Data processing method and system in virtual production line changeover process

Abstract

The application relates to the technical field of digital twinning, and discloses a data processing method and system in a virtual change production process of a production line, so as to improve change production efficiency and reliability. The method comprises the following steps: when encapsulating each device model on the current production line, a function relationship that a structure parameter of a part in an increase encapsulation part is changed with a geometric parameter of a machining object is encapsulated; after a user modifies the geometric parameters of machining objects corresponding to each device model in a task scheduler according to an actual change production task on a copy of the current production line, an initial change production line is automatically generated according to the modification of the task scheduler, and the structure parameter of the part of the device model retained in the change production line is automatically changed with the geometric parameter of the machining object according to the encapsulated function relationship; and then simulation results are output for the user to determine existing resources to be reused and new resources to be introduced.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of digital twinning, in particular to a data processing method and system in a production line virtual change production process. BACKGROUND

[0002] Part of the manufacturers based on their own production line products prepared with multi-species, small batch, high precision, high reliability production characteristics, which also makes the product production line face the severe challenge of frequent change production. The traditional change production process highly depends on manual experience, which needs to adjust the device parameters, switch the process route, and optimize the material configuration, and there are three core pain points.

[0003] 1. The change production cycle is long. The physical device joint debugging needs to stop the whole production line, and the single change production time is up to 48-72 hours, which seriously restricts the comprehensive efficiency of the device.

[0004] 2. Change production leads to frequent problems. Based on the experience of change production, it is difficult to accurately predict the compatibility of tooling fixtures and other problems, and the device parameter setting or process flow is difficult to adjust in place at one time, and needs to be adjusted and optimized for multiple times.

[0005] 3. Lack of timely production line evaluation means. After the change production, the new production line needs to run the processed products to actually evaluate the yield, yield and other indicators. In this process, not only the change production time is prolonged, but also some products that do not meet the specifications or standards are produced, resulting in resource waste.

[0006] At present, the existing technology cannot discover and solve potential problems in advance before the change production, resulting in long change production downtime, high cost, and high quality risk, which is difficult to meet the extreme pursuit of production flexibility and efficiency of intelligent manufacturing of some products. SUMMARY

[0007] The purpose of the present application is to disclose a data processing method and system in a production line virtual change production process to improve the change production efficiency and reliability.

[0008] In order to achieve the above purpose, the data processing method in the production line virtual change production process disclosed by the present application comprises:

[0009] Step S1, the digital twinning simulation system software saves the 1:1 three-dimensional model of each device on the current production line constructed by the user to the three-dimensional model library for encapsulation; wherein, in the process of encapsulating the action, control program and control signal of at least part of the device model, the function relationship between the structure parameters of the encapsulated part and the geometric parameters of the processing object is changed; and in the encapsulated program, the function relationship between the driving parameters of the action part and the overall beat of the production line is set to adaptively adjust.

[0010] Step S2, the digital twin simulation system software acquires a first operation of the user, the first operation comprising: arranging the packaged device model in position according to the layout of the current production line, then segmenting the current production line according to the process, and then creating a task scheduler, the task scheduler being used to, after listening to and receiving a device model end signal, judge the next device model triggered according to a preset current production line process logic, and send a start signal to the next device model after the trigger time arrives, wherein the preset current production line process logic is used to assign values to the overall production line beat, the buffer strategy and the geometric parameters of the processing object corresponding to each device model, and adjust the process order in response to the user's changeover demand;

[0011] Step S3, the digital twin simulation system software simulates the current production line, so that the user can judge whether the simulation result is consistent with the actual situation, if yes, go to the next step; if not, prompt the user to return to step S1 to adjust the modeling, packaging, position arrangement of the device model and / or the task scheduler;

[0012] Step S4, the digital twin simulation system software acquires a second operation of the user, the second operation being to modify the overall production line beat, the geometric parameters of the processing object corresponding to each device model and / or the process order in the task scheduler according to the actual changeover task on the copy of the current production line;

[0013] Step S5, the digital twin simulation system software automatically generates an initial changeover production line according to the modification of the task scheduler, simulates the initial changeover production line, and then outputs the simulation result for the user to determine the existing resources to be reused and the new resources to be introduced; wherein part of the parts of the device model retained in the changeover production line are automatically modified according to the functional relationship of packaging, and the part of the device model corresponding to the deleted process segment is deleted in its entirety.

