, deploy scanning code devices and sensors;

[0076] S2. Use the scanning code devices to obtain the scanning code data for evaluating the production line output performance indicators in real time. At the same time, collect the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information in real time through the deployed sensors and the built-in sensors of the production line equipment. Then, evaluate the scanning code data to obtain the production line output performance indicators of different production lines;

[0077] S3. Compare the production line output performance indicators of different production lines with the corresponding production line output performance standard indicators to obtain the abnormal production line information where the production line output performance indicators are lower than the production line output performance standard indicators. Based on the abnormal production line information, determine the abnormal equipment information, and trace the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information corresponding to the abnormal equipment, and evaluate the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information corresponding to the abnormal equipment to obtain the cause of the abnormality.

[0078] Further, obtaining the production line equipment location information from the factory layout diagram specifically includes:

[0079] Based on the factory layout diagram, obtain the workshop structure information and area information. The workshop structure information includes equipment physical location information, passage information, and power supply point information. The area information includes assembly area information and quality inspection area information;

[0080] Determine the power supply point location information based on the power supply point information, and construct a digital space coordinate system with any power supply point location information as the origin;

[0081] According to the equipment physical location information and passage information, determine the production line equipment location information in the digital space coordinate system. At the same time, label the production line equipment in the digital space coordinate system with equipment IDs and area tags based on the production line equipment location information and area information.

[0082] Specifically, based on the factory layout diagram, the first step is to collect various detailed information related to the workshop. The workshop structure information includes equipment physical location information (i.e., the actual specific location of the equipment in the workshop), passageway information (such as the location, orientation, width, etc. of the passageways for personnel and material movement in the workshop), and power source point information (the location of the power access points in the workshop). The area information includes assembly area information (defining the location and scope of the area for assembling products) and quality inspection area information (determining the location and scope of the area for quality inspection of products). After obtaining the power source point information, further determine the power source point location information, that is, precisely find the specific location of the power access point in the workshop. Then, select any one of these power source point location information as the origin, and construct a digital space coordinate system based on this. This coordinate system is like a virtual grid, providing a unified reference framework for subsequent determination of equipment positions, enabling all positions in the workshop to be represented by coordinate values, facilitating precise positioning and analysis. According to the obtained equipment physical location information (the actual location of the equipment in the workshop) and passageway information (such as the orientation of the passageways), place the production line equipment accurately in the constructed digital space coordinate system to determine its position information in the coordinate system (representing the position of the equipment with coordinate values). At the same time, based on the production line equipment position information (the position of the equipment in the coordinate system) and area information (assembly area, quality inspection area, etc.), assign an equipment ID (a number used to uniquely identify each piece of equipment) and an area label (indicating the functional area where the equipment is located, such as the assembly area or the quality inspection area, etc.) to each production line equipment in the digital space coordinate system. It can clearly distinguish and manage the equipment, facilitating subsequent operations such as data collection, analysis, and production arrangement according to the area where the equipment is located and the characteristics of the equipment itself.

[0083] Furthermore, obtain the production line output performance standard indicators from the product production plan, specifically including:

[0084] The product production plan is exported from the internal ERP system of the factory. The product production plan includes the total production demand of the product, available production time, and the requirement for the qualified product rate;

[0085] Take the ratio of the available production time to the total production demand of the product as the takt time;

[0086] Based on the factory layout diagram, obtain the number of production lines, and take the ratio of the takt time to the number of production lines as the production line takt time;

[0087] Import the production line takt time and the requirement for the qualified product rate into the same Excel table to obtain the production line output performance standard indicators.

