CTU-AGV integrated logistics-oriented intelligent beat control system for sock manufacturing workshop
By collecting real-time data from production equipment to identify faults and generate alarm signals, material supply can be blocked, and production rhythm and logistics scheduling can be dynamically adjusted. This solves the problem of the disconnect between production rhythm control and logistics scheduling in the sock manufacturing workshop, and achieves rapid response and resource optimization.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- ZHEJIANG JASAN GRP JIANGSHAN KNITTING CO LTD
- Filing Date
- 2026-03-04
- Publication Date
- 2026-05-19
AI Technical Summary
The disconnect between production rhythm control and logistics scheduling in sock manufacturing workshops leads to material accumulation and resource waste when key equipment fails, and existing technologies struggle to achieve rapid response and dynamic adjustment.
The PLC collects production equipment data in real time, identifies faults and generates alarm signals, and transmits them to the AGV and CTU control systems via the MQTT protocol to block the material supply to the faulty workstations, and performs logistics replanning to dynamically adjust production cycle and logistics scheduling.
It enables real-time collaboration between the production and logistics systems, rapid response to equipment failures, prevention of material backlog and resource waste, and improved production flexibility and efficiency.
Smart Images
Figure CN122064003A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of industrial automation technology, specifically to an intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics. Background Technology
[0002] Sock manufacturing is a typical labor-intensive, multi-stage discrete manufacturing process, encompassing winding, warping, knitting, sewing, shaping, and packaging. The processing time for each stage varies significantly, and frequent changes in colors, sizes, and styles make it difficult to maintain a consistent production pace, leading to bottlenecks or stockpiles of work-in-process. Traditional sock workshops typically rely on manual handling or fixed-track conveyors for material flow, resulting in low logistics efficiency and slow response times, making it difficult to support the flexible, small-batch, and fast-delivery demands of modern production.
[0003] In recent years, with the development of intelligent manufacturing technology, Automated Guided Vehicles (AGVs) and Cell Transport Units (CTUs) have been gradually introduced into the textile manufacturing field. CTUs, as standardized and identifiable carriers, can carry semi-finished socks and integrate RFID or QR code information; AGVs are responsible for autonomously transporting CTUs within the workshop according to instructions, achieving point-to-point delivery from workstation to workstation. The CTU-AGV integrated logistics system significantly improves the automation and informatization level of material flow. However, most current applications remain at the level of "logistics automation," with production cycle control and logistics scheduling being disconnected: production plans are determined by MES or manual scheduling, while AGV scheduling is based on static paths or simple task queues, lacking collaborative perception and dynamic response to real-time data such as equipment status, work-in-process location, and order priority.
[0004] Chinese invention patent application CN112198846A discloses an adaptive scheduling system and method for assembly line operations. The main control unit includes a task scheduling server, an assembly line scheduling module, and a database; the controlled unit includes a judgment module, a self-adjustment module, a data acquisition module, an allocation module, and a threshold module. The task scheduling server allocates tasks, and the database stores assembly line tasks, part status data, and the total number of tasks. The assembly line scheduling module adjusts the number of start-up lines based on the total number of tasks and the maximum number of tasks. The judgment module determines whether the current number of tasks exceeds the maximum number of tasks. The self-adjustment module returns excess tasks to the task scheduling server. The data acquisition module collects the current number of tasks. The allocation module allocates the parts required for each assembly line task. The threshold module adjusts the maximum number of tasks.
[0005] However, the above and similar technical solutions still have the following shortcomings: when key equipment on the sock production line (such as sewing machines) malfunctions, the upper-level production management system (MES) is unable to generate and issue global rescheduling instructions in a timely manner. At the same time, the AGV logistics system and CTU storage system will still carry out delivery and outbound tasks based on the original production plan, thus continuously supplying materials to the faulty workstation (such as sewing machines), causing material accumulation at the front end of the faulty workstation and wasted logistics resources. Summary of the Invention
[0006] The purpose of this invention is to provide an intelligent cycle control system for sock manufacturing workshops with CTU-AGV integrated logistics, in order to solve the problems mentioned in the background art.