[0014] Preferably, the method of the application further comprises:

[0015] Step S6, after the user performs the same three-dimensional modeling, packaging and saves the three-dimensional model to the three-dimensional model library of the digital twin simulation system software on the new resources to be introduced, the digital twin simulation system software acquires a third operation of the user, the third operation being to arrange the device model corresponding to the new resources according to the changeover task, and reconstruct the task scheduler based on the device model corresponding to the new resources and the deleted process;

[0016] Step S7, the digital twin simulation system software simulates the production line for change production and according to the simulation result, then outputs the simulation result for the user to iteratively adjust the modeling of the related equipment model, packaging, position arrangement and / or the task scheduler until it meets the expectation.

[0017] Preferably, the dimensions judged to meet the expectation of the application include any one or any combination of the following dimensions:

[0018] The first judging dimension is to perform collision detection on the motion trajectory of the equipment model and the action range of the tooling fixture, verify whether the station spacing, motion parameters and safety distance meet the design requirements, and if the detection result exists interference or unreasonable parameters, it is judged as not meeting the expectation.

[0019] The second judging dimension is to verify the correctness of the process sequence, interlocking logic and assembly path, and if there is a process logic error or assembly conflict, it is judged as not meeting the expectation.

[0020] The third judging dimension is to analyze the operation time of each station and the overall production rhythm, identify the bottleneck station, and evaluate whether the production capacity of the production line meets the demand of the new product, and if the production capacity is insufficient or the rhythm is unbalanced, it is judged as not meeting the expectation.

[0021] The fourth judging dimension is to construct a material flow model, simulate the material supply, transportation and buffering process, verify the timeliness of material supply, the smoothness of logistics channel, and the rationality of buffer zone and buffering strategy, and if there is material backlog, insufficient supply or congestion, it is judged as not meeting the expectation.

[0022] The fifth judging dimension is to calculate the energy consumption of the production line according to the running state and power parameters of the equipment model, evaluate the economy of the change production scheme combined with the equipment modification cost and operation and maintenance cost, and if the energy consumption is too high or the cost exceeds the expectation, it is judged as not meeting the expectation.

[0023] Preferably, the task scheduler of the application integrates an MES system functional module to trace and control the state of at least part of the equipment model.

[0024] Preferably, the method of the application further comprises: comparing the production line for change production that meets the expectation after change production with the current production line to generate a change production report.

[0025] In order to achieve the above purpose, the application further discloses a data processing system in a virtual change production process of a production line, which comprises a memory, a processor and a computer program stored in the memory and executable on the processor, and the processor executes the computer program to realize the above-mentioned method.

[0026] The application has the following beneficial effects:

[0027] 1. Through the simulation of the current production line, the reliability of the retained equipment model and process during the changeover process can be ensured.

[0028] 2. When the equipment model is encapsulated, the function relationship of the structural parameters of the increased sealing part changing with the geometric parameters of the machining object is changed; and in the subsequent adjustment of the task scheduler according to the actual changeover task, the structural parameters of the parts of the retained equipment model in the generated initial changeover production line are automatically changed according to the function relationship of the encapsulation; while improving the efficiency, the comprehensiveness of the adaptive adjustment is also ensured.

[0029] 3. In the program encapsulated by each equipment model, the function relationship of the driving parameters of the action part changing with the overall beat of the production line is set, and during the simulation, the driving control of the action part can be adaptively controlled according to the adjustment beat of the task scheduler; the user can verify the correctness of the virtual changeover and realize the optimization processing of the beat by comparing multiple changeover beats.

[0030] 4. During the automatic generation of the initial changeover production line based on the changeover task, the task scheduler can adjust the process based on the verified segmented relationship of the current production line, so as to match the flexible changeover demand of the user, and assist the user in checking and optimizing the changeover process.