[0088] Specifically, the product production plan is exported from the ERP (Enterprise Resource Planning) system within the factory, such as ERP systems like SAP and Oracle. The takt time is calculated by the ratio of available production time to the total product production demand. The significance of this ratio is that it represents the average time required to produce one product under the existing production time and production demand. For example, if the available production time is 8 hours (converted to seconds, which is 28,800 seconds) and the total product production demand is 1000 pieces, then the takt time is 28.8 seconds per piece. The takt time is an important indicator for measuring the production rhythm, which reflects the production speed of the production system. First, based on the factory layout diagram, obtain the number of production lines within the factory, that is, how many production lines are used to produce this product. Then divide the previously calculated takt time by the number of production lines, and the result obtained is the takt time of the production line. The takt time of the production line represents the average time required for each production line to produce one product. For example, if the takt time is 28.8 seconds per piece and the number of production lines is 5, then the takt time of the production line is 5.76 seconds per piece. This indicator is very important for evaluating the production efficiency of each production line and arranging production tasks.

[0089] Furthermore, according to the production line equipment location information, deploy barcode scanning devices and sensors, specifically including:

[0090] Compare the factory layout diagram and the product production plan to determine the production logic sequence of the production line equipment;

[0091] According to the production logic sequence of the production line equipment, mark the material flow path in the digital space coordinate system;

[0092] According to the production line equipment location information and the production logic sequence of the production line equipment in the digital space coordinate system, generate a production line topology diagram, and embed the marked material flow path, equipment ID, and area label into the production line topology diagram;

[0093] Based on the production line topology diagram, determine the station entrance coordinates and material transfer point coordinates in the digital space coordinate system;

[0094] Taking the station entrance coordinates and the material transfer point coordinates as a reference, deploy barcode scanning devices on the Z-axis of the station entrance coordinates and the material transfer point coordinates;

[0095] Obtain the first production line equipment location information corresponding to the station entrance coordinates, and at the same time obtain the second production line equipment location information corresponding to the material transfer point coordinates. The second production line equipment location information is the location information of the two production line equipment closest to the material transfer point coordinates in the material flow path;

[0096] Based on the first production line equipment location information and the second production line equipment location information, obtain the historical material flow speed, and determine the rotation speed and initial angle of the barcode scanning device with the average value of the historical material flow speed;

[0097] Based on the position information of production line equipment in the digital space coordinate system, determine the production line equipment specification information and production line equipment production task information corresponding to the production line equipment position information;

[0098] According to the production line equipment specification information and production line equipment production task information, determine whether to deploy sensors at the production line equipment position.

