Method for adapting a production arrangement and production system for performing the method

Abstract

The invention relates to a method for adapting a production arrangement 2, in which the production arrangement 2 has a system initial state 100, in which a change of the production arrangement 2 is made as a result of a change event 200 such that the system initial state is changed into a system intermediate state 300, in which the change is automatically detected 400 as a trigger event, in which the trigger event triggers a software-based adapting process, wherein a data technical image of the production arrangement 2 having a system intermediate state is determined 500 in a matching process, the system intermediate state is matched 600 in the matching process in order to obtain 700 a system final state of the production arrangement 2, and the system final state is provided 800 for implementation on the production arrangement 2.

Description

Technical Field

[0001] The present invention relates to a method for matching production layout and a production equipment for implementing the method. Background Technology

[0002] In manufacturing, changes in production cell configurations necessitate frequent reconfiguration of the corresponding production cells. This type of reconfiguration is typically achieved by operators on-site, or, in the case of more complex production cells, by production planners and production planning staff.

[0003] Document DE 10 2016 202 772 A1 relates to a method for monitoring and planning a production unit having multiple devices that exchange data between these devices, wherein a first production unit can be characterized by hardware and software configurations and by the data exchanged between the devices. The method comprises the steps of: a) detecting information about the hardware and software configurations at a determined time point and about the data exchanged at the same determined time point as characteristics of the first production unit; b) creating at least one virtual, identical image of the first production unit (at least a portion thereof) using the detected information; c) feeding data to be processed to the virtual image of the production unit at a time point after the determined time point; d) processing the data to be processed using the virtual image of the first production unit; e) analyzing the operation of the virtual image of the production unit and using the results for monitoring and / or planning of a first or other production unit. Summary of the Invention

[0004] The subject of this invention is a method for matching production layouts having the features of claim 1, and a production apparatus for performing the method having the features of claim 9. Preferred or advantageous embodiments of the invention will be derived from the dependent claims and the description that follows with the accompanying drawings.

[0005] This invention relates to a method for matching production layout.

[0006] In particular, production layout is understood as any unit or whole piece of equipment constructed to realize at least one production process. The production process can be constructed as a manufacturing process, a logistics process, a quality assurance process, a measurement process, etc.

[0007] In particular, the production layout has at least one production component, wherein the production component may be configured as a robotic device, a manufacturing device, a separation device, a transport device, etc.

[0008] In particular, the matching of production layout is understood as a change in the system state of the production layout. The system state preferably includes the structural and procedural configuration of the production layout.

[0009] Therefore, the structural configuration includes the selection and / or layout of production components, i.e., spatial arrangement. Furthermore, the structural configuration may optionally include the conveying and / or removal of workpieces within the production arrangement. Additionally, the structural configuration may include the supply of energy, gas, generally amorphous production media, liquids, such as coolants or lubricants, to the production arrangement. In particular, the structural configuration is constructed as the hardware of the production arrangement.

[0010] The program structure for production layout includes the procedures, particularly the methods, for production layout. Therefore, the program structure includes, for example, executable control programs for controlling production components and / or structural configurations as a whole. The program structure is specifically configured as software for production layout.

[0011] The production layout has a system initial state, wherein the production layout in the system initial state is configured as an actual and / or realized production layout, the actual and / or realized production layout being configured to perform a production process, or to perform a production process in the system initial state.

[0012] Change events can affect production layout. These events cause changes to the production layout from its initial state to an intermediate state. Specifically, they cause changes to the structural and / or programmatic configuration of the production layout, particularly altering the software and / or hardware. This change is particularly characterized by altering the production process itself, especially the flow of the production process.

[0013] Changes in production layout are detected automatically as trigger events. The changes themselves or their impact on the production layout, particularly on the initial state of the system, can be detected here.

[0014] Triggering events form triggers used to execute a software-based matching process. Thus, the matching process is automatically initiated by detecting changes.

[0015] The matching process based on software, especially the construction of an optimization process, is based on the intermediate states of the system, which form the basis for the matching process, particularly the optimization process.

[0016] During the matching process, a data technology image of the production layout in an intermediate system state is determined. This data technology image specifically includes the structural and procedural configuration of the production layout. The data technology image is constructed, for example, as a simulation model of the production layout in the intermediate system state. Preferably, the data technology image is constructed as a digital twin and / or digital representation of the production layout in the intermediate system state.

