Intelligent production takt assembling method and system

Abstract

The invention provides an intelligent production takt assembling method and system, and relates to the technical field of intelligent production, and the method comprises the steps: a WMS system generates an assembling order; the WMS system sends a cargo allocation instruction, and the WCS system dispatches logistics equipment to transport a material box of a material required by the current component out of a warehouse and place the material box at a designated position of a selection area; the WMS system updates the electronic tag, and an assembler selects materials in a selection area based on display information of the electronic tag and places the materials on an assembly table for assembly until all assembly of the total beat number of the current component is completed; the WMS system judges whether a next to-be-assembled part and a common part needed by the current part have coincident items or not, and needed materials are correspondingly adjusted; and the WMS system updates the next to-be-assembled part to the current part for assembling until all the to-be-assembled parts are assembled. The use efficiency and the taking and replacing reasonability of the parts are guaranteed, and the assembly efficiency is improved.

Description

Technical Field

[0001] This invention relates to the field of intelligent production assembly technology, and in particular to an intelligent production cycle assembly method and system. Background Technology

[0002] Assembly is a crucial part of product manufacturing. During the assembly process, operators need to assemble several parts into components or several parts and components into products according to the specified technical requirements.

[0003] Existing assembly methods typically rely on single-station assembly line operations, resulting in unclear assembly planning, mixed and overlapping handling of required parts, and overall low assembly efficiency. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides an intelligent production cycle assembly method and system that uses a cycle-based approach to assemble components in an orderly manner, thereby improving assembly efficiency.

[0005] In a first aspect, the present invention provides an intelligent production cycle assembly method, comprising: S1, the WMS system generates an assembly order, and based on the assembly order and the workload of one assembly cycle, obtains the total number of parts to be assembled and the total number of cycles for each part. S2, the WMS system sends a picking instruction, and the WCS system dispatches logistics equipment to transport the material boxes of the materials required for the current component from the warehouse and place them in the designated location of the picking area. The picking area is set up with a standard parts area and a general parts area. The required materials are divided into standard parts and general parts. S3, the WMS system updates the electronic tag. The electronic tag displays information including the component serial number, assembly cycle number, and material quantity list. Based on the information displayed on the electronic tag, the assembly personnel select materials in the selection area and place them on the assembly table for assembly until the assembly of the current component for the total number of cycles is completed. S4, the WMS system determines whether the next component to be assembled overlaps with the required ordinary parts of the current component; if so, the standard parts and overlapping ordinary parts remain unchanged, and all remaining materials of the current component are returned to the warehouse; if not, the standard parts remain unchanged, and all remaining materials of the current component are returned to the warehouse. In step S5, the WMS system updates the next component to be assembled to the current component and returns to execute step S2 until all components to be assembled are completed.

[0006] Preferably, in S3, the WMS system updating the electronic tag includes the following steps: The WMS system determines whether the quantity of materials in each material box is sufficient for one assembly cycle. If so, the WMS system updates the electronic tags, and the quantity list of materials in the electronic tags is displayed as the quantity list of materials required for one assembly cycle; If not, the WMS system updates the electronic tag, and the quantity list of materials on the electronic tag displays the actual quantity list of materials currently in the material box; after the materials in the material box are all taken and replenished, the electronic tag continues to display the quantity list of materials to be taken in the current assembly cycle.

[0007] Preferably, the WMS system determines whether the quantity of material in each material box is sufficient for one assembly cycle based on the weight of each material.

[0008] Preferably, in S3, the assembler selects materials in the selection area based on the display information of the electronic tag and places them on the assembly table for assembly until all assembly of the current component for the total number of cycle times is completed, including the following steps: The WMS system control indicator light is on; Based on the information displayed on the electronic tag, the assembly personnel select materials in the selection area, take away the materials required for the assembly cycle, and then press the indicator light corresponding to the material. After all the indicator lights corresponding to the materials required for the current component are turned off, the WMS system determines whether the assembly of the current component has been completed for the total number of cycle counts. If yes, it executes S4 to proceed with the assembly of the next component to be assembled. If no, it controls all the indicator lights to turn on again and executes the assembly of the next assembly cycle count for the current component.