[0099] Specifically, by comparing the factory layout diagram and the product production plan, the factory layout diagram shows the physical location distribution of equipment, while the product production plan clarifies the steps and requirements of product production. By combining and analyzing the two, the sequential operation order of production line equipment during the production process can be determined. For example, when producing cars, body welding is carried out first, then painting, and finally assembly. The corresponding welding equipment, painting equipment, and assembly equipment thus have a clear production logic sequence. According to the determined production logic sequence of production line equipment, in the previously constructed digital space coordinate system, mark the flow path of materials between each piece of equipment. This step can visually present the transfer process of materials from raw materials to finished products, helping to understand the flow direction and transportation of materials in the production process. For instance, raw materials start from the warehouse, pass through various processing equipment in sequence, and finally reach the finished product warehouse, and this flow path can be clearly drawn in the coordinate system. Combining the position information of production line equipment in the digital space coordinate system and the production logic sequence of production line equipment, generate a production line topology diagram. The production line topology diagram is a graphical representation that shows the connection relationships and hierarchical structures between various pieces of equipment in the production line. At the same time, embed the previously marked material flow path, equipment ID (used to uniquely identify each piece of equipment), and area label (indicating the area where the equipment is located, such as the assembly area, quality inspection area, etc.) into the production line topology diagram. In this way, the production line topology diagram contains rich information, facilitating subsequent management and analysis of the production line. Based on the production line topology diagram, find the station entrance coordinates and material transfer point coordinates in the digital space coordinate system. The station entrance coordinates are the position coordinates where materials enter each processing station, and the material transfer point coordinates are the key position coordinates where materials are transferred between different pieces of equipment or stations. These coordinates are of great guiding significance for subsequent operations of equipment and personnel. Taking the station entrance coordinates and material transfer point coordinates as the basis, deploy barcode scanning equipment on the Z-axis of these coordinates. The Z-axis usually represents the vertical direction. Deploying barcode scanning equipment at this position can conveniently scan the materials passing through the station entrance or material transfer point to obtain relevant information about the materials, such as material numbers, batches, etc., for tracking and managing the production process. Obtain the position information of the first production line equipment corresponding to the station entrance coordinates, and the position information of the second production line equipment corresponding to the material transfer point coordinates. Among them, the position information of the second production line equipment is the position information of the two production line equipment closest to the material transfer point coordinates in the material flow path. This equipment position information is very important for subsequent analysis of the interaction relationship between materials and equipment. Based on the position information of the first production line equipment and the position information of the second production line equipment, obtain the historical material flow speed. By statistically analyzing the flow speed of materials near these pieces of equipment over a period of time, calculate the average value of the historical material flow speed. Then, based on this average value, determine the rotation speed and initial angle of the barcode scanning equipment.This can ensure that the barcode scanning device can accurately and timely scan the materials, improving the efficiency and accuracy of barcode scanning. For example, assume that the average material flow velocity is v (unit: m / s), the length of the effective barcode scanning range of the barcode scanning device in the material flow direction is L (unit: m), the time for the barcode scanning device to rotate one week is T (unit: s), and the rotation speed is ω (unit: rps). Then, the time t required for the material to pass through the barcode scanning area is calculated as t = L / v. In order to complete n barcode scans when the material passes through the barcode scanning area, the barcode scanning device needs to rotate n weeks. Therefore, the time for the barcode scanning device to rotate n weeks should be equal to the time t for the material to pass through the barcode scanning area, that is, nT = t. From nT = t, we can get T = t / n = L / nv, and then the rotation speed ω of the barcode scanning device is ω = 1 / T = nv / L (rps).

[0100] According to the production line equipment position information in the digital space coordinate system, find the corresponding production line equipment specification information (such as the model, power, size, etc. of the equipment) and production line equipment production task information (such as the number of products to be produced by the equipment, quality requirements, etc.). According to the production line equipment specification information and production line equipment production task information, judge whether it is necessary to deploy sensors at the production line equipment position. For example, if the operating state of the equipment has a great impact on the production quality, or the equipment needs to monitor certain parameters in real time (such as temperature, pressure, vibration, etc.), then it may be necessary to deploy corresponding sensors to detect equipment failures and abnormalities in a timely manner and ensure the smooth progress of production.

[0101] Furthermore, use the barcode scanning device to obtain in real time the barcode scanning data for evaluating the production line output performance indicators, specifically including:

[0102] Obtain the initial barcode scanning data value Co through the barcode scanning device S1 , and perform preliminary verification on Co S1 , including digit verification and regular expression verification. The barcode scanning data value includes basic barcode scanning data, process operation data, and advanced association data;

[0103] Perform validity determination on the verified Co S1 :

[0104] If the verified Co S1 is invalid, then call the next barcode scanning device corresponding to Co S1 , and use the next barcode scanning device to perform multiple barcode scans to obtain the secondary barcode scanning data values Co S2 and Co S3 , compare the secondary barcode scanning data values Co S2 and Co S3 to determine whether the two barcode scanning data values are the same. If they are the same, then use Co S3 as the barcode scanning data S for evaluating the production line output performance indicators n, if they are not the same, call the next scanning device of the scanning device to perform multiple scans until Co is obtained S2n and Co S3n When Co are the same S3n as the scanning data S for evaluating the production line output performance index n , if the two scanning data values are still different when reaching the last scanning device, exit the scanning;

[0105] If the verified Co S1 is valid, call the next scanning device of the corresponding scanning device of Co S1 to perform a single scan on the material, and obtain the single scan data value Co S4 ;

[0106] Judge whether there is a production line device between Co S1 and Co S4 through the production line topology diagram:

[0107] If so, judge whether the scanning data values of Co S1 and Co S4 are the same. If they are the same, it proves that the production line device is abnormal, and mark the abnormal device in the production line topology diagram. If they are not the same, it proves that the production line device is normal, and Co S1 and Co S4 are both the scanning data S for evaluating the production line output performance index corresponding to the current time point n ;

[0108] If not, judge whether the scanning data values of Co S1 and Co S4 are the same. If they are the same, use Co S4 as the scanning data S for evaluating the production line output performance index n , if they are not the same, call the next scanning device of the scanning device to perform multiple scans, and obtain the secondary scanning data values Co S5n and Co S6n until Co S5n and Co S6n When they are the same, Co S6n is used as the scanning data S for evaluating the production line output performance index n , if the two scanning data values are still different when reaching the last scanning device, exit the scanning.

[0109] Specifically, the digit check examines whether the length of the scanning data meets the expectation. In a production environment, different types of scanning data may have a specified number of digits. For example, the product number may be specified as 10 digits, the material batch number may be specified as 8 digits, etc. By checking Co S1Whether the length is consistent with the preset number of digits can initially determine the validity of the data. Regular expression validation is a powerful text matching tool that can be used to check whether the scanned code data conforms to specific format rules. The scanned code data usually includes basic scanned code data, process operation data, and advanced association data, and different types of data may have different format requirements.

[0110] It can be understood that the basic scanned code data includes the product number, serial number, etc., and the format is a combination of letters and numbers, such as "ABC123456". The process operation data records information such as the operation steps and timestamps of the product in the production process. The advanced association data includes supply chain information, status tracking, etc.

[0111] Furthermore, by deploying sensors and the built-in sensors of production line equipment, the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information are collected in real time, specifically including:

[0112] The deployed sensors include temperature sensors, vibration sensors, and power sensors;

[0113] The temperature sensor selects an infrared thermometer, and takes 1 second as the acquisition unit to obtain a temperature heat map;

[0114] The vibration sensor uses a wireless accelerometer and takes 1 minute as the acquisition unit to monitor the bearing and gearbox and obtain a vibration spectrum diagram;

[0115] The power sensor uses a CT current transformer to monitor the real-time power of the production line equipment and obtain a power trend diagram;

[0116] Through the deployed sensors and the built-in sensors of the production line equipment, the temperature heat map, vibration spectrum diagram, and power trend diagram corresponding to each equipment are collected in real time, and the temperature heat map, vibration spectrum diagram, and power trend diagram corresponding to the same equipment are respectively stored in the corresponding files to obtain the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information.

[0117] Specifically, a temperature heat map is an image that intuitively shows the temperature distribution on the surface of an object. By collecting the temperature data on the surface of the device once every 1 second and presenting these data in the form of a heat map, the temperature changes in each part of the device can be clearly seen. For example, on the heat map, areas with higher temperatures will be shown in red, and areas with lower temperatures will be shown in blue, so that it is easy to discover problems such as local overheating of the device. A wireless accelerometer can measure the acceleration changes of an object, and by analyzing the acceleration data, the vibration situation of the device can be understood. In industrial devices, bearings and gearboxes are components prone to failure, and their vibration situations can reflect the operating state of the device. The advantage of a wireless accelerometer is that it is easy to install, does not require complex wiring, and can transmit the collected data to the monitoring system in real time. A vibration spectrum diagram is a graph obtained by decomposing vibration signals into different frequency components. By collecting vibration data on bearings and gearboxes once every 1 minute and performing spectrum analysis, a vibration spectrum diagram can be obtained. On the spectrum diagram, the magnitudes of vibration components at different frequencies can be seen, so as to judge whether there is abnormal vibration in the device. For example, if the vibration component at a specific frequency increases significantly, it may indicate that a certain component of the device has failed.