[0031] In summary, the present application can construct a multi-dimensional, high-fidelity digital twin production line scene integrating geometric attributes, physical attributes, behavior rules and business logic, and can automatically generate an initial changeover production line in a virtual scene, and then accurately evaluate the existing resources for reuse and new resources to be introduced according to the simulation results. Further, the effect of the virtual changeover can be evaluated through simulation, and if the effect does not meet the expectation, the scheme needs to be adjusted again and the changeover effect needs to be re-evaluated, and so on until the actual landing changeover scheme is finally determined to guide the actual changeover implementation; by predicting the changeover effect in advance, the cost loss caused by repeated adjustment of the equipment, process, etc. of the actual production line can be effectively avoided, and the changeover cycle of the production line can be significantly shortened.

[0032] The present application will be further described below with reference to the drawings. BRIEF DESCRIPTION OF DRAWINGS

[0033] The accompanying drawings, which form a part of this application, are included to provide a further understanding of the application, and are incorporated in and constitute a part of this application. The embodiments of the application illustrated in the drawings, and their description thereto, are presented to provide the practitioner with a thorough and enabling disclosure of the application, and are included as a part of this application to convey the scope of the application to those who are skilled in the art. In the drawings:

[0034] Figure 1 is a schematic diagram of the data processing method flow in the production line virtual changeover process disclosed by the embodiment of the present application. DETAILED DESCRIPTION

[0035] The embodiments of the present application will be described in detail below with reference to the accompanying drawings, but the present application can be implemented in various different ways as defined and covered by the claims.

[0036] Embodiment 1

[0037] The embodiment discloses a data processing method in a virtual changeover process of a production line, mainly applied to the field of mechanical manufacturing (not applicable to the assembly of precision electronic components in the process of circuit board preparation, etc.), such as Figure 1 As shown in the figure, the method comprises the following steps:

[0038] Step S1, the digital twin simulation system software saves the 1:1 three-dimensional model of each device on the current production line constructed by the user to the three-dimensional model library for encapsulation; wherein, in the process of encapsulating the actions, control programs and control signals of at least part of the device models, the function relationship between the structure parameters of the encapsulated parts and the geometric parameters of the machining objects is changed; and in the encapsulated program, the function relationship between the driving parameters of the action parts and the overall beat of the production line is set to adaptively adjust.

[0039] In this step, model encapsulation includes action encapsulation, control program encapsulation, control signal encapsulation and special extensibility encapsulation based on changeover.

[0040] When performing action encapsulation, first, the device is imported from the three-dimensional model library, and the static parts, moving parts and their corresponding actions in the device are analyzed, and then the dynamic characteristics of the model are encapsulated to truly reproduce the motion behavior of the device in the digital twin environment. The core of encapsulation is to abstract the kinematics and dynamics characteristics of the moving parts into adjustable parameters, and combine them with the process logic to provide a basis for subsequent simulation and verification.

[0041] Specifically, first, the key moving parts of the device need to be managed in layers, including main shafts, sliding tables, clamps and other parts that can produce relative motion. For each part, extract its motion-related data such as motion mode, motion direction, initial position, speed, acceleration, motion time, etc., and encapsulate these parameters as standardized motion attributes. In this way, the motion of each axis of the device is defined as an object that can be independently called and adjusted, which facilitates flexible modification during simulation and realizes comparative analysis under different working conditions and boundary conditions.

[0042] The so-called control program packaging is based on the fact that the production line equipment has multiple types of actions, and the actions have a sequence. Therefore, after the action is packaged, the processing process of the material entering the equipment needs to be analyzed. The sequence of actions of various moving parts of the equipment is written in a control program or control script to simulate the actual processing process of the equipment. The processing rhythm of the equipment is adjusted to the real processing scene by adjusting the moving time or speed of the moving parts in the control program or control script. Then, the speed / beat parameters are increased when the specific driving time or speed of the moving parts is increased, and when the rhythm of the equipment needs to be adjusted, the corresponding parameters can be set by adjusting the corresponding parameters.