[0007] To achieve the above objectives, the present invention provides the following technical solution: an intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics, comprising: Fault determination and alarm module: By analyzing the operating data stream of the production equipment, the corresponding actual production cycle time is determined, and the corresponding fault alarm signal is determined based on the comparison result between the actual production cycle time and the target production cycle time. Logistics priority blocking module: Based on the fault alarm signal, it regulates the operation of the controllers of the AGV scheduling system and the CTU control system to block the task flow of the AGV scheduling system and the outbound flow of the CTU control system; Logistics replanning and adjustment module: Adjusts the actual production cycle time and determines emergency instructions based on the operating data flow of the production equipment.
[0008] Furthermore, the corresponding fault alarm signals are identified, including: SA1: Cycle time determination: By interacting with the PLC controller of the production equipment, the operation data stream of the production equipment is collected and obtained, the quantity of all qualified products produced within a preset time period is obtained, and the corresponding actual production cycle time is determined based on the preset time period and the quantity of all qualified products produced. SA2: Fault Single Judgment: The target production cycle time and cycle time tolerance coefficient of the production equipment are combined to set a corresponding single cycle time threshold. Simultaneously, the actual production cycle time and the single cycle time threshold are compared. Based on the comparison result, the corresponding judgment result is determined, specifically: When the actual production cycle time is less than the single cycle time threshold, the corresponding production equipment is in a faulty operating state; otherwise, the corresponding production equipment is not in a faulty operating state. SA3: Fault Determination: Obtain all judgment results within a preset time period. If all judgment results within the preset time period indicate that a fault has occurred, then the corresponding production cycle is abnormal; otherwise, the corresponding production cycle is not abnormal.
[0009] Furthermore, the production equipment is subjected to standard operations in a cycle to obtain the corresponding standard operating time and standard operating output. At the same time, the standard operating time and standard operating output are combined to set the corresponding target production cycle.
[0010] Furthermore, the PLC controller of the production equipment is electrically connected to the controller of the AGV scheduling system and the controller of the CTU control system through the central controller, and transmits fault alarm signals through the MQTT protocol. The fault alarm signal includes the fault station ID, fault type and timestamp. The fault type includes abnormal cycle time and complete shutdown.
[0011] Furthermore, blocking the task flow of the AGV scheduling system includes: SB1.1: First instruction determination: Based on the faulty workstation ID, a first control instruction is sent to the controller of the AGV scheduling system. The first control instruction includes instruction type, target workstation, operating range, expected action, timestamp, and instruction ID. SB1.2: First Classification Processing: Based on the target workstation, all scheduling tasks in the AGV scheduling system are classified to determine all scheduling tasks that match the target workstation. Simultaneously, based on the status of the matching scheduling tasks, corresponding blocking operations are determined, specifically: For tasks in execution status, pause or stop operations are performed via the vehicle communication network; For tasks in the waiting state and tasks in the planned state, perform a deletion operation.
[0012] Furthermore, based on the state classification, the matching and scheduling task includes execution state tasks, waiting state tasks, and planning state tasks. The execution state tasks are those that have been assigned to AGV vehicles and are physically moving. The waiting state tasks are those that have not been assigned to AGV vehicles and have been successfully created. The planning state tasks are those that have been assigned to AGV vehicles but have not physically moved.
[0013] Furthermore, blocking the outbound flow of the CTU control system includes: SB2.1: Second instruction determination: Based on the fault station ID, send a second control instruction to the controller of the CTU control system. The first control instruction includes instruction type, target station, operation object, execution action, timestamp, and instruction ID. SB2.2: Second Classification Processing: Based on the target workstation, all outbound tasks in the CTU control system are classified to identify all outbound tasks matching the target workstation. Simultaneously, the matching outbound tasks are divided into sub-tasks, and based on the sub-task division results, corresponding blocking operations are determined. Specifically: For outbound task instructions that have not yet been physically executed, the execution is stopped through the corresponding underlying device controller; For outbound task instructions that have been physically executed, the faulty workstation is modified to a preset emergency dynamic buffer area or a preset safety temporary storage location, and the materials already in transit are transported to the preset emergency dynamic buffer area or the preset safety temporary storage location.