[0017] The matching process involves matching, and particularly modifying, intermediate system states to obtain the final system state for production layout. Here, the data technology mapping may involve altering the structural and / or program structures to obtain the final system state as a modified intermediate state. The matching process may, for example, be aligned with target quantities—such as increasing production capacity, reducing process time, or narrowing process paths—so that the production layout in the final system state has, for example, higher performance, faster speed, and less space requirements compared to the production layout in the intermediate system state.

[0018] Next, the system final state is provided for implementation in the production layout. The system final state is implemented specifically at the production layout, thereby configuring the production layout as an actual and / or implemented production layout with the system final state, in which production is available and / or put into use.

[0019] In particular, the method enables an automated chain of operations, from the detection of changes in production layout to the provision of the final state of the system for production layout, which is automated and / or fully automated.

[0020] One advantage of this invention is that, particularly in the absence of a pre-planned, optimized final system state, changes in production layout automatically trigger a matching process, thereby automatically providing a final system state that can be immediately implemented in the production layout. In practical terms, this type of change is implemented and the changed production layout is automatically matched, particularly optimized, through this method, thus achieving a matched, particularly optimized, production layout in the shortest possible time.

[0021] This invention enables the automated detection of spontaneous physical changes at production sites, such as production systems undergoing transformation, caused by human or other influencing factors. It calculates potential improvements to the system configuration and outputs these improvement recommendations, allowing for system reconfiguration or refitting if necessary. Therefore, one can benefit from methods for matching, and particularly optimizing, production systems where the changes do not need to be proactively planned by humans beforehand. In conventional methods, multiple personnel are typically involved in practice, such as production planners and production planning staff, resulting in slower implementation of improvements and a significantly higher human workload.

[0022] In a preferred embodiment of the invention, the change event is constructed as a change in a process component of the production layout. For example, a process component may change its characteristics, such as due to renewal or wear and tear or due to functional limitations. Alternatively or supplementarily, a change in a process component may mean the replacement of a process component, wherein the replaced process component has different functional characteristics. A process component can be understood as, for example, a manipulator, a robot, a manufacturing apparatus, a workpiece carrier, a workpiece support, etc.

[0023] Change events can also be constructed as, in particular, manual changes in the setting of process components in the production layout.

[0024] Change events can occur either expected or unexpectedly. Expected change events include, for example, the replacement of process components. Unexpected change events include, for example, the failure of process components.

[0025] Alternatively or additionally, change events may involve changes in the delivery conditions of energy, gases, liquids, such as coolants or lubricants.

[0026] Generally, changing events lead to, particularly indirect, changes in the performance characteristics of the production layout. Specifically, there is an interaction between changing events in the production layout and performance characteristics.

[0027] In a preferred improvement scheme, the achieved final system state is evaluated, and particularly verified. For example, the actual system characteristics of the production layout under the achieved final system state are compared with the system characteristics calculated or estimated during the matching process. If the evaluation is unsatisfactory—that is, if the actual system characteristics do not correspond to the calculated or estimated system characteristics, or if other optimization potential is discovered—the matching process is repeated using the final system state as a new intermediate system state. Through this iteration, the final system state can be matched and, in particular, optimized further.

[0028] In a preferred implementation, the production layout is constructed as a changeable production system, particularly as a changeable production unit. In this design, the production layout comprises multiple production components that can be freely arranged and / or replaced within a pre-defined layout. This degree of freedom in the configuration of the changeable production system is used as a degree of freedom in the matching process.

[0029] In one possible embodiment, changes are detected at the software and / or hardware levels. In the case of changes to production components, for example, these components can be connected to the network as new network partners, where changes are detected at the software level by identifying the new network partners. Alternatively or supplementarily, sensors can be provided, which record measurement parameters indicating changes or change events, thereby detecting the changes at the hardware level.

[0030] Particularly preferred is the configuration that allows for the automated detection of the system's initial state and / or intermediate states and / or changes. For example, the structural and program configurations, i.e., the production layout, can be read and / or exist so completely in data technology that the intermediate states of the system can be automatically and completely determined by detecting changes.

[0031] In a preferred embodiment of the invention, matching of intermediate system states is performed based on model predictive conditioning. Model predictive conditioning, particularly known as Model Predictive Control (MPC) or Receding Horizon Control (RHC), is a method for predictive conditioning of complex, often multivariable processes. In model predictive conditioning, measurement data of the actual production process are automatically acquired and provided to a software-based model of the process. The future behavior of the process can be predicted using the model and the measurement data. This prediction is used to optimize process control and thereby achieve matching.