[0118] Furthermore, evaluate the scanning code data to obtain the production line output performance indicators for different production lines, specifically including:

[0119] For the scanning code data S n Perform anti-duplication logic determination:

[0120] Traverse the scanning code data S n , and compare the scanning code data S n one by one, delete the same scanning code data S n , and retain any one of the scanning code data S n ;

[0121] After the start of a shift on a certain production line, record the duration as T shift , continuously record the quantity of the scanning code data S n , and use it as the output N prod1 for the shift;

[0122] Set the initial successful scanning time as T S1 , and the next successful scanning time adjacent to it as T S2 , calculate the single-beat T S = T S2 - T S1 ;

[0123] Set the time threshold λ idle , and use it to judge whether to enter the no-load state:

[0124] When Timenow -T S1 <λ idle and N prod2 -N prod1 > 0, the on-duty operation duration is T run = Time now -T S1 where N prod2 is the on-duty output corresponding to T S2 ;

[0125] When and N prod2 -N prod1 = 0, the on-duty no-load duration is T idle = Time now -T S1 where the mean of the single cycle time, and n is the total number of scanned code data;

[0126] After the on-duty period ends, through OEE time = T run / T shift , obtain the time utilization rate OEE time , and at the same time obtain the ratio of the qualified products to the total products of the on-duty output to determine the on-duty good product rate;

[0127] Obtain the ratio of the on-duty operation duration to the qualified products of the on-duty output as the on-duty cycle time;

[0128] Take the on-duty cycle time and the on-duty good product rate as the production line output performance indicators of this production line.

[0129] Furthermore, based on the abnormal production line information, determine the abnormal equipment information, and trace the equipment temperature distribution information, equipment vibration distribution information, and equipment operation power information corresponding to the abnormal equipment, specifically including:

[0130] Based on the abnormal production line information, obtain all the T S1 corresponding to the abnormal production line and the equipment temperature distribution information, equipment vibration distribution information, and equipment operation power information within the time period of T S2 ;

[0131] Find the marked abnormal equipment corresponding to the abnormal production line in the production line topology diagram to obtain the abnormal equipment information, and then based on Co S1 and Co S4 scan code data values, determine the initial scan success time T S1 (Co S1 ) of the abnormal equipment, and the next scan success time T S2 (Co S4 ) adjacent to it in time;

[0132] Obtain T S1 (Co S1 ) and T S2 (Co S4 ) The device temperature distribution information, device vibration distribution information, and device operating power information of abnormal devices within the time period.

[0133] Furthermore, evaluate the device temperature distribution information, device vibration distribution information, and device operating power information corresponding to the abnormal devices to obtain the reasons for the abnormalities, specifically including:

[0134] Based on the device temperature distribution information, device vibration distribution information, and device operating power information corresponding to the abnormal devices, push the corresponding temperature heat map, vibration spectrum map, and power trend map to relevant personnel through a visualization tool for them to judge the reasons for the abnormalities, and reply and record the reasons for the abnormalities.

[0135] Furthermore, propose a production line output performance index evaluation system based on scanned code data for implementing the evaluation method as described in any one of the above, including:

[0136] A collection module, which is used to obtain the factory layout map and product production plan from within the factory, and use a scanned code device to obtain the scanned code data for evaluating the production line output performance index in real time. At the same time, it collects the device temperature distribution information, device vibration distribution information, and device operating power information in real time through the deployed sensors and the built-in sensors of the production line equipment;

[0137] A data processing module, which is used to obtain the production line equipment location information from the factory layout map and the production line output performance standard index from the product production plan, compare the production line output performance index of different production lines with the corresponding production line output performance standard index, obtain the abnormal production line information where the production line output performance index is lower than the production line output performance standard index, determine the abnormal device information based on the abnormal production line information, and trace the device temperature distribution information, device vibration distribution information, and device operating power information corresponding to the abnormal devices;

[0138] A deployment module, which is used to deploy the scanned code device and sensors according to the production line equipment location information;

[0139] An evaluation module, which is used to evaluate the scanned code data to obtain the production line output performance index of different production lines, and is used to evaluate the device temperature distribution information, device vibration distribution information, and device operating power information corresponding to the abnormal devices to obtain the reasons for the abnormalities.

