Air conditioner outdoor unit detection line buffering amount adjusting method

Abstract

The invention relates to the technical field of air conditioner outdoor unit detection processes, in particular to an air conditioner outdoor unit detection line buffer amount adjusting method. According to the method, by dynamically calculating the caching probability and matching with a retry distribution mechanism, the mode that materials are stored only according to a fixed sequence in a traditional caching strategy is changed. When the host passes through each cache region, the system can decide the distribution direction according to the real-time cache state, the process can be re-entered for retry when the distribution is not successful, the flexible closed-loop design can effectively cope with the fluctuation of the production rhythm, the condition that the front-end cache region is overstocked and the rear-end cache region is idle is avoided, and the workload of each link of the detection line is more balanced.

Description

Technical Field

[0001] The present invention relates to the technical field of air conditioner outdoor unit detection processes, and specifically to a method for adjusting the buffer capacity of an air conditioner outdoor unit detection line. Background Art

[0002] Air conditioner outdoor units produced in factories usually adopt an assembly line operation mode. That is, multiple sets of four-way transfer machines are combined to form multiple conveyor lines, one of which is the main conveyor line, and two sub-conveyor lines are arranged on both sides of the main conveyor line respectively. While these two sub-conveyor lines serve as buffer areas, they can also transport outdoor units to each detection station.

[0003] In the detection link of air conditioner outdoor units, to further improve the detection efficiency, the production system adopts a partitioned collaborative operation mode: according to the situation of the detection stations on site, multiple detection stations are scientifically divided into several detection areas; at the same time, corresponding buffer areas are equipped at the front end of each detection area. These buffer areas, as "material transfer stations", can not only buffer the production capacity fluctuations caused by process rhythm differences, but also dynamically allocate the transfer sequence of outdoor units through an intelligent scheduling system, realizing the efficient utilization of detection resources, significantly shortening the detection cycle of a single product, and ensuring the continuity and smoothness of the entire detection process.

[0004] In practical applications, the principle of nearest buffer operates according to the material transportation direction. Only when the immediately adjacent previous buffer area is completely full, will the material be stored in the next buffer area. However, this strategy has significant drawbacks. It is difficult to respond in real time to the dynamic changes in the production rhythm, and it is extremely easy to cause an imbalance in the allocation of buffer area resources, that is, the front buffer areas are frequently full due to fluctuations in the upstream process efficiency or short-term production capacity surges, resulting in the corresponding detection areas operating at an overloaded state for a long time; at the same time, the rear buffer areas are left empty for a long time due to reasons such as downstream process failures and process adjustments, causing a serious imbalance in the workload of the detection areas, and a large difference in the working states of each link on the same detection line, thereby affecting the overall production efficiency and the service life of the equipment.

[0005] It can be seen that the current detection method based on the principle of nearest buffer has significant deficiencies and needs to be further improved to solve the above existing problems. Summary of the Invention

[0006] In order to avoid and overcome the technical problems existing in the prior art, the present invention provides a method for adjusting the buffer capacity of an air conditioner outdoor unit detection line. The present invention determines whether the host is allocated to the corresponding buffer area according to the real-time buffer capacity of the buffer area, so as to balance the allocation of each buffer area and optimize the utilization rate of detection resources.

[0007] To achieve the above object, the present invention provides the following technical solutions: A method for adjusting the buffer capacity of an air conditioner outdoor unit detection line includes the following adjustment steps: S1. Convey each main machine to be detected on the main conveyor line; S2. When the main machine passes through the buffer area, calculate the buffering probability of storing it in this buffer area according to the real-time buffer volume of this buffer area; if this buffering probability is greater than the set buffering probability threshold of this buffer area, then allocate the main machine to this buffer area; otherwise, the main machine continues to be conveyed to the next buffer area; S3. Convey each main machine in sequence according to step S2. If the main machine traverses all buffer areas and is not allocated to any buffer area, then put this main machine back onto the main conveyor line and continue the allocation work according to step S2.

[0008] As a further solution of the present invention: The calculation formula of the buffering probability is as follows: (1); In the formula, represents the buffering probability of the current main machine being allocated to the current buffer area at moment; represents the volume dynamic parameter of the current main machine; represents the th buffer area at moment, that is, the real-time buffer volume of the buffer area at the conveying position where the main machine is currently located; represents the th buffer area at moment, the real-time maximum buffer capacity; represents the natural constant; represents the time decay coefficient; represents the time interval from the last allocation of the main machine to the th buffer area; represents the th buffer area at moment, the real-time buffer weight; represents the total number of buffer areas.