[0032] In one possible implementation, the final system state is manually achieved within the production setup. This final system state is then passed to the operator, who reassembles the production setup in this manner, bringing it to the final system state.

[0033] Alternatively, and particularly in the case of a changeable production system, it is preferable to automate the final state of the system. Especially in the case of a changeable production system, the movement and / or relocation and / or replacement of production components, as well as the automated execution of additional structural and procedural settings, can be automated. In this way, the production layout is fully automated in response to change events to a matched and / or optimized final state of the system. Preferably, the production layout includes setting components for setting the production layout or production equipment. The setting components are particularly configured for moving and / or relocating and / or replacing and / or removing and / or setting production components based on the provided final state of the system. For example, the setting components are configured for reconfiguring a robot as a production component and / or placing the robot in a different location.

[0034] Another subject of the invention is formed by a production apparatus, wherein the production apparatus is preferably configured to perform the previously described method. The production apparatus includes a production arrangement, particularly as previously described. Furthermore, a detection device is provided for detecting changes in the production arrangement as it transitions from an initial state to an intermediate state of the system. The production apparatus has a matching device, wherein the matching device is particularly configured as a digital data processing device. The matching device is configured to perform a matching process as previously described in order to obtain a final state of the system. Furthermore, the production apparatus includes a providing device for providing the final state of the system.

[0035] Alternatively or supplementing, the present invention can be described as follows: To optimize the use of production layouts, especially transformable production systems, it is essential to accurately plan the transformed system state (the goal of the system transformation) and optimize it towards a defined target quantity. For example, the spatial arrangement of workstations within a robot cell plays a fundamental role in the product processing time. Correspondingly, changes to the layout must be carried out purposefully.

[0036] In some cases, system changes can be technically achieved without prior planning and optimization. For example, in production layouts, the arrangement of work positions can also be achieved spontaneously by physically moving modular production media, particularly production components (and consequently, work positions).

[0037] This invention enables the automated detection of spontaneous physical changes, such as those caused by personnel at production locations, particularly in changeable production systems; the calculation of potential improvements to system configuration; and the output of these improvement recommendations. This allows for system matching or, if necessary, re-matching of the system after a change. Therefore, one can benefit from methods for matching, and particularly optimizing, production layouts where the change does not necessarily require proactive human planning. In conventional methods, multiple personnel are typically involved in practice, such as production planners and production planning staff, resulting in slower implementation of improvements and a significantly higher human workload.

[0038] This solution can be based on the application of different technological concepts: 1. Automated identification of physical changes in production layout, especially for changeable production systems, caused by external influences, such as personnel matching.

[0039] 2. The change is transmitted to a software technology system configured as a matching device for implementing the matching process, one or more of which can make predictions about the system, for example, in the sense of model prediction adjustment. These predictions are used to calculate the improved system state relative to the new state as the final system state. The software need not be specifically developed for this purpose, but can also be used for system optimization outside the processes described herein.

[0040] 3. Inform the triggerer of the physical change (usually a human) of the improved final state of the system, so that the system can be re-modified if necessary to achieve the improved state.

[0041] This method uses some or all of the following elements: 1. At least one production system that can be transformed.

[0042] a. Alternatively: A typical production layout, which has performance characteristics that can be indirectly altered by physical interventions as variations, and in the case of such a layout, a complex relationship exists between the interventions and the performance characteristics. Example: The number of workpiece supports in a conventional production system.

[0043] 2. A detection device for automatically identifying performed changes / modifications in the production layout.

[0044] a. In particular, a detection device capable of identifying anticipated or unexpected changes in production layout. Examples: subsystem failures, changes in environmental conditions (temperature, humidity, etc.), and delays in timelines. The detection device can be implemented as a purely software system or as a software and hardware system (e.g., with hardware sensors and change detection in software).

[0045] 3. Data technology mapping of the intermediate state of the production layout system.

[0046] 4. Software capable of calculating the improved production system state as the final state of the system based on data technology imaging.

[0047] a. Optional: Calculate the final state of multiple systems with different performance characteristics improved.