[0043] The control program packaging completes the processing process of a single process equipment, and the processing sequence between different equipment. The physical production line realizes the processing sequence of different equipment through signal interaction of the control network. Therefore, in the design of the control signal packaging, the start and end signals of the equipment action are set, the transmission between the signals of different equipment and the judgment of the signal value in the equipment are realized to achieve the start and end of the equipment processing, and the function relationship of the driving parameters of the action parts is set to adaptively adjust with the overall rhythm of the production line. Among them, the start signal is a waiting signal, and only when the signal is input with appropriate data, the program after the waiting signal can run; the end signal is a setting signal, and the signal value can be set. The end signal can be obtained by other equipment.

[0044] For example, the material is loaded by the RGV offline device, transferred by the transfer device, detected by the quality center, and finally placed in the assembly device for overall assembly. Between the RGV offline device and the transfer device, there is a Boolean type signal with the same name "transfer device starts to transport RGV offline device material". The transfer device is always waiting for the start signal value to be "true". When the RGV offline device finishes loading, the signal value is set to "true", the transfer device ends waiting and starts executing the subsequent control program. By setting the start and end signals, the processing action logic of the front and rear process equipment can be realized to achieve the dynamic production process of the simulation production line.

[0045] Alternatively, the input and output signals can be connected through the setting panel of the digital twin simulation system to synchronize the update of the input signal value of the next process equipment by setting the value of the output signal of the previous process equipment.

[0046] Parameter modeling refers to abstracting the process of processing and assembly of the production line, the geometric parameters, stroke, and action of the structure of the equipment into a parameterized model. The motion data extracted in the model motion package is the motion parameter. The position of the mechanism, the structure of the parts of the mechanism, and the action distance of the mechanism in the equipment model usually have certain change rules during the production line changeover process, such as the length of the equipment base is usually related to the length of the material processed on the base, the position between the material clamps and the length of the clamp mechanism is related to the width or diameter of the material, and the movement distance of the detection device is related to the length of the material. In order to respond to the rapid changeover demand, the embodiment adds a special extension package based on changeover, which extracts the key parameters of the production line, changes the values of the key parameters, and quickly changes the structure of part of the equipment, the specific steps are as follows:

[0047] 1. Extract key parameters. The change of the production object is usually the change of some typical parameters, common parameters include the length, width, height, diameter of the material, production rhythm, etc., and these key parameters are extracted as parameter values of single machine equipment.

[0048] 2. Analyze the key parameters and determine the key data. The change of the key parameters changes the structure of the mechanism in the equipment, such as the length of the material changes the relative position between the two clamps of the transfer device, the diameter changes the structure of the clamp, and the production rhythm changes the feeding speed of the feeding mechanism and the processing speed of the equipment. This step is to analyze which mechanisms or parts in the equipment will change when the key parameters change.

[0049] 3. Parameterization of key data. The parameterization objects can include parameterization of structure, position, movement distance, quantity, etc. This step can be regarded as expressing the key data analyzed in step 2 with a mathematical expression about the attribute values saved in step 1. Based on the digital twin system, the conventional graphic part structure (length, width, diameter of the part), position (position of the mechanism in the equipment), and quantity of the mechanism in the equipment are characterized by key parameter attribute expressions, and the value of the key parameter can be quickly changed to change the structure of these mechanisms and realize virtual changeover of part of the mechanism in the production line. Key data parameterization is equivalent to expressing structure (length, width, height), position (X, Y, Z three-axis coordinates), and movement distance with a mathematical expression about the extracted parameter value. For example, the length L of the support surface of the support seat, in the design stage, it has the following relationship with the length S of the material: L=A*S, and S as the extracted key attribute, the value of the mathematical expression can be used to control the length L of the support surface. When the length S of the material changes, the length of the support surface can be quickly changed by assigning a value to S, so as to achieve the purpose of structure change.

[0050] To this end, in the embodiment, based on the step, a function relationship of the structure parameters of the encapsulated part changing with the geometric parameters of the processing object is encapsulated in the process of encapsulating the action, control program and control signal of at least part of the device model; and in the encapsulated program, a function relationship of the driving parameters of the action part being adaptively adjusted with the change of the overall beat of the production line is set.