[0009] As a further solution of the present invention: The calculation formula of the real-time maximum buffer capacity of the buffer area is as follows: (2); (3); In the formula, represents the standard buffer capacity of the th buffer area; represents the minimum buffer capacity of the th buffer area; represents the th buffer area at moment, the time fluctuation coefficient; represents the The partition decay coefficient of a buffer at moment; Indicates the rounding operation; Indicates the maximum value taking operation.

[0010] As a further solution of the present invention: The calculation formula of the time fluctuation coefficient is as follows: (4); In the formula, Indicates the th real-time detection period of the detection area corresponding to the buffer at Indicates the th average detection period of the detection area corresponding to the buffer from the start of detection to

[0011] As a further solution of the present invention: The calculation formula of the partition decay coefficient is as follows: (5); In the formula, Indicates the th number of unit time conflicts in the buffer at

[0012] As a further solution of the present invention: The calculation formula of the detection period is as follows: (6); In the formula, Indicates the th standard detection period of the detection area corresponding to the buffer; Indicates the single rotation time consumption during detection of the detection area corresponding to the th buffer at detection period parameter of the detection area corresponding to the Indicates the standard volume of the host; Indicates the actual volume of the current host; Indicates the maximum volume of the host; Indicates the volume balance coefficient.

[0013] As a further solution of the present invention: The calculation formula of the detection period parameter is as follows: (7); In the formula, Indicates the th number of hosts being detected at the moment of the detection area corresponding to the buffer; Indicates the maximum host carrying capacity of the detection area corresponding to the th buffer area.

[0014] As a further solution of the present invention: The cache weight of the buffer area will be updated in real time during the transportation of the host, and its update formula is as follows: (8); In the formula, Indicates the real-time cache weight of the th buffer area at the moment; Indicates the real-time cache volume of the th buffer area at the moment; Indicates the real-time maximum cache capacity of the th buffer area at the moment, ; Indicates the time compensation coefficient; Indicates the total running time of the main conveyor line from the start to the current moment.

[0015] As a further solution of the present invention: The calculation formula of the volume dynamic parameter of the host is as follows: (9); In the formula, Indicates the set standard volume of the host; Indicates the actual volume of the host; Indicates the set maximum volume of the host; Indicates the over-volume compensation coefficient.

[0016] As a further solution of the present invention: The calculation formula of the volume balance coefficient is as follows: (10); In the formula, Indicates the proportionality factor, .

[0017] Compared with the prior art, the beneficial effects of the present invention are: 1. By dynamically calculating the cache probability and collocating with the retry allocation mechanism, this method changes the mode in the traditional cache strategy where materials are only stored in a fixed order. When the host passes through each buffer area, the system will decide the allocation destination according to the real-time cache status. When the allocation is not successful, it can re-enter the process for retry. This flexible closed-loop design can effectively cope with the fluctuations in the production rhythm, avoid the backlog in the front-end buffer area and the idleness in the back-end, and make the workload of each link in the detection line more balanced.

[0018] 2. The calculation of the caching probability integrates multiple dynamic factors: the volume of the host affects its allocation priority, the proportion of the remaining space in the buffer determines the current available degree, the time interval since the last allocation can reflect the idle state of the buffer, and the caching weight reflects the importance differences of each area. This multi-dimensional calculation logic endows the system with an "intelligent scheduling brain", which can dynamically adjust the allocation strategy according to real-time production data, giving priority to large-volume hosts to enter suitable areas, and making full use of the buffer that has not been used for a long time, so as to achieve the optimal allocation of resources.

[0019] 3. The real-time maximum cache capacity is not a fixed value, but will be dynamically adjusted according to the partition decay coefficient and the time fluctuation coefficient. When the working state of the detection area is unstable or the buffer conflicts increase, the system will automatically shrink the maximum capacity of this area, and at the same time ensure the basic caching ability through the minimum capacity setting. This "elastic capacity" design is like installing an "adaptive valve" on the buffer, which can reduce the risk of material backlog during production fluctuations and avoid excessive waste of cache space.

[0020] 4. The core of the time fluctuation coefficient is to reflect the production stability of each detection area by detecting the fluctuation of the cycle. When the cycle fluctuation of a certain detection area is large, the corresponding time fluctuation coefficient will increase, which in turn affects the adjustment of the buffer capacity and promotes the flow of materials to more stable detection areas. This mechanism is like establishing a "dynamic balancer" for the detection line, which can automatically guide the flow of materials to the smoother-running links and reduce the overall efficiency loss caused by local fluctuations.