[0048] 5. A means of providing a system that enables notification of the improved system final state in such a way that the improved system final state can be achieved in the production layout by human and / or automated means, i.e., also partially by human and partially automated means.

[0049] a. Preferably: the improved system final state is applied automatically.

[0050] 6. Software implementation for automating the matching process. One possible implementation scheme is to use CI / CD software (such as Jenkins, GitLab, Azure DevOps).

[0051] The method may include some or all of the following steps: 1. Automated identification of changes / modifications in production layout; 2. Update the data technology image of the production layout system state, which serves as an intermediate state of the system; 3. Use the data from the intermediate state of the system as the initial value to match, and especially optimize, the intermediate state of the system; 4. Generate a new data technology image of the system state as the final system state; 5. Notify the providing device of the existence of a new image of the system's final state, which informs humans of the improved system final state, and / or implements the system final state in the production setup; 6. The system automatically identifies changes / transformations in the production layout toward the improved system state, thus avoiding restarting the process in response to these changes. Specifically, it sets the system's final state as the new initial state. 7. Verify the change in the final state of the system relative to the system characteristics calculated in step 3 or 4.

[0052] 8. If necessary, repeat the matching process if the predicted system characteristics are not achieved or if additional optimization potential is found.

[0053] The production equipment has, for example, the following characteristics: • There exists a production system that can be transformed.

[0054] • Following a change in the production layout, a non-trivial further change is proposed independently by the technical system configured as a matching device. This change enables better performance characteristics of the production layout.

[0055] • Use the system model to determine the final state of the system with improved performance characteristics. The system model may also be used or has been used for purposes different from those used in the methods mentioned herein, and may be created for other purposes if necessary (e.g., the initial build of a production system). Attached Figure Description

[0056] Further features, advantages, and effects will become apparent from the following description of preferred embodiments of the invention and from the accompanying drawings. The drawings show: Figure 1 : A schematic block diagram used to illustrate embodiments of the present invention. Detailed Implementation

[0057] Figure 1 The schematic block diagram shows a production facility 1 configured to perform a method for matching a production layout 2, which is an embodiment of the present invention.

[0058] Production equipment 1 includes production arrangement 2, wherein production arrangement 2 is specifically configured as a changeable production system, or more specifically as a changeable production unit. Production arrangement 2 is configured to execute production processes.

[0059] Production layout 2, for example, has multiple production components that cooperate to execute a production process. The production process can be, for example, a manufacturing process, an assembly process, a logistics process, etc. Production layout 2 is characterized by structural and procedural configurations, wherein the structural configuration includes the selection and arrangement of the production components, particularly their layout. The procedural configuration specifically includes the control and / or monitoring of the processes used for the structural configuration to realize the production process.

[0060] In step 100, production arrangement 2 is in the initial state of the system. The initial state of the system specifically characterizes the structural and procedural configuration of production arrangement 2 in production, that is, in a state ready for operation or during operation.

[0061] In step 200, a triggering event is performed that causes a change in production arrangement 2. Specifically, the change in production arrangement 2 is configured as a physical change such that, due to the change and / or the change event, the performance characteristics of the production process with respect to production arrangement 2 change. The triggering event can be expected or unexpected.

[0062] An example of a triggering event is: - Failure of production components; - Replacement of production components, wherein the replacement production components have different characteristics from the original production components; - Changes to the settings of Production Layout 2; - Changes in the number of production components such as workpiece brackets and transport robots.

[0063] -Changes in the state of transported production media, such as energy, gas, and liquid.

[0064] By triggering an event, in step 300, production arrangement 2 is moved from the initial state of the system to an intermediate state of the system, which is different from the initial state of the system.

[0065] The production equipment has a detection device 3 for detecting changes, particularly triggering events, wherein changes are detected by the detection device 3 in step 400. This detection is automated and / or performed automatically. Therefore, the detection device 3 is also configured as a monitoring device for monitoring the system status of the production arrangement 2. The detection device 3 may be software-supported, wherein changes are detected by registering or deregistering production components in a network or in the control device of the production equipment 1. The detection device 3 may be hardware-supported, wherein it has one or more sensors for detecting changes. The detection device 3 may also be both software-supported and hardware-supported.

[0066] Production equipment 1 has a matching device 4, wherein the matching device 4 is configured, for example, as a digital data processing device. The matching device 4 is configured to provide an improved final state of the system for the purpose of matching production layout 2.