[0140] The basic principles, main features and advantages of the present invention have been shown and described above. Those skilled in the art should understand that the present invention is not limited by the above embodiments. What is described in the above embodiments and the specification is only the principle of the present invention. Without departing from the spirit and scope of the present invention, various changes and improvements will occur to the present invention, and all these changes and improvements fall within the scope of the present invention claimed. The scope of protection required by the present invention is defined by the appended claims and their equivalents.

Claims

1. A method for evaluating production line output performance indicators based on scanning code data, characterized in that Including: S1. Obtain the factory layout diagram and the product production plan from within the factory. Then, obtain the production line equipment location information from the factory layout diagram, and obtain the production line output performance standard indicators from the product production plan. According to the production line equipment location information, deploy barcode scanning devices and sensors. S2. Use the barcode scanning devices to obtain in real time the barcode data for evaluating the production line output performance indicators. At the same time, collect the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information in real time through the deployed sensors and the built-in sensors of the production line equipment. Then, evaluate the barcode data to obtain the production line output performance indicators for different production lines. S3. Compare the production line output performance indicators of different production lines with the corresponding production line output performance standard indicators to obtain the abnormal production line information where the production line output performance indicators are lower than the production line output performance standard indicators. Based on the abnormal production line information, determine the abnormal equipment information, trace the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information corresponding to the abnormal equipment, and evaluate the equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information corresponding to the abnormal equipment to obtain the cause of the abnormality.

2. The evaluation method for production line output performance indicators based on scanning code data according to claim 1, wherein The obtaining of the production line equipment location information from the factory layout diagram specifically includes: Based on the factory layout diagram, obtain the workshop structure information and the area information. The workshop structure information includes equipment physical location information, passage information, and power source point information. The area information includes assembly area information and quality inspection area information. Determine the power source point location information based on the power source point information, and construct a digital space coordinate system with any power source point location information as the origin. According to the equipment physical location information and the passage information, determine the production line equipment location information in the digital space coordinate system. At the same time, label the production line equipment in the digital space coordinate system with equipment IDs and area tags based on the production line equipment location information and the area information.

3. The evaluation method for production line output performance indicators based on scanning code data according to claim 1, wherein The obtaining of the production line output performance standard indicators from the product production plan specifically includes: The product production plan is exported from the ERP system within the factory. The product production plan includes the total product production demand, available production time, and the required yield rate. Use the ratio of the available production time to the total product production demand as the takt time. Based on the factory layout diagram, obtain the number of production lines, and use the ratio of the takt time to the number of production lines as the production line takt time. Import the production line takt time and the required yield rate into the same Excel table to obtain the production line output performance standard indicators.

4. The evaluation method for production line output performance indicators based on scanning code data according to claim 2, characterized in that, The deployment of the barcode scanning devices and sensors according to the production line equipment location information specifically includes: Compare the factory layout diagram and the product production plan to determine the production logic sequence of the production line equipment. Mark the material flow path in the digital space coordinate system according to the production logic sequence of the production line equipment. Generate a production line topology diagram according to the production line equipment location information and the production logic sequence of the production line equipment in the digital space coordinate system, and embed the marked material flow path, equipment IDs, and area tags into the production line topology diagram. Based on the production line topology diagram, determine the workstation entrance coordinates and the material transfer point coordinates in the digital space coordinate system. Based on the coordinates of the station entrance and the material transfer point, deploy a barcode scanning device on the Z-axis of the coordinates of the station entrance and the material transfer point; Obtain the position information of the first production line equipment corresponding to the coordinates of the station entrance, and at the same time obtain the position information of the second production line equipment corresponding to the coordinates of the material transfer point. The position information of the second production line equipment is the position information corresponding to the two production line equipment closest to the coordinates of the material transfer point in the material flow path; Based on the position information of the first production line equipment and the position information of the second production line equipment, obtain the historical material flow speed, and determine the rotation speed and initial angle of the barcode scanning device with the average value of the historical material flow speed; Based on the position information of the production line equipment in the digital space coordinate system, determine the production line equipment specification information and production line equipment production task information corresponding to the production line equipment position information; According to the production line equipment specification information and the production line equipment production task information, judge whether to deploy sensors at the production line equipment position.