[0051] In step S2, the digital twin simulation system software acquires the first operation of the user, and the first operation includes: arranging the encapsulated device model in position according to the layout of the current production line, segmenting the current production line according to the process, and then creating a task scheduler. The task scheduler is used to listen to and receive the end signal of the device model, judge the next device model triggered according to the preset process logic of the current production line, and send a start signal to the next device model after the trigger time arrives. The preset process logic of the current production line is used to assign values to the overall beat of the production line, the buffer strategy and the geometric parameters of the processing object corresponding to each device model, and adjust the process order in response to the changeover demand of the user.

[0052] In step S3, the digital twin simulation system software simulates the current production line, so that the user can judge whether the simulation result is consistent with the actual situation. If it is consistent, go to the next step; if it is not consistent, prompt the user to return to step S1 to adjust the modeling, encapsulation, position arrangement of the device model and / or the task scheduler.

[0053] In the above two steps, the production line digital twin modeling generally includes production line digital twin model layout building, control network building and beat parameter assignment.

[0054] The process of production line digital twin model layout building can be specifically: combining the material flow direction and process route of the actual production line, determining the number and combination form of the equipment. According to the process flow and logistics channel, the front, rear, left, right and up and down relationship of the equipment is reasonably arranged to ensure that the materials can smoothly flow according to the process sequence. Secondly, the position and attitude of the equipment are adjusted by using the three-dimensional coordinate system, and the precise assembly between the equipment is realized by means of reference surface alignment, reference point calibration and constraint positioning. For example, according to the layout of the current airborne product production line, the encapsulated model is arranged in position.

[0055] The process of building the control network can be specifically: for real simulation of the production line processing process, a task scheduler is created in the digital twin model, the end signal of the device is received through the scheduler, the internal logic program is judged, and the start signal of the device is issued to realize the control of the device processing. Create various signals, realize the judgment of various states through the interaction between the signals, and then control the execution of the high-level methods of the model (such as the movement of the mechanical arm, the operation of the conveyor belt, etc.) to achieve the dynamic control between the production lines. The core of building the control network is the writing of the internal logic program of the scheduler, which logically processes and issues the start signal of each device processing according to the actual production line processing sequence, thereby realizing the control of the device processing.

[0056] The beat type parameter assignment can be achieved by collecting the on-site action process parameters and assigning the parameter values related to the action beat encapsulated in the foregoing, so as to restore the device processing beat to the real processing scene.

[0057] Through the above two steps, the real processing scene of the current production line can be restored in the digital twin simulation system software.

[0058] Step S4, the digital twin simulation system software acquires the second operation of the user, and the second operation is to modify the overall beat of the production line, the geometric parameters of the processing object corresponding to each device model, and / or the process sequence in the task scheduler according to the actual changeover task on the copy of the current production line.

[0059] In this step, a copy of the current production line can be generated through copying or cloning operations; and the task scheduler is modified according to the identified production line changeover driving factors. The process of identifying the production line changeover driving factors can be specifically: first, the differences between the new and old products in design and process need to be clarified, because these differences will directly determine the direction of the production line modification. Usually, product model changes will bring changes in geometric dimensions, structural forms, assembly processes, process requirements, etc. For example, the increase in the size of the fuselage section of an airborne product will require the redesign or expansion of the fixture; the change in the connection method of the structural part may introduce new processes or adjust the process sequence. These product-level differences will be transmitted to the workstation setting, process path, beat allocation, and logistics organization of the production line, thereby forming the driving factors for the modification of the production line.

[0060] Step S5, the digital twin simulation system software automatically generates an initial changeover production line according to the modification of the task scheduler, simulates the initial changeover production line, and then outputs the simulation results for the user to determine the existing resources to be reused and the new resources to be introduced; wherein part of the parts of the device model retained in the changeover production line automatically change according to the encapsulated function relationship that the structural parameters change with the geometric parameters of the processing object, and the part of the device model corresponding to the deleted process section is deleted in whole.