[0014] Furthermore, emergency instructions are defined, including: SC1: Cycle Adjustment: Based on the fault station ID in the fault alarm signal, collect the corresponding production line status and adjust the current production cycle. SC2: Logistics Scheduling: Based on the process content corresponding to the faulty workstation, determine all backup workstations compatible with the process of the faulty workstation from the CTU control system, and determine the corresponding logistics coordination scheduling instruction based on the status of each backup workstation, specifically: When the downstream standby workstation corresponding to the faulty workstation is in an idle state, the material delivered to the faulty workstation is delivered to the corresponding downstream standby workstation in the CTU control system through the AGV scheduling system. When the downstream backup station corresponding to the faulty station is in a busy state, the preset emergency dynamic buffer zone is partitioned according to the process attributes of the conveyed material, and the material conveyed to the faulty station is conveyed to the partitioned preset emergency dynamic buffer zone.
[0015] Furthermore, adjustments will be made to the current production cycle, including: SC1.1: Status Assessment: Based on the faulty workstation ID, collect the operating data of the upstream and downstream buffer areas of the faulty workstation, obtain the current inventory of the upstream buffer area and the current inventory of the downstream buffer area, determine the corresponding upstream buffer area utilization rate and downstream buffer area idle rate, and at the same time, determine the corresponding backlog risk and acceptance risk based on the upstream buffer area utilization rate and downstream buffer area idle rate. SC1.2: Cycle Time Determination: Based on the aforementioned fault type and backlog risk, adjust the current production cycle time, specifically as follows: When the failure type is a complete shutdown or the backlog risk is high, the upstream output cycle time drops to zero; When the failure type is low risk of backlog, the upstream output cycle time will be reduced to the current production cycle time corresponding to the failure station.
[0016] Furthermore, the upstream cache utilization rate is compared with a preset backlog threshold, and based on the comparison result, the corresponding backlog risk is determined, specifically as follows: When the upstream cache utilization rate is greater than the preset backlog threshold, the corresponding backlog risk is high; otherwise, the corresponding backlog risk is low. The downstream buffer idle rate is compared with a preset acceptance threshold, and the corresponding acceptance risk is determined based on the comparison result, specifically: When the idle rate of the downstream buffer is less than the preset acceptance threshold, the corresponding acceptance risk is low risk, and the standby workstation is idle; conversely, the corresponding acceptance risk is high risk, and the standby workstation is busy.
[0017] Compared with the prior art, the beneficial effects of the present invention are: Firstly, this invention collects data in real time through the PLC of the production equipment, calculates and judges the actual production cycle, thereby enabling timely and automatic detection of equipment faults. At the same time, alarm signals containing faulty workstations, fault types and timestamps are transmitted to the controllers of the AGV scheduling system and CTU control system via the MQTT protocol. This can solve the pain points of information silos between the production system and the logistics system and slow fault information transmission in the traditional mode, and provide a foundation for subsequent rapid response. Secondly, based on the received fault alarm signal, this invention divides the AGV scheduling task and CTU outbound task into task states, and performs blocking processing according to the state division results to immediately cut off the material supply to the faulty workstation. This effectively prevents material backlog in front of the fault point and the ineffective operation of the AGV scheduling system and CTU control system, and minimizes the waste of global resources and logistics congestion caused by local faults. Thirdly, this invention assesses the backlog risk and takeover risk based on the status of the upstream and downstream buffer zones of the faulty workstation, so as to dynamically adjust the output speed of the upstream workstation. At the same time, based on the process of the faulty workstation, it determines the process-compatible backup workstation and uses the backup workstation for logistics scheduling. Attached Figure Description
[0018] Figure 1 This is a system block diagram of the intelligent rhythm control system for the sock manufacturing workshop in this invention; Figure 2 This is a flowchart illustrating the fault determination and alarm method of the present invention; Figure 3 This is a schematic diagram of the blocking process for AGV transportation tasks in this invention; Figure 4 This is a schematic diagram of the blocking process for CTU outbound tasks in this invention; Figure 5This is a flowchart illustrating the logistics replanning and adjustment method of the present invention. Detailed Implementation
[0019] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. 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.
[0020] refer to Figure 1 This embodiment provides an intelligent cycle control system for a sock manufacturing workshop with integrated CTU-AGV logistics. This system includes a fault diagnosis and alarm module, a logistics priority blocking module, and a logistics replanning and adjustment module. The fault diagnosis and alarm module identifies corresponding fault events based on the production equipment's operational data stream. The logistics priority blocking module schedules the task flow of the AGV scheduling system and the outbound flow of the CTU control system based on the identified fault events. After scheduling the task flow and outbound flow, the logistics replanning and adjustment module adjusts the local cycle time of the faulty workstation and generates corresponding emergency logistics scheduling instructions based on the adjusted local cycle time.