[0009] Preferably, after the assembler presses the indicator light corresponding to the material, the assembly process further includes: The WMS system determines whether the current actual weight of the material bin matches the current theoretical weight of the material bin. If yes, the indicator light will turn off when pressed; otherwise, the indicator light will start flashing when pressed.

[0010] Preferably, between S1 and S2, the following is also included: The WMS system determines whether the inventory meets the requirements of the assembly order. If yes, it executes step S2; otherwise, it performs inventory analysis, purchases the required materials, puts them into storage, and updates the inventory information.

[0011] Preferably, the intelligent production cycle assembly method also includes: The WMS system updates the inventory list of assembled parts in real time. If a part in the inventory list meets the requirements of an assembly order, the WMS system sends a packing instruction and uses the WCS system to schedule logistics equipment to pack the part into a finished product box for storage.

[0012] Secondly, the present invention also provides an intelligent production cycle assembly system for performing the intelligent production cycle assembly method described above, comprising: storehouse; The selection area includes a standard parts area and a general parts area. Both the standard parts area and the general parts area are equipped with shelves for placing material boxes. Multiple electronic tags are installed on the shelves. Assembly table; The control system includes a WMS system and a WCS system. The WMS system is used for inventory management, order processing, goods circulation, and data analysis. The WCS system is used to receive instructions from the WMS system and control and manage the corresponding logistics equipment.

[0013] Preferably, the shelf is equipped with multiple indicator lights, each of which is matched with a single material box.

[0014] Preferably, the shelf is equipped with multiple weighing sensors, each of which is used to weigh a single material box.

[0015] Compared with the prior art, the present invention has the following beneficial effects: The intelligent production cycle assembly method and system described above improves the rationality of assembly planning by performing orderly assembly in a cycle-by-cycle manner; by setting up standard parts area and ordinary parts area, and judging whether there are any overlaps between the ordinary parts required for the next part to be assembled and the current part, the utilization efficiency and rationality of parts replacement are ensured, thereby improving assembly efficiency; and by changing the part category in real time according to the current assembly part, the storage space occupation is reduced and the space utilization rate is improved.

[0016] The intelligent production cycle assembly method and system described above guides operators to pick up materials through electronic tags, forming a human-machine collaborative work mode, which reduces the error rate of purely manual assembly, reduces rework, and further ensures assembly efficiency.

[0017] The intelligent production cycle assembly method and system described above uses indicator lights to check the current actual weight of the material box against the current theoretical weight of the material box, which further reduces the error rate and improves the intelligence of production assembly. Attached Figure Description

[0018] To more clearly illustrate the specific embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the specific embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are some embodiments of the present invention. For those skilled in the art, other drawings can be obtained from these drawings without creative effort.

[0019] Figure 1 This is a flowchart illustrating the intelligent production cycle assembly method in an embodiment of the present invention; Figure 2 This is a logical schematic diagram of the intelligent production cycle assembly method in an embodiment of the present invention; Figure 3 This is a schematic diagram of the intelligent production cycle assembly system in an embodiment of the present invention; Figure 4 This is a schematic diagram of the shelf structure in an embodiment of the present invention.

[0020] The attached diagram is labeled as follows: 1. Warehouse; 2. Sorting area; 21. Standard parts area; 22. Common parts area; 23. Shelves; 24. Material boxes; 25. Electronic tags; 26. Indicator lights; 27. Weighing sensors; 3. Assembly table. Detailed Implementation

[0021] The technical solution of the present invention will be clearly and completely described below with reference to the embodiments. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0022] In the description of this invention, it should be understood that the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined as "first" or "second" may explicitly or implicitly include one or more of the stated features. In the description of this invention, "a plurality of" means two or more, unless otherwise explicitly specified. Furthermore, the terms "connecting," "connected," and "joined" should be interpreted broadly; for example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0023] like Figures 1 to 2 As shown, this embodiment of the invention provides an intelligent production cycle assembly method, including: S1, the WMS system generates an assembly order. Based on the assembly order and the workload of one assembly cycle, it obtains the total number of parts to be assembled and the total number of cycles for each part.

[0024] Specifically, an assembly order includes the total number of parts, the types and total quantity of materials required for assembly, and the workload of one assembly cycle. The total number of cycles for each part is the ratio of the total number of parts to the workload of one assembly cycle.