[0067] Since a change is detected, a matching process in the matching device 4 is triggered in step 400. The triggering is particularly automated, thereby automating the following steps based on the triggering event in step 200.

[0068] In step 500, a data technology image of the production arrangement 2 with a system intermediate state is determined within the scope of the matching process. The configuration of this data technology image depends on what needs to be used for calculating the system's final state. The data technology image is constructed, for example, as a simulation model and / or model prediction adjustment. The data technology image reflects the system intermediate state of the production arrangement 2. For this purpose, the matching device 4 acquires the system intermediate state, particularly the structural configuration and / or program configuration of the production arrangement 2 in the system intermediate state.

[0069] In step 600, the system intermediate state is aligned with, for example, the target quantity. The target quantity could involve higher production speed, higher production efficiency, smaller space requirements, smaller energy requirements, etc. The system intermediate state is modified to achieve the target quantity. This step 600 can therefore also be referred to as optimization.

[0070] In step 700, the final state of the system is created as the result of the matching.

[0071] Production equipment 1 has a providing device 5, wherein the final state of the system from the matching device 4 is provided in step 800.

[0072] In step 900, the final state of the system is realized, particularly implemented, in production arrangement 2, so that the actual production arrangement 2 is in the final state of the system. The realization of the final state of the system in production arrangement 2 can be performed by humans, or alternatively, it can be automated.

[0073] In step 1000, an evaluation, and particularly verification, is performed on the production arrangement 2 with the achieved final system state. This evaluation is therefore conducted at the actual production arrangement 2. Specifically, this evaluation verifies whether the actual system characteristics of the production arrangement 2 are consistent with the calculated system characteristics of the final system state in the matching device 4, i.e., with the system characteristics of the digital image of the production arrangement 2 in that final system state. Alternatively or supplementarily, further optimization potential may also be explored in step 1000.

[0074] If the evaluation result is unqualified, that is, if the actual system characteristics are not sufficiently consistent with the calculated system characteristics, or if optimization potential has been found, the final state of the system is passed to the matching device 4 as the intermediate state of the system, and the matching process is repeated.

[0075] If the evaluation result is satisfactory, that is, the actual system characteristics are sufficiently consistent with the calculated system characteristics or no optimization potential is found, the final state of the system forms a new initial state of the system for production layout 2, and thus the method is repeated if necessary in the event of another triggering event.

Claims

1. A method for matching production layout (2), in, The production layout (2) has a (100) system initial state. The production arrangement (2) is changed due to the change event (200), thereby changing the initial state of the system to the intermediate state (300). The change is automatically detected as a trigger event, and this trigger event automatically triggers (400) a software-based matching process. In the matching process, a data technology image of the production layout (2) having the intermediate state of the system is determined (500). In the matching process, the intermediate state of the system (600) is matched in order to obtain the final state of the system (700) of the production layout (2). The final state of the system (800) is provided for implementation on the production arrangement (2).

2. The method according to claim 1, characterized in that, The final state of the system (900) is achieved on the production arrangement (2).

3. The method according to claim 1 or 2, characterized in that, The change event is constructed as a change in the process components of the production arrangement (2).

4. The method according to any one of the preceding claims, characterized in that, The final system state achieved by evaluation (1000) is evaluated, wherein, in the case of an unsatisfactory evaluation, the matching process is performed again with the final system state as a new intermediate system state.

5. The method according to any one of the preceding claims, characterized in that, The production layout (2) is constructed as a production system that can be transformed.

6. The method according to any one of the preceding claims, characterized in that, The changes are detected in terms of software technology and / or hardware technology.

7. The method according to any one of the preceding claims, characterized in that, The matching of intermediate states of the system is performed based on model prediction adjustment.

8. The method according to any one of the preceding claims, characterized in that, The final state of the system is manually achieved in the production setup (2).

9. The method according to any one of the preceding claims, characterized in that, The final state of the system is achieved automatically in the production layout (2).

10. A production apparatus (1), said production apparatus being particularly used for performing the method according to any one of the preceding claims, said production apparatus It has a production layout (2); It has a detection device (3) for detecting changes in the production arrangement (2) when the production arrangement (2) changes from the initial state of the system to the intermediate state of the system; It has a matching device (4), wherein, The matching device (4) is configured to perform a matching process in order to obtain the final state of the system; and It has a providing device (5) for providing the final state of the system.

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