[0021] 5. The partition decay coefficient is directly related to the number of conflicts per unit time in the buffer. When frequent material congestion occurs in a certain buffer, this coefficient will automatically increase, accelerating the decay of the maximum capacity of the corresponding buffer, thereby reducing its allocation probability. This "conflict-sensitive" adjustment method is like setting a "flow-limiting valve" for the congested area, which can quickly relieve local bottlenecks and reduce the pauses in the detection process.

[0022] 6. The calculation of the detection cycle will adopt an intelligent discrimination strategy according to the volume of the host: hosts within the standard volume adopt the basic detection cycle, while hosts with an oversized volume will dynamically extend the detection time according to the volume difference. This "tailored" design can not only ensure the detection accuracy of hosts of different volumes, but also avoid the waste of detection time or insufficient accuracy caused by a unified standard, making the detection process more in line with the actual production needs.

[0023] 7. The detection cycle parameter comprehensively considers the host volume ratio and the current load in the detection area: when the host is larger in volume or the detection area is busier, this parameter will automatically increase, reasonably extending the detection time. This mechanism is like adding an "intelligent speed governor" to the detection device, which can not only meet the detection requirements of large-volume hosts but also adjust the rhythm according to the real-time load, reducing the risk of equipment failures caused by overload.

[0024] 8. The cache weight is updated in real time according to the time integral of the historical cache volume. For buffer areas that have been in a high-load state for a long time, their weights will gradually decay, thereby reducing the allocation probability. This "load feedback" mechanism is like establishing a "flow regulation channel" among buffer areas, which can automatically guide materials to flow to idle areas, avoid individual buffer areas from operating under overload for a long time, and achieve an even distribution of the overall load.

[0025] 9. The volume dynamic parameter adopts a compensation mechanism for super-volume hosts. When the host volume exceeds the standard, its allocation probability will be correspondingly reduced, avoiding blockages in small buffer areas due to excessive volume. This "volume adaptation" strategy is like establishing a "size matching rule" between the buffer area and the host, which can effectively reduce material jams caused by space mismatch and improve the space utilization rate of the buffer area.

[0026] 10. The volume balance coefficient and the super-volume compensation coefficient are linearly correlated through a proportionality factor, and the influence degree of volume on the detection cycle can be flexibly adjusted according to production requirements. This "flexible correlation" design is like setting a "regulation knob" for the system, which can not only ensure the detection quality of super-volume hosts when needed but also avoid overly extending the detection cycle and affecting the overall efficiency, finding the best balance point between precision and production capacity. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] Figure 1 is a flowchart of the present invention. DETAILED DESCRIPTION OF THE EMBODIMENTS

[0028] 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. All other embodiments obtained by those of ordinary skill in the art based on the embodiments of the present invention without creative efforts shall fall within the protection scope of the present invention.

[0029] Please refer to Figure 1 , in the embodiments of the present invention, it mainly includes the following contents: I. Setting of Main Parameters A modular layout design is adopted for a certain air conditioner outdoor unit detection line, which includes a main conveyor line with a rated speed of 1.5 m / s. Along one side of it in the material flow direction, buffer zones A, B, and C are arranged in series in sequence, with a total of three buffer zones. Each buffer zone is equipped with an independent detection station: Buffer zone A corresponds to the appearance detection area, equipped with an industrial vision camera and a laser distance sensor, which can automatically detect multiple appearance indicators such as the flatness of the main unit shell and coating defects; after the detection is completed, the detection results (qualified / unqualified) are marked in real time at the specified position of the main unit through an inkjet coding machine, and the data is synchronously uploaded to the MES system. Each buffer zone is connected by a variable-frequency conveyor chain plate, and the chain plate speed is dynamically synchronized with the main conveyor line at ±0.2 m / s to ensure the smooth transition of the main unit to the next detection process. Buffer zones B and C correspond to the performance test area and the packaging process area respectively, forming a full-process automated detection closed loop. An optoelectronic sensor array is set between the main conveyor line and each buffer zone to monitor the position of the main unit and the capacity status of the buffer zone in real time, providing data support for the subsequent dynamic adjustment of the buffer volume, and the corresponding parameter values are shown in Table 1.

[0030] Table 1 Parameter values 。

[0031] II. Main unit transportation The main unit P001 to be detected enters the main conveyor line, and its current position is about to pass through buffer zone A. The time at this moment t is 1000 s, and the total running time of the main conveyor line from the start to the current moment T is 1000 s.