[0021] Specifically, the fault diagnosis and alarm module acquires the real-time operating data stream of the production equipment through the PLC's communication interface (such as Profibus, Profinet, EtherNet / IP), including but not limited to operating status, speed, and output data. Based on the acquired operating data stream, it determines the corresponding actual production cycle time. Simultaneously, it compares the determined actual production cycle time with the target production cycle time. Based on the comparison result, it determines the corresponding fault alarm signal and sends the determined fault alarm signal to the controllers of the AGV scheduling system and the CTU control system via the MQTT protocol.
[0022] Furthermore, the logistics priority blocking module, based on the fault alarm signal sent by the fault judgment and alarm module, regulates the operation of the controllers of the AGV scheduling system and the CTU control system to adjust the task flow of the AGV scheduling system and the outbound flow of the CTU control system. In other words, based on the fault alarm signal, it sends a first control command and a second control command to the AGV scheduling system and the CTU control system, respectively. The AGV scheduling system, based on the first control command, suspends all AGV delivery tasks to the faulty workstation and processes the transportation tasks already assigned to the faulty workstation but not yet executed. Simultaneously, the CTU control system, based on the second control command, locks all material batches outbound to the faulty workstation.
[0023] Furthermore, after the logistics priority blocking module blocks the task flow and outbound flow, the logistics replanning and adjustment module makes local adjustments to the actual production rhythm and issues corresponding emergency instructions based on the operating data flow of the production equipment. For example, it redirects materials to standby workstations or transfers them to the emergency dynamic buffer area in the CTU control system based on process attributes, and reschedules the AGV scheduling system.
[0024] In this embodiment, based on a comparison between the actual production cycle time and the target production cycle time, a corresponding fault alarm signal is determined and sent to the controllers of the AGV scheduling system and the CTU control system. (Reference) Figure 2 This embodiment provides a fault determination and alarm method, which specifically includes the following steps: Step SA1: Cycle Time Determination. This involves exchanging information with the PLC controller of the production equipment via an industrial fieldbus (such as Profibus, Profinet, EtherNet / IP) to collect real-time operating data streams of the production equipment, including but not limited to operating status (start / stop status), operating speed, and cumulative output. Simultaneously, based on the collected real-time operating data streams, the number of all qualified products produced within a preset time period (which can be specifically set according to actual needs, and therefore not specifically described in this embodiment, e.g., 30 seconds) is determined.
[0025] Furthermore, based on the quantity of all qualified products produced within the predetermined time period, the corresponding actual production cycle time is determined, specifically as follows: in: For actual production cycle time, This refers to the total number of qualified products produced within a preset time period. This is a preset time period.
[0026] Step SA2: Fault Diagnosis. This involves using time measurement or a predetermined time standard method to cycle through standard operations on the production equipment to obtain the corresponding standard operating time and standard operating output. Based on the obtained standard operating time and standard operating output, a corresponding target production cycle time is set. Simultaneously, the obtained target production cycle time is combined with a set cycle time tolerance coefficient (which can be specifically set according to actual needs; therefore, it is not specifically described in this embodiment. It is worth noting that the cycle time tolerance coefficient in this embodiment does not exceed 1, for example, it is set to 0.5) to obtain the corresponding single cycle time threshold.
[0027] Furthermore, the actual production cycle time obtained in step SA1 is compared with the set single-cycle cycle time threshold, and the judgment result of the single actual production cycle time is determined based on the comparison result, specifically as follows: When the actual production cycle time is less than the single cycle time threshold, the production equipment corresponding to that single actual production cycle time is considered to be malfunctioning. Conversely, when the actual production cycle time is not less than the single cycle time threshold, the production equipment corresponding to that single actual production cycle time is considered to be functioning correctly.