[0061] In this step, the initial changeover production line is not perfect in most changeover tasks, and the meaning of the simulation result is not only to provide the user with the existing resources to be reused and the new resources to be introduced, but also to output the problems to be improved to the user based on the analysis logic (including but not limited to the subsequent algorithm for judging whether the changeover scheme meets the expected multiple dimensions) of the underlying digital twin simulation system software. Therefore, preferably, the method of the embodiment can further include the following steps S6 and S7 (not shown in the figure).

[0062] Step S6, after the user performs the same three-dimensional modeling, packaging and saving to the three-dimensional model library of the digital twin simulation system software as in step S1 on the new resources to be introduced, the digital twin simulation system software obtains a third operation of the user, which is to arrange the device model corresponding to the new resource according to the changeover task, and reconstruct the task scheduler based on the device model corresponding to the new resource and the deleted process.

[0063] Step S7, the digital twin simulation system software simulates the changeover production line and outputs the simulation result for the user to iteratively adjust the modeling, packaging, position arrangement of the related device model and / or the task scheduler until it meets the expectation according to the simulation result.

[0064] In the above steps, the driving factor configuration parameters and control program adjustment are required. For example, for the device structure change caused by the product geometric size change driving factor, the device structure adaptive change is completed according to the product size setting parameter value. At the same time, for the new product machining process change driving factor, the control program in the device is re-adjusted.

[0065] Under the condition of changeover, the process equipment required by the process route needs to be determined. Since the new product has differences in size (length, width, height, diameter, etc.), material properties, and process time (such as normalizing, annealing, quenching, and tempering), etc. with the original product, part of the structure and cycle of the equipment cannot meet the processing requirements of the new product, and adaptive adjustment of the equipment is required. Therefore, the device virtual variant method based on structural parameterization, cycle parameter assignment and signal logic adjustment of the embodiment enables the device to realize rapid adaptation in a virtual environment.

[0066] Structural variant mainly refers to: through the establishment of a key parameter driven attribute packaging mechanism, the geometric size of the product and the process cycle are converted into parameter input of the geometric characteristics of the equipment. Conventional geometric structures (such as cuboid, cylinder, sphere) can be quickly adjusted through key data assignment; and for unconventional parts that cannot be characterized by parameter expressions, a local reconstruction mechanism is introduced, thereby balancing modeling efficiency and accuracy.

[0067] The structural modification mainly changes the specific attribute values in the attribute encapsulation, such as the length, width, height, and beat of the product.

[0068] The key data parameterization assignment and the assignment to the key parameter attribute in the foregoing encapsulation quickly complete the change of the equipment mechanism position and the regular graphic structure (the mechanism such as the cuboid, the cylinder, and the sphere), and realizes the partial modification of the equipment.

[0069] If the geometric size or the beat of the assigned key parameter exceeds the range constrained in the encapsulation of the corresponding equipment model, the equipment model is regarded as the existing resource that cannot be reused. In addition, the irregular graphic part is redesigned. There are a certain number of irregular shape parts in the production line, such as various castings. The mechanism of this kind of part cannot be characterized by the key parameter attribute expression when the key parameter changes. For this kind of part, it needs to be redesigned.

[0070] When the beat parameter is assigned, the processing speed modification can be determined by changing the value of the speed / beat parameter in the encapsulation function (in this embodiment, the value is uniformly set by the task scheduler), determining the processing action beat value through the analysis of the processing time requirement, and assigning the value.

[0071] When the control program is adjusted, the action execution sequence in the control program can be modified by analyzing the processing procedure, and the position of the encapsulated signal in the control program is changed, so that the equipment can meet the processing requirement of the new product.

[0072] Further, in step S7, it is judged whether the expected dimensions include any one or any combination of the following dimensions:

[0073] Dimension one is to perform collision detection on the motion trajectory of the equipment model and the action range of the tooling fixture, verify whether the station spacing, motion parameters, and safety distance meet the design requirements, and if the detection result exists interference or the parameters are unreasonable, it is judged as not meeting the expectation.