5. The evaluation method for production line output performance indicators based on scanning code data according to claim 4, characterized in that, The real-time acquisition of barcode scanning data for evaluating the production line output performance indicators by using the barcode scanning device specifically includes: Obtain the initial scanned code data value Co through a code scanning device S1 , and perform a preliminary verification on Co S1 , including digit verification and regular expression verification. The scanned code data value includes basic scanned code data, process operation data, and advanced associated data; Perform validity determination on the verified Co S1 : If the verified Co S1 is invalid, then call the next code scanning device corresponding to Co S1 and use the next code scanning device to perform multiple code scans to obtain the secondary code scan data values Co S2 and Co S3 . Compare the secondary code scan data values Co S2 and Co S3 to determine whether the two code scan data values are the same. If they are the same, use Co S3 as the code scan data S n for evaluating the production line output performance indicator. If they are not the same, call the next code scanning device of this code scanning device to perform multiple code scans until Co S2n and Co S3n are the same, and use Co S3n as the code scan data S n for evaluating the production line output performance indicator. If the two code scan data values are still not the same when reaching the last code scanning device, exit the code scan; If the verified Co S1 is valid, then call Co S1 to perform a single scan of the material by the next scanning device of the corresponding scanning device, and obtain a single scan data value Co S4 ; Determine Co through the production line topology diagram S1 and Co S4 Whether there is a production line device between the corresponding code scanning devices: If so, judge Co S1 and Co S4 whether the scanned code data values are the same. If they are the same, it proves that there is an abnormality in the production line equipment, and the abnormal equipment is marked in the production line topology diagram. If they are different, it proves that the production line equipment is normal. Co S1 and Co S4 are both the scanned code data S corresponding to the current time point for evaluating the production line output performance indicators n ; Otherwise, judge Co S1 and Co S4 whether the scanned code data values are the same. If they are the same, use Co S4 as the scanned code data S for evaluating the production line output performance index n . If they are not the same, call the next scanning device of this scanning device to perform multiple scans to obtain the secondary scanned code data values Co S5n and Co S6n until Co S5n and Co S6n are the same, and use Co S6n as the scanned code data S for evaluating the production line output performance index n . If the two scanned code data values are still not the same when reaching the last scanning device, exit the scanning.

6. The evaluation method for production line output performance indicators based on scanning code data according to claim 5, wherein The real-time collection of equipment temperature distribution information, equipment vibration distribution information and equipment operation power information through the deployed sensors and the built-in sensors of the production line equipment specifically includes: The deployed sensors include temperature sensors, vibration sensors and power sensors; The temperature sensor selects an infrared thermometer, and takes 1 second as the acquisition unit to obtain a temperature heat map; The vibration sensor uses a wireless accelerometer and monitors the bearings and gearboxes with 1 minute as the acquisition unit to obtain a vibration spectrum diagram; The power sensor uses a CT current transformer to monitor the real-time power of the production line equipment and obtain a power trend diagram; Through the deployed sensors and the built-in sensors of the production line equipment, the temperature heat map, vibration spectrum diagram and power trend diagram corresponding to each equipment are collected in real time, and the temperature heat map, vibration spectrum diagram and power trend diagram corresponding to the same equipment are respectively stored in the corresponding files to obtain equipment temperature distribution information, equipment vibration distribution information and equipment operation power information.