[0028] Step SA3: Fault Determination. Based on the determination results of a single actual production cycle in Step SA2, obtain the determination results of all single actual production cycles within a preset time period (which can be specifically set according to actual needs, so it is not specifically described in this embodiment, for example, 10 seconds). Based on the determination results within the preset time period, determine the abnormal state of the production cycle. In other words, if the determination results of a single actual production cycle all indicate a fault in the production equipment's operating state within the preset time period, then the corresponding production cycle is abnormal. Conversely, if the determination results of a single actual production cycle do not all indicate a fault in the production equipment's operating state within the preset time period, then the corresponding production cycle is not abnormal.
[0029] Furthermore, the fault alarm signals in this embodiment include cycle time abnormality and complete shutdown. When a production cycle time abnormality occurs, the corresponding fault alarm signal is cycle time abnormality. When the operating signal of the production equipment is 0, the corresponding fault alarm signal is complete shutdown.
[0030] Furthermore, the PLC controller of the production equipment is electrically connected to the controllers of the AGV scheduling system and the CTU control system through the central controller, and exchanges information via the MQTT protocol. In other words, the PLC controller of the production equipment sends fault alarm signals to the controllers of the AGV scheduling system and the CTU control system. Specifically, the fault alarm signal in this embodiment includes the faulty workstation ID, fault type, and timestamp. The fault types include cycle time abnormality and complete shutdown.
[0031] In this embodiment, based on the fault alarm signal obtained in step SA3, a first control command and a second control command are sent to the AGV scheduling system and the CTU control system, respectively, to regulate the controller operation status of the AGV scheduling system and the CTU control system. (Reference) Figure 3 and Figure 4 This embodiment provides a method for prioritizing the blocking of logistics, which specifically includes the following steps: Step SB1: Task Interruption. This involves clearing the AGV transport task at the faulty workstation based on the faulty workstation ID in the fault alarm signal. Details are as follows: Step SB1.1: First Instruction Determination. Based on the faulty workstation ID, the central controller sends a first control instruction to the AGV scheduling system controller. This first control instruction includes the instruction type (task interruption and emergency pause), target workstation (faulty workstation ID), operating range (all scheduled tasks in the AGV scheduling system), desired action (pausing or moving to a safe point for tasks in progress, removing tasks from the queue), timestamp, and instruction ID. Simultaneously, the first control instruction is transmitted via the application programming interface (API).
[0032] Step SB1.2: First Classification Processing. Based on the target workstation obtained in the first control instruction in Step SB1.1, all scheduling tasks in the AGV scheduling system are classified to identify all scheduling tasks matching the target workstation. Simultaneously, all identified matching scheduling tasks are categorized into three states: executing tasks, waiting tasks, and planning tasks. Specifically, tasks assigned to AGVs and physically moving are classified as executing tasks; tasks not assigned to AGVs but successfully created are classified as waiting tasks; and tasks assigned to AGVs but not physically moving are classified as planning tasks.
[0033] Furthermore, based on the state division of the matched scheduling tasks, the corresponding blocking operation is determined for each state task. Specifically, the AGV scheduling system interacts with the AGVs assigned to the tasks being executed via vehicle communication networks (such as Wi-Fi and 5G), and uses these networks to pause or navigate the assigned AGVs to the nearest safe waiting point for parking. Simultaneously, the AGV scheduling system deletes waiting and planned state tasks.
[0034] Step SB2: Outbound Blocking. This involves blocking the outbound task from the CTU at the faulty workstation based on the faulty workstation ID in the fault alarm signal. Details are as follows: Step SB2.1: Second Instruction Determination. Based on the faulty workstation ID, the central controller sends a second control instruction to the controller of the CTU control system. This second control instruction includes the instruction type (outbound freeze or inventory lock), target workstation (faulty workstation ID), operation object (all outbound tasks in the CTU control system), execution action (stop executing outbound instructions, lock material inventory status), timestamp, and instruction ID. Simultaneously, the second control instruction is transmitted via the application programming interface (API).
[0035] Step SB2.2: Second Classification Processing. Based on the target workstations obtained in the second control instructions in Step SB2.1, all outbound tasks in the CTU control system are classified to identify all outbound tasks matching the target workstations. Simultaneously, all identified matching outbound tasks are further divided into outbound task instructions that have not yet been physically executed and those that have been physically executed. Specifically, task instructions that have been generated and issued to the equipment control layer but not yet executed or completed by the corresponding storage equipment (e.g., stacker cranes, shuttles, and conveyors) are classified as outbound task instructions that have not yet been physically executed. Task instructions where physical actions (e.g., grabbing, removing from the storage location) are completed and materials leave their original storage location are classified as outbound task instructions that have been physically executed.