[0074] Dimension two is to verify the correctness of the process sequence, interlocking logic, and assembly path, and if there is a process logic error or assembly conflict, it is judged as not meeting the expectation.

[0075] Dimension three is to analyze the operation time of each station and the overall production beat, identify the bottleneck station, and evaluate whether the production line capacity meets the new product demand. If the capacity is insufficient or the beat is unbalanced, it is judged as not meeting the expectation.

[0076] Dimension four is to construct a material flow model, simulate the material supply, transportation, and buffering process, verify the timeliness of the material supply, the smoothness of the logistics channel, and the rationality of the buffer zone and the buffering strategy. If there is material backlog, insufficient supply, or congestion, it is judged as not meeting the expectation.

[0077] Judgment dimension five, according to the equipment model running state and power parameter, calculate the energy consumption of production line, combined with equipment modification cost, operation and maintenance cost, evaluate the economy of the change production scheme, if the energy consumption is too high or the cost exceeds the expectation, it is judged as not meeting the expectation.

[0078] Further, the task scheduler of the embodiment described integrates the MES system function module to trace and control the state of at least part of the equipment model; and compares the production line after the change production meeting the expectation with the current production line to generate a change production report to assist the user to implement the change production operation step by step.

[0079] Embodiment 2

[0080] The embodiment discloses a data processing system in a virtual change production process of a production line, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, and the processor implements the method of embodiment 1 when executing the computer program.

[0081] In summary, the data processing method and system in the virtual change production process of the production line disclosed by the above two embodiments have at least the following beneficial effects:

[0082] 1. The reliability of the retained equipment model and process in the change production process can be ensured through simulation of the current production line.

[0083] 2. When the equipment model is packaged, the function relationship of the structural parameters of the increased packaging parts changing with the geometric parameters of the machining object is changed; and the function relationship of the structural parameters of the retained parts of the equipment model in the generated initial change production line changing with the geometric parameters of the machining object is changed according to the function relationship of the packaging when the task scheduler is adjusted according to the actual change production task, so that the adaptability of the adjustment is ensured.

[0084] 3. In the program packaged by each equipment model, the function relationship of the driving parameters of the action parts changing with the overall beat of the production line is set, and the driving control of the action parts is adaptively controlled according to the adjustment beat of the task scheduler during simulation, so that the user can verify the correctness of the virtual change production and realize the optimization processing of the beat by comparing multiple change production beats.

[0085] 4. During the automatic generation of the initial change production line based on the change production task, the task scheduler can adjust the process based on the verified segmented relationship of the current production line, so as to match the flexible change production demand of the user, and assist the user to check and supplement the change production process and optimize the process.

[0086] In conclusion, the present application can construct a multi-dimensional and high-fidelity digital twin production line scene integrating geometric attributes, physical attributes, behavior rules and business logic, and can automatically generate an initial changeover production line in a virtual scene, and then accurately evaluate the existing resources for reuse and new resources to be introduced according to the simulation results. Further, the effect of virtual changeover can be evaluated by simulation, and if the effect does not meet the expectation, the scheme needs to be adjusted and the changeover effect needs to be re-evaluated, and so on until the changeover scheme that can be actually implemented is finally determined to guide the actual changeover implementation. By predicting the changeover effect in advance, the cost loss caused by repeated adjustment of the actual production line equipment, process, etc. can be effectively avoided, and the changeover cycle of the production line can be significantly shortened.