7. A method for evaluating production line output performance indicators based on scanned code data according to claim 5, characterized in that The evaluation of the barcode scanning data to obtain the production line output performance indicators of different production lines specifically includes: Perform duplicate prevention logic determination on the scanned code data S n as follows: Traverse the scanned code data S n and compare the scanned code data S n one by one. Delete the identical scanned code data S n and retain any one of the scanned code data S n ; After the start of a shift on a certain production line, record the duration as T shift , and continuously record the quantity of the scanned code data S n as the output N for the shift prod1 ; Let the initial successful code scanning time be T S1 , and the next successful code scanning time adjacent to it in time be T S2 , calculate the single beat T S = T S2 - T S1 ; Set the time threshold λ idle , which is used to determine whether to enter the no-load state: When Time now -T S1 <λ idle and N prod2 -N prod1 > 0, the operation duration of the current shift is T run = Time now -T S1 where N prod2 is the output of the current shift corresponding to T S2 ; When and N prod2 -N prod1 = 0, the no-load duration of the shift is T idle = Time now -T S1 , where the mean value of a single beat, and n is the total number of scanned code data; After the shift ends, obtain the Overall Equipment Effectiveness (OEE) through time = T run / T shift , and obtain the time utilization rate OEE time . At the same time, obtain the ratio of the qualified products to the total products produced during the shift to determine the first-pass yield of the shift; Obtain the ratio of the operation duration of the current shift to the qualified products produced during the current shift as the beat time of the current shift; Take the beat time of the current shift and the yield of the current shift as the production line output performance indicators of this production line.

8. A method for evaluating production line output performance indicators based on scanned code data according to claim 7, characterized in that, Based on the abnormal production line information, determine the abnormal equipment information, and trace the equipment temperature distribution information, equipment vibration distribution information and equipment operation power information corresponding to the abnormal equipment. Specifically includes: Based on the abnormal production line information, obtain all Ts corresponding to the abnormal production line S1 and T S2 equipment temperature distribution information, equipment vibration distribution information, and equipment operating power information within the time period; Find the marked abnormal devices corresponding to the abnormal production lines in the production line topology diagram to obtain the abnormal device information, and then based on Co S1 and Co S4 's scanned code data values, determine the initial successful scanning time T S1 (Co S1 ), and the next successful scanning time T S2 (Co S4 ) adjacent to it in time; Obtain T S1 (Co S1 ) and the device temperature distribution information, device vibration distribution information, and device operating power information of abnormal devices within the time period of T S2 (Co S4 ) 9. The evaluation method for production line output performance indicators based on scanning code data according to claim 8, wherein The evaluation of the equipment temperature distribution information, equipment vibration distribution information and equipment operation power information corresponding to the abnormal equipment to obtain the abnormal reasons specifically includes: According to the equipment temperature distribution information, equipment vibration distribution information and equipment operation power information corresponding to the abnormal equipment, push the alarm of the corresponding temperature heat map, vibration spectrum diagram and power trend diagram to relevant personnel through a visualization tool, and let the relevant personnel judge the abnormal reasons and record the abnormal reasons after reply.

10. A production line output performance index evaluation system based on scan code data, which is used to implement the evaluation method described in any one of claims 1-9, and is characterized in that, Include: A collection module, which is used to obtain the factory layout diagram and product production plan from inside the factory, use a barcode scanning device to obtain barcode data for evaluating the production line output performance indicators in real time, and simultaneously collect the device temperature distribution information, device vibration distribution information and device operation power information in real time through the deployed sensors and the built-in sensors of the production line equipment; A data processing module, which is used to obtain the production line equipment location information from the factory layout diagram, obtain the production line output performance standard indicators from the product production plan, compare the production line output performance indicators of different production lines with the corresponding production line output performance standard indicators, obtain the abnormal production line information where the production line output performance indicators are lower than the production line output performance standard indicators, determine the abnormal equipment information based on the abnormal production line information, and trace the device temperature distribution information, device vibration distribution information and device operation power information corresponding to the abnormal equipment; A deployment module, which is used to deploy barcode scanning devices and sensors according to the production line equipment location information; An evaluation module, which is used to evaluate the barcode data to obtain the production line output performance indicators of different production lines, and is used to evaluate the device temperature distribution information, device vibration distribution information and device operation power information corresponding to the abnormal equipment to obtain the cause of the abnormality.

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