[0036] Furthermore, based on the status of the outbound task, the corresponding blocking operation is determined for each status task. Specifically, in this embodiment, outbound task instructions that have not yet been physically executed include those that are queued, assigned, and in execution. Queued refers to task instructions waiting for equipment resources in the job scheduler queue; assigned refers to task instructions that have been assigned to a specific device (e.g., assigned to stacker crane #3) but have not yet performed a physical action; and in execution refers to task instructions that have performed a physical action but have not yet completed the retrieval. It is worth noting that in this embodiment, the task status corresponding to the outbound task instructions that have not yet been physically executed (i.e., queued, assigned, and in execution) is set to "paused" or "cancelled," and the corresponding underlying device controller (e.g., stacker crane controller, conveyor line PLC) stops the execution of these outbound task instructions. This prevents the stacker crane from proceeding to the corresponding storage location for retrieval, or intercepts the corresponding pallet already on the conveyor line within the warehouse.
[0037] Furthermore, in this embodiment, the physically executed outbound task instructions include "picking complete" and "transporting in progress." "Picking complete" means the goods have been retrieved from their storage location and placed on the loading platform, while "transporting in progress" means the task has been taken over by the conveying system. Specifically, in this embodiment, the task status corresponding to the physically executed outbound task instructions (i.e., "picking complete" and "transporting in progress") is converted. This involves changing the destination of the outbound task instruction from the faulty workstation to a preset emergency dynamic buffer area (such as another location in the CTU control system besides the faulty workstation) or a preset safe temporary storage location. The material already en route is then transported to the preset emergency dynamic buffer area or the preset safe temporary storage location via the conveying system.
[0038] In this embodiment, after the AGV scheduling system blocks the transportation task in step SB1.2 and the CTU control system blocks the outbound task in step SB2.2, an emergency command is determined based on the adjustment of the production cycle at the faulty workstation, and the AGV scheduling system is rescheduled. (Reference) Figure 5This embodiment provides a logistics replanning and adjustment method, which specifically includes the following steps: Step SC1: Cycle Time Adjustment. Based on the fault alarm signals obtained in Step SA3, the corresponding faulty workstation ID and fault type are determined, and the corresponding production line status is collected based on the faulty workstation ID. Simultaneously, the current production cycle time is adjusted based on the collected production line status. Details are as follows: Step SC1.1: Status Assessment. Based on the identified faulty workstation ID, operational data from the upstream and downstream buffers of the faulty workstation are collected via the workshop industrial network (e.g., industrial Ethernet) to obtain the current inventory of the upstream and downstream buffers. Simultaneously, the current inventory of the upstream buffer is compared with its maximum buffer capacity, and the current inventory of the downstream buffer is compared with its maximum buffer capacity to obtain the corresponding upstream buffer utilization rate and downstream buffer idle rate. Specifically: in: For upstream cache utilization, This represents the current material inventory in the upstream buffer. This represents the maximum cache capacity of the upstream cache. This refers to the downstream buffer free rate. This represents the current material inventory in the downstream buffer area. This represents the maximum cache capacity of the downstream cache area.
[0039] Furthermore, the obtained upstream cache utilization rate is compared with a preset backlog threshold (which can be set according to actual needs, but is not specifically described in this embodiment, for example, 80%), and the corresponding backlog risk is determined based on the comparison result. Specifically: When the obtained upstream buffer utilization rate is greater than the preset backlog threshold, the corresponding backlog risk is high. Conversely, when the obtained upstream buffer utilization rate is not greater than the preset backlog threshold, the corresponding backlog risk is low. In other words, in this embodiment, the backlog risk corresponding to the tick anomaly includes both high and low risks.
[0040] Step SC1.2: Cycle Time Determination. This involves adjusting the current production cycle time in real time based on the determined fault type (complete shutdown or abnormal cycle time) and the backlog risk identified in Step SC1.1. Specifically, when the fault type is a complete shutdown or abnormal cycle time and the backlog risk is high, the upstream output cycle time is reduced to zero. Further, when the fault type is an abnormal cycle time and the backlog risk is low, the upstream station speed is reduced. In other words, the upstream output cycle time is adjusted to match the current production cycle time of the faulty station.