[0087] The above merely describes the preferred embodiments of the present application and is not intended to limit the present application. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A data processing method for a virtual production changeover process on a production line, characterized in that, include: Step S1: The digital twin simulation system software saves the 1:1 three-dimensional models of each piece of equipment on the current production line constructed by the user to the three-dimensional model library for encapsulation. In the process of encapsulating the actions, control programs and control signals of at least some equipment models, the functional relationship of the structural parameters of some parts changing with the geometric parameters of the processed object is added. In addition, in the encapsulated program, the functional relationship of the driving parameters of the moving parts adaptively adjusting with the overall cycle time of the production line is set. Step S2: The digital twin simulation system software acquires the user's first operation, which includes: arranging the packaged equipment models according to the current production line layout, dividing the current production line into segments according to the process, and then creating a task scheduler. The task scheduler is used to listen to and receive the equipment model's end signal, determine the next equipment model to be triggered according to the preset current production line process logic, and send a start signal to the next equipment model after the trigger time arrives. The preset current production line process logic is used to assign values ​​to the overall production line cycle time, buffer strategy, and geometric parameters of the processing objects corresponding to each equipment model, and to respond to the user's production change request to adjust the process sequence. Step S3: The digital twin simulation system software simulates the current production line so that the user can judge whether the simulation results are consistent with the actual situation. If they are consistent, proceed to the next step; if they are inconsistent, prompt the user to return to step S1 to adjust the modeling, encapsulation, and location arrangement of the equipment model and / or the task scheduler. Step S4: The digital twin simulation system software obtains the user's second operation, which is to modify the overall cycle time of the production line, the geometric parameters of the processing objects corresponding to each equipment model, and / or the process sequence in the task scheduler on the copy of the current production line according to the actual production change task. Step S5: The digital twin simulation system software automatically generates an initial production line based on the modification of the task scheduler, simulates the initial production line, and outputs the simulation results for the user to determine the existing resources to be reused and the new resources to be introduced; wherein, some parts of the equipment model retained in the production line automatically deform according to the encapsulated function relationship, and the structural parameters change with the geometric parameters of the processed object, and the equipment model corresponding to the deleted process is deleted in its entirety.

2. The data processing method for virtual production changeover in a production line according to claim 1, characterized in that, Also includes: Step S6: After the user performs the same 3D modeling, encapsulation and saving of the new resource to be introduced in step S1 to the 3D model library of the digital twin simulation system software, the digital twin simulation system software then obtains the user's third operation. The third operation is to arrange the equipment model corresponding to the new resource according to the production change task, and to reconstruct the task scheduler based on the equipment model corresponding to the new resource and the deleted process. Step S7: The digital twin simulation system software simulates the production line and outputs the simulation results based on the simulation results. The user can then iteratively adjust the modeling, encapsulation, and location arrangement of the relevant equipment models and / or the task scheduler until the expected results are met.

3. The data processing method during the virtual production changeover process of the production line according to claim 2, characterized in that, The dimensions for determining whether something meets expectations include any one or any combination of the following dimensions: The first dimensional judgment involves conducting collision detection on the motion trajectory of the equipment model and the range of motion of the tooling fixtures to verify whether the workstation spacing, motion parameters, and safety distances meet the design requirements. If the detection results show interference or unreasonable parameters, it is judged as not meeting expectations. The second judgment dimension is to verify the correctness of the process sequence, interlock logic and assembly path. If there are errors in the process logic or assembly conflicts, it is judged as not meeting expectations. The third dimensional of the judgment is to analyze the operation time of each workstation and the overall production cycle, identify bottleneck workstations, and assess whether the production line capacity meets the needs of new products. If the capacity is insufficient or the cycle is unbalanced, it is judged as not meeting expectations. The fourth judgment dimension is to construct a material flow model, simulate the material supply, transportation and buffering process, and verify the timeliness of material supply, the smoothness of logistics channels, and the rationality of buffer and buffering strategies. If material backlog, insufficient supply or congestion occurs, it is judged as not meeting expectations. Fifthly, based on the equipment model's operating status and power parameters, calculate the production line's energy consumption. Combine this with equipment modification costs and operation and maintenance costs to evaluate the economics of the production change plan. If the energy consumption is too high or the cost exceeds expectations, it is judged as not meeting expectations.

4. The data processing method during the virtual production changeover process of the production line according to claim 2, characterized in that, The task scheduler integrates MES system functional modules to trace and manage the status of at least some device models.

5. The data processing method during the virtual production changeover process of the production line according to claim 2, characterized in that, Also includes: A changeover report is generated by comparing the production line that meets expectations after the changeover with the current production line.

6. A data processing system for a virtual production changeover process on a production line, comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the method described in any one of claims 1 to 5.

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