[0032] III. Calculate the buffering probability 1. Detection cycle The system detects the actual volume of the main unit P001 to be detected through a common volume detection device , which is larger than the standard volume. The number of main units being detected in detection area A at 1000 s units.

[0033] Substituting the above data into formula (7) gives the detection cycle parameter of detection area A at 1000 s , and substituting it into formula (6) gives the standard detection cycle of detection area A at 1000 s .

[0034] 2. Time fluctuation coefficient The average detection cycle of buffer zone A at 1000 s is statistically obtained , and substituting it into formula (4) gives the time fluctuation coefficient of buffer zone A at 1000 s .

[0035] 3. Partition attenuation coefficient Statistically obtain the number of unit-time conflicts in buffer A at 1000s times per hour, substitute it into formula (5) to obtain the partition decay coefficient of buffer A at 1000s .

[0036] 4. Real-time maximum cache capacity Calculate the minimum cache capacity of buffer A according to formula (3) , substitute it into formula (2), and the real-time maximum cache capacity of buffer A at 1000s can be obtained units.

[0037] 5. Volume dynamic parameter Substitute the above corresponding data into formula (9) to obtain the volume dynamic parameter of the host P001 to be detected .

[0038] 6. Real-time cache volume

[0039] The real-time cache volume of buffer A at 1000s units.

[0040] 7. Time interval The time interval since the last host was allocated to buffer A .

[0041] 8. Real-time cache weight The real-time cache weight of buffer A at 1000s .

[0042] 9. Data of buffer B Similarly, through the above analysis steps, the required data of buffer B are: the real-time cache volume of buffer B units, the real-time maximum cache capacity of buffer B at 1000s units, the real-time cache weight of buffer B at 1000s , the time interval since the last host was allocated to buffer B .

[0043] 10. Data of buffer C Similarly, through the above analysis steps, the required data of buffer C are: the real-time cache volume of buffer C units, the real-time maximum cache capacity of buffer C at 1000s units, the real-time cache weight of buffer B at 1000s , the time interval since the last host was allocated to buffer C .

[0044] 11. Cache probability of buffer A Substitute the above data into formula (1) to calculate the caching probability of the host P001 to be detected assigned to buffer A , which is less than the set threshold of 0.5, so it is not stored in buffer A and is transported to buffer B

[0045] 12. Caching probability of buffer B Similarly, substitute the above data into formula (1) to calculate the caching probability of the host P001 to be detected assigned to buffer B , which is less than the set threshold of 0.5, so it is not stored in buffer B and is transported to buffer C

[0046] 12. Caching probability of buffer C Similarly, substitute the above data into formula (1) to calculate the caching probability of the host P001 to be detected assigned to buffer C , which is less than the set threshold of 0.5, so it is not stored in buffer C and the host P001 to be detected traverses all buffers without being assigned

[0047] The host P001 to be detected is returned to the main conveyor line, and the retry counter is incremented by 1 (currently 1 time). The system sets the maximum number of retries to 3 times. When the number of retries reaches 3 times and still no assignment is made, it is guided to the temporary buffer and an alarm is triggered

[0048] IV. Real-time update of caching weight Taking buffer A as an example, t + 1 = 1001s

[0049] Total operating duration of the main conveyor line T is 1000s is the integral of the caching quantity of buffer A in the previous 1000 seconds. Assuming the calculated result is units units. Substitute the above data into formula (8) to update the weight, and the updated real-time caching weight is .

[0050] V. Comparison with the principle of nearest assignment Taking the assignment situation at 1000s, compare the differences between this method and the nearest principle. The comparison results are briefly shown in Table 2

[0051] Table 2 Comparison results ; From the data in Table 2, it can be seen that this method realizes the optimization of the traditional nearest caching principle and effectively solves the problem of caching imbalance on the detection line

[0052] VI. Simulation of the application scenario of multi-host assignment Establish the conveying and caching process of multiple hosts, and the corresponding caching situation is shown in Table 3

[0053] Table 3 Multi-host caching situation ; VI. Abnormal situation handling When the utilization rate of buffer A is > 90% for 5 consecutive minutes (e.g., for [X] hosts, utilization rate 90%), the system automatically increases the caching weight of buffer B by 20% (from 0.3 → 0.36), and reduces the allocation threshold of A to 0.4, guiding subsequent hosts to preferentially store data in B.