[0041] Step SC2: Logistics Scheduling. This involves determining the corresponding logistics instructions based on the identified fault type and the downstream buffer idle rate determined in Step SC1.1. Specifically, based on the process content corresponding to the faulty workstation, all backup workstations compatible with the faulty workstation's process are identified from the CTU control system. Simultaneously, based on the downstream buffer idle rate determined in Step SC1.1, the downstream buffer idle rate corresponding to each backup workstation is determined.
[0042] Furthermore, the idle rate of the downstream buffer corresponding to each standby workstation is compared with a preset acceptance threshold (which can be set according to actual needs, so it is not specifically described in this embodiment, for example, 10%), and the corresponding acceptance risk is determined based on the comparison result. Specifically: When the downstream buffer idle rate is less than the preset acceptance threshold, the corresponding acceptance risk is low, and the standby workstation is idle. Conversely, when the downstream buffer idle rate is not less than the preset acceptance threshold, the corresponding acceptance risk is high, and the standby workstation is busy.
[0043] Furthermore, based on the status of each standby workstation (i.e., idle or busy), the corresponding logistics coordination and scheduling instructions are determined. Specifically: When the downstream standby station corresponding to the faulty workstation is idle, the AGV scheduling system will transfer the material to the corresponding downstream standby station in the CTU control system. When the downstream standby station corresponding to the faulty workstation is busy, the preset emergency dynamic buffer area will be partitioned according to the process attributes of the conveyed material (such as model and color) so that the material to the faulty workstation will be transferred to the partitioned preset emergency dynamic buffer area, and materials with the same attributes will be stored in the same partition.
[0044] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended embodiments and their equivalents.
Claims
1. A smart cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics, characterized in that, Including: Fault determination and alarm module: By analyzing the operating data stream of the production equipment, the corresponding actual production cycle time is determined, and the corresponding fault alarm signal is determined based on the comparison result between the actual production cycle time and the target production cycle time. Logistics priority blocking module: Based on the fault alarm signal, it regulates the operation of the controllers of the AGV scheduling system and the CTU control system to block the task flow of the AGV scheduling system and the outbound flow of the CTU control system; Logistics replanning and adjustment module: Adjusts the actual production cycle time and determines emergency instructions based on the operating data flow of the production equipment.
2. The intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics as described in claim 1, characterized in that, The corresponding fault alarm signals were identified, including: SA1: Cycle time determination: By interacting with the PLC controller of the production equipment, the operation data stream of the production equipment is collected and obtained, the quantity of all qualified products produced within a preset time period is obtained, and the corresponding actual production cycle time is determined based on the preset time period and the quantity of all qualified products produced. SA2: Fault Single Judgment: The target production cycle time and cycle time tolerance coefficient of the production equipment are combined to set a corresponding single cycle time threshold. Simultaneously, the actual production cycle time and the single cycle time threshold are compared. Based on the comparison result, the corresponding judgment result is determined, specifically: When the actual production cycle time is less than the single cycle time threshold, the corresponding production equipment is in a faulty operating state; otherwise, the corresponding production equipment is not in a faulty operating state. SA3: Fault Determination: Obtain all judgment results within a preset time period. If all judgment results within the preset time period indicate that a fault has occurred, then the corresponding production cycle is abnormal; otherwise, the corresponding production cycle is not abnormal.
3. The intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics as described in claim 2, characterized in that, The production equipment is operated in a cyclical manner according to standard procedures to obtain the corresponding standard operating time and standard operating output. The standard operating time and standard operating output are then combined to set the corresponding target production cycle time.
4. The intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics as described in claim 1, characterized in that, The PLC controller of the production equipment is electrically connected to the controller of the AGV scheduling system and the controller of the CTU control system through the central controller, and transmits fault alarm signals through the MQTT protocol. The fault alarm signal includes the fault station ID, fault type and timestamp. The fault type includes abnormal cycle time and complete shutdown.