[0025] Preferably, after determining the types and total quantities of materials required for assembly, the WMS system checks whether the inventory meets the needs of the assembly order. If yes, it executes step S2; otherwise, it performs inventory analysis, purchases the required materials, puts them into storage, and updates the inventory information.

[0026] S2, the WMS system sends a picking instruction, and the WCS system schedules logistics equipment to transport the material boxes of the materials required for the current component from the warehouse and place them in the designated location of the picking area. The picking area is divided into a standard parts area and a general parts area, and the required materials are divided into standard parts and general parts.

[0027] Specifically, starting with the k-th component as the current component (k initially valued at 1), the WMS system allocates materials according to the requirements of the k-th component. The WCS system schedules logistics equipment to transport the corresponding material boxes of standard parts and ordinary parts required for assembling the k-th component to the standard parts area and ordinary parts area of ​​the sorting zone, respectively. Specifically, the logistics equipment may include one or more automated logistics equipment such as stacker cranes, AGVs, conveyor belts, and CTUs. Standard parts specifically refer to components such as bolts, washers, and industry standard parts that are used in multiple components.

[0028] S3, WMS system updates electronic tags. The electronic tags display information including part serial number, assembly cycle number, and material quantity list. Assembly personnel select materials in the selection area based on the information displayed on the electronic tags and place them on the assembly table for assembly until the assembly of the current part for the total number of cycles is completed.

[0029] Specifically, the component serial number in the electronic tag is k, which represents the assembly sequence of the current component, and the assembly cycle sequence number is kn (n is initially 1), which represents the assembly cycle sequence of the current component. The assembly personnel select materials and assemble them starting from the knth assembly cycle until the assembly of the current component is completed for a total of knmax cycles.

[0030] Preferably, updating electronic tags in the WMS system includes the following steps: The WMS system determines whether the quantity of materials in each material box is sufficient for one assembly cycle. If so, the WMS system updates the electronic tags, and the quantity list of materials in the electronic tags is displayed as the quantity list of materials required for one assembly cycle; If not, the WMS system updates the electronic tag, and the quantity list of materials in the electronic tag displays the actual quantity list of materials currently in the material box; after the materials in the material box are taken out and replenished, the electronic tag continues to display the quantity list of materials to be taken in the current assembly cycle.

[0031] Preferably, the WMS system determines whether the quantity of materials in each material box is sufficient for one assembly cycle based on the weight of each material.

[0032] Preferably, the WMS system can also determine whether the quantity of materials in each material box is sufficient for one assembly cycle based on image recognition.

[0033] Taking weight determination as an example, after the electronic tag is updated, the assembly personnel select materials in the selection area based on the information displayed on the electronic tag and place them on the assembly table for assembly. The assembly process continues until all assembly steps for the current component are completed, including the following steps: The WMS system control indicator light is on; Based on the information displayed on the electronic tag, the assembly personnel select materials in the selection area. After taking the materials required for the assembly cycle, the assembly personnel press the indicator light corresponding to the material. The WMS system checks whether the current actual weight of the material bin matches the current theoretical weight of the material bin. If yes, the indicator light will turn off after being pressed; if no, the indicator light will start flashing after being pressed. After the indicator light starts flashing, the operator needs to check and verify, adjusting for any over- or under-weighted materials until the correct material is selected. After all the indicator lights corresponding to the materials required for the current component are turned off, the WMS system determines whether the assembly of the current component's total number of cycles knmax has been completed. If yes, it executes S4 to proceed with the assembly of the next component to be assembled. If no, it controls all the indicator lights to turn on again and executes the assembly work of the next assembly cycle kn+1 for the current component.

[0034] S4, the WMS system determines whether the next component to be assembled overlaps with the required ordinary parts of the current component; if so, it keeps the standard parts and overlapping ordinary parts unchanged and returns all remaining materials of the current component to the warehouse; if not, it keeps the standard parts unchanged and returns all remaining materials of the current component to the warehouse.

[0035] When the next component to be assembled, i.e. the (k+1)th component, has the same common parts required by the current component, i.e. the kth component, the invalidation operation of returning some of the common parts to the warehouse and then repeatedly issuing them can be reduced, thereby improving assembly efficiency.