[0054] The above is only a preferred specific implementation manner of the present invention, but the protection scope of the present invention is not limited thereto. Any person skilled in the art within the technical scope disclosed by the present invention, according to the technical solution and inventive concept of the present invention, makes equivalent substitutions or changes, and should be covered by the protection scope of the present invention. Note: There is an unclear part "[X]" in the original text for item

[11] , which is retained as is in the translation. If there is specific information that needs to be filled in this position, it should be adjusted according to the actual situation.

Claims

1. A method for adjusting the buffer capacity of an air conditioner outdoor unit detection line, characterized in that: Including the following adjustment steps: S1. Convey each host to be detected on the main conveyor line; S2. When the host passes through the buffer area, calculate its buffering probability of being stored in the buffer area according to the real-time buffer volume of the buffer area; If the buffering probability is greater than the set buffering probability threshold of the buffer area, assign the host to the buffer area; otherwise, the host continues to be conveyed to the next buffer area; S3. Convey each host in turn according to step S2. If the host traverses all buffer areas and is not assigned to any buffer area, then put the host back onto the main conveyor line and continue the assignment work according to step S2.

2. The method for adjusting the buffer capacity of an air conditioner outdoor unit detection line according to claim 1, wherein, The calculation formula of the buffering probability is as follows: ； Wherein, represents the caching probability that the current host is allocated to the current buffer at time; represents the volume dynamic parameter of the current host; represents the th buffer at time, that is, the real-time cache volume of the buffer at the conveying position where the host is currently located; represents the th buffer at time, the real-time maximum cache capacity; represents the natural constant; represents the time decay coefficient; represents the time interval since the last allocation of the host to the th buffer; represents the th buffer at time, the real-time cache weight; represents the total number of buffers.

3. The method for adjusting the buffer capacity of the detection line of the air conditioner outdoor unit according to claim 2, characterized in that: The calculation formula of the real-time maximum buffer capacity of the buffer area is as follows: ； ； In the formula, represents the standard cache capacity of the th buffer; represents the minimum cache capacity of the th buffer; represents the time fluctuation coefficient of the th buffer at the moment; represents the partition attenuation coefficient of the th buffer at the moment; represents the rounding operation; represents the maximum value operation.

4. The method for adjusting the buffer capacity of the detection line of the air conditioner outdoor unit according to claim 3, characterized in that: The calculation formula of the time fluctuation coefficient is as follows: ； In the formula, represents the real-time detection period of the detection area corresponding to the th buffer at the moment; represents the average detection period of the detection area corresponding to the th buffer from the start of detection to the moment.

5. The method for adjusting the buffer capacity of the detection line of the air conditioner outdoor unit according to claim 4, characterized in that: The calculation formula of the partition attenuation coefficient is as follows: ； In the formula, Indicates the In the cache The number of conflicts per unit time at a given moment.

6. A method for adjusting the buffer capacity of an air conditioner outdoor unit detection line according to claim 5, characterized in that, The calculation formula of the detection period is as follows: ； Where, Indicates the The standard detection cycle of the detection area corresponding to each buffer area; Indicates the The detection area corresponding to the cache area is The time taken for a single rotation during moment detection; Indicates the The detection area corresponding to the cache area is Detection cycle parameters at the moment; Indicates the standard volume of the host; Indicates the actual volume of the current host; Indicates the maximum volume of the host; Represents the volume balance coefficient.

7. A method for adjusting the buffer capacity of an air conditioner outdoor unit detection line according to claim 6, characterized in that, The calculation formula of the detection period parameter is as follows: ； In the formula, represents the number of hosts being detected at the moment in the detection area corresponding to the th buffer; represents the maximum load capacity of the hosts in the detection area corresponding to the 8. A method for adjusting the buffer capacity of an air conditioner outdoor unit detection line according to any one of claims 2-7, characterized in that The buffer weight of the buffer area will be updated in real time during the conveying process of the host, and its update formula is as follows: ； In the formula, represents the real-time cache weight of the th buffer at the moment; represents the real-time cache volume of the th buffer at the moment; represents the real-time maximum cache capacity of the th buffer at the moment, ; represents the time compensation coefficient; represents the total running time of the main conveyor line from the start to the current moment.

9. The method for adjusting the buffer capacity of the detection line of the air conditioner outdoor unit according to claim 7, characterized in that: The calculation formula of the volume dynamic parameter of the host is as follows: ； In the formula, represents the set standard volume of the host; represents the actual volume of the host; represents the set maximum volume of the host; represents the over-volume compensation coefficient.

10. The method for adjusting the buffer capacity of the detection line of the air conditioner outdoor unit according to claim 9, characterized in that: The calculation formula of volume balance coefficient is as follows: ; In the formula, represents the scale factor, .

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