5. The intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics as described in claim 1, characterized in that, Blocking the task flow of the AGV scheduling system includes: SB1.1: First instruction determination: Based on the faulty workstation ID, a first control instruction is sent to the controller of the AGV scheduling system. The first control instruction includes instruction type, target workstation, operating range, expected action, timestamp, and instruction ID. SB1.2: First Classification Processing: Based on the target workstation, all scheduling tasks in the AGV scheduling system are classified to determine all scheduling tasks that match the target workstation. Simultaneously, based on the status of the matching scheduling tasks, corresponding blocking operations are determined, specifically: For tasks in execution status, pause or stop operations are performed via the vehicle communication network; For tasks in the waiting state and tasks in the planned state, perform a deletion operation.
6. The intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics as described in claim 5, characterized in that, Based on the state classification, the matching and scheduling tasks include execution state tasks, waiting state tasks, and planning state tasks. The execution state tasks are those that have been assigned to AGV vehicles and are physically moving. The waiting state tasks are those that have not been assigned to AGV vehicles and have been successfully created. The planning state tasks are those that have been assigned to AGV vehicles but have not physically moved.
7. The intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics as described in claim 1, characterized in that, Blocking the outbound flow of the CTU control system includes: SB2.1: Second instruction determination: Based on the fault station ID, send a second control instruction to the controller of the CTU control system. The first control instruction includes instruction type, target station, operation object, execution action, timestamp, and instruction ID. SB2.2: Second Classification Processing: Based on the target workstation, all outbound tasks in the CTU control system are classified to identify all outbound tasks matching the target workstation. Simultaneously, the matching outbound tasks are divided into sub-tasks, and based on the sub-task division results, corresponding blocking operations are determined. Specifically: For outbound task instructions that have not yet been physically executed, the execution is stopped through the corresponding underlying device controller; For outbound task instructions that have been physically executed, the faulty workstation is modified to a preset emergency dynamic buffer area or a preset safety temporary storage location, and the materials already in transit are transported to the preset emergency dynamic buffer area or the preset safety temporary storage location.
8. The intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics as described in claim 1, characterized in that, Determine emergency instructions, including: SC1: Cycle Adjustment: Based on the fault station ID in the fault alarm signal, collect the corresponding production line status and adjust the current production cycle. SC2: Logistics Scheduling: Based on the process content corresponding to the faulty workstation, determine all backup workstations compatible with the process of the faulty workstation from the CTU control system, and determine the corresponding logistics coordination scheduling instruction based on the status of each backup workstation, specifically: When the downstream standby workstation corresponding to the faulty workstation is in an idle state, the material delivered to the faulty workstation is delivered to the corresponding downstream standby workstation in the CTU control system through the AGV scheduling system. When the downstream backup station corresponding to the faulty station is in a busy state, the preset emergency dynamic buffer zone is partitioned according to the process attributes of the conveyed material, and the material conveyed to the faulty station is conveyed to the partitioned preset emergency dynamic buffer zone.
9. The intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics as described in claim 8, characterized in that, Adjustments to the current production cycle include: SC1.1: Status Assessment: Based on the faulty workstation ID, collect the operating data of the upstream and downstream buffer areas of the faulty workstation, obtain the current inventory of the upstream buffer area and the current inventory of the downstream buffer area, determine the corresponding upstream buffer area utilization rate and downstream buffer area idle rate, and at the same time, determine the corresponding backlog risk and acceptance risk based on the upstream buffer area utilization rate and downstream buffer area idle rate. SC1.2: Cycle Time Determination: Based on the aforementioned fault type and backlog risk, adjust the current production cycle time, specifically as follows: When the failure type is a complete shutdown or the backlog risk is high, the upstream output cycle time drops to zero; When the failure type is low risk of backlog, the upstream output cycle time will be reduced to the current production cycle time corresponding to the failure station.
10. The intelligent cycle control system for a sock manufacturing workshop oriented towards CTU-AGV integrated logistics as described in claim 9, characterized in that, The upstream cache utilization rate is compared with a preset backlog threshold, and the corresponding backlog risk is determined based on the comparison result, specifically as follows: When the upstream cache utilization rate is greater than the preset backlog threshold, the corresponding backlog risk is high; otherwise, the corresponding backlog risk is low. The downstream buffer idle rate is compared with a preset acceptance threshold, and the corresponding acceptance risk is determined based on the comparison result, specifically: When the idle rate of the downstream buffer is less than the preset acceptance threshold, the corresponding acceptance risk is low risk, and the standby workstation is idle; conversely, the corresponding acceptance risk is high risk, and the standby workstation is busy.