[0036] In step S5, the WMS system updates the next component to be assembled to the current component and returns to execute step S2 until all components to be assembled are completed.

[0037] WMS updates the value of k until the assembly of the kmax-th component is completed, then ends the work of the assembly order to avoid omissions or errors.

[0038] Preferably, the intelligent production cycle assembly method also includes: The WMS system updates the inventory list of assembled parts in real time. If a part in the inventory list meets the requirements of an assembly order, the WMS system sends a packing instruction and uses the WCS system to schedule logistics equipment to pack the part into a finished product box for storage.

[0039] Preferably, when the inventory of a pre-assembled component meets the requirements of an assembly order, the packing operation for that order begins. The WCS system dispatches logistics equipment such as stacker cranes, conveyors, or AGVs to transport the pre-assembled component to the packing conveyor line, while simultaneously transporting the empty finished product box corresponding to the order to the beginning of the packing conveyor line. Workers scan the barcode of the empty finished product box, and the WMS system displays the detailed order information corresponding to that box, along with a list of the specific components required for the order on an electronic screen. Following the instructions on the electronic screen, workers operate robotic arms to grab the corresponding components and place them into the finished product box. After packing, the boxes are sealed, secured, and stacked, and the processed finished product boxes are placed on pallets. AGVs then transport the entire pallet of finished product boxes to the warehouse, where a stacker crane completes the warehousing.

[0040] When shipment is required, the WMS system issues an outbound order, and the WCS system dispatches logistics equipment to retrieve the finished boxes from the warehouse location; finally, forklifts transport the finished boxes to complete the loading operation.

[0041] The intelligent production cycle assembly method described in this application improves the rationality of assembly planning by performing orderly assembly in a cycle-based manner. By setting up standard parts areas and ordinary parts areas, and determining whether the ordinary parts required for the next component to be assembled overlap with those required for the current component, it ensures efficient use of parts and rationality of replacement, thereby improving assembly efficiency. Electronic tags guide operators in retrieving materials, forming a human-machine collaborative work mode, reducing the error rate of purely manual assembly, minimizing rework, and further ensuring assembly efficiency. Indicator lights verify the current actual weight of the material box against its theoretical weight, further reducing the error rate and improving the intelligence of production assembly.

[0042] like Figures 3 to 4 As shown, this embodiment of the invention also provides an intelligent production cycle assembly system for executing the intelligent production cycle assembly method described above, including: Warehouse 1; Selection area 2 includes a standard parts area 21 and a general parts area 22. Both the standard parts area 21 and the general parts area 22 are equipped with shelves 23. The shelves 23 are used to place material boxes 24. Multiple electronic tags 25 are installed on the shelves 23. Assembly table 3; The control system includes a WMS system and a WCS system. The WMS system is used for inventory management, order processing, goods circulation, and data analysis, while the WCS system is used to receive instructions from the WMS system and control and manage the corresponding logistics equipment.

[0043] Preferably, the shelf 23 is equipped with multiple indicator lights 26, each indicator light 26 being matched with a single material box 24.

[0044] Preferably, the shelf 23 is equipped with multiple weighing sensors 27, each weighing sensor 27 being used to weigh a single material box 24.

[0045] By setting up indicator lights 26 and weighing sensors 27, a human-machine collaborative working mode is formed during the assembly process, which reduces the assembly error rate, prevents manual selection of materials not in accordance with electronic tags 25, and further ensures assembly efficiency.

[0046] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention, and not to limit them; although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand that modifications can still be made to the technical solutions described in the foregoing embodiments, or equivalent substitutions can be made to some or all of the technical features; and these modifications or substitutions do not cause the essence of the corresponding technical solutions to deviate from the scope of the technical solutions of the embodiments of the present invention.

Claims

1. An intelligent production cycle assembly method, characterized in that, include: S1, the WMS system generates an assembly order, and based on the assembly order and the workload of one assembly cycle, obtains the total number of parts to be assembled and the total number of cycles for each part. S2, the WMS system sends a picking instruction, and the WCS system dispatches logistics equipment to transport the material boxes of the materials required for the current component from the warehouse and place them in the designated location of the picking area. The picking area is set up with a standard parts area and a general parts area. The required materials are divided into standard parts and general parts. S3, the WMS system updates the electronic tag. The electronic tag displays information including the component serial number, assembly cycle number, and material quantity list. Based on the information displayed on the electronic tag, the assembly personnel select materials in the selection area and place them on the assembly table for assembly until the assembly of the current component for the total number of cycles is completed. S4, the WMS system determines whether the next component to be assembled overlaps with the required ordinary parts of the current component; if so, the standard parts and overlapping ordinary parts remain unchanged, and all remaining materials of the current component are returned to the warehouse; if not, the standard parts remain unchanged, and all remaining materials of the current component are returned to the warehouse. In step S5, the WMS system updates the next component to be assembled to the current component and returns to execute step S2 until all components to be assembled are completed.

2. The intelligent production cycle assembly method according to claim 1, characterized in that, In S3, the WMS system updates the electronic tag by including the following steps: The WMS system determines whether the quantity of materials in each material box is sufficient for one assembly cycle. If so, the WMS system updates the electronic tags, and the quantity list of materials in the electronic tags is displayed as the quantity list of materials required for one assembly cycle; If not, the WMS system updates the electronic tag, and the quantity list of materials on the electronic tag displays the actual quantity list of materials currently in the material box; after the materials in the material box are all taken and replenished, the electronic tag continues to display the quantity list of materials to be taken in the current assembly cycle.

3. The intelligent production cycle assembly method according to claim 2, characterized in that: The WMS system determines whether the quantity of materials in each material box is sufficient for one assembly cycle based on the weight of each material.

4. The intelligent production cycle assembly method according to claim 2, characterized in that: In S3, the assembler selects materials in the selection area based on the information displayed on the electronic tag and places them on the assembly table for assembly until all assembly of the current component for the total number of cycle times is completed, including the following steps: The WMS system control indicator light is on; Based on the information displayed on the electronic tag, the assembly personnel select materials in the selection area, take away the materials required for the assembly cycle, and then press the indicator light corresponding to the material. After all the indicator lights corresponding to the materials required for the current component are turned off, the WMS system determines whether the assembly of the current component has been completed for the total number of cycle counts. If yes, it executes S4 to proceed with the assembly of the next component to be assembled. If no, it controls all the indicator lights to turn on again and executes the assembly of the next assembly cycle count for the current component.

5. The intelligent production cycle assembly method according to claim 4, characterized in that: After the assembler presses the indicator light corresponding to the material, the process also includes: The WMS system determines whether the current actual weight of the material bin matches the current theoretical weight of the material bin. If yes, the indicator light will turn off when pressed; otherwise, the indicator light will start flashing when pressed.

6. The intelligent production cycle assembly method according to claim 1, characterized in that: Between S1 and S2, it also includes: The WMS system determines whether the inventory meets the requirements of the assembly order. If yes, it executes step S2; otherwise, it performs inventory analysis, purchases the required materials, puts them into storage, and updates the inventory information.

7. The intelligent production cycle assembly method according to claim 1, characterized in that, Also includes: The WMS system updates the inventory list of assembled parts in real time. If a part in the inventory list meets the requirements of an assembly order, the WMS system sends a packing instruction and uses the WCS system to schedule logistics equipment to pack the part into a finished product box for storage.

8. An intelligent production cycle assembly system, used to execute the intelligent production cycle assembly method as described in any one of claims 1-7, characterized in that, include: storehouse; The selection area includes a standard parts area and a general parts area. Both the standard parts area and the general parts area are equipped with shelves for placing material boxes. Multiple electronic tags are installed on the shelves. Assembly table; The control system includes a WMS system and a WCS system. The WMS system is used for inventory management, order processing, goods circulation, and data analysis. The WCS system is used to receive instructions from the WMS system and control and manage the corresponding logistics equipment.

9. The intelligent production cycle assembly system according to claim 8, characterized in that: The shelf is equipped with multiple indicator lights, each of which is matched with a single material box.

10. The intelligent production cycle assembly system according to claim 8, characterized in that: The shelf is equipped with multiple weighing sensors, each of which is used to weigh a single material box.

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