Digital operation auxiliary method, system and equipment for multi-mode production and medium

Abstract

The invention relates to a digital operation auxiliary method, system and equipment for multi-mode production and a medium. The method comprises the steps of obtaining production order information and generating an operation guidance program which comprises a process route, processes, steps and steps, and issuing the process route, the processes, the steps and the steps to an operation terminal. After receiving the operation guidance program, loading the first process information, and determining whether the qualification of the operator meets the requirement or not. And if yes, loading the bill of materials, guiding material taking, and verifying the materials through an indicating lamp or bar code scanning. And after material verification, executing a tool operation step, activating a tool through the operation terminal, setting control parameters, and completing tool operation. And after the operation is completed, collecting and recording operation data including results, material barcodes and tool states, and storing the operation data to the terminal. And judging whether the process is completed, if not, entering the next process step, and if so, uploading operation data. And if the process is the last process, generating and recording product resume information. According to the method, the cooperation efficiency and the quality control capability of the operation process are improved.

Description

Technical Field

[0001] This invention relates to the field of digital operation assistance technology, specifically to a digital operation assistance method, system, equipment, and medium for multi-mode production. Background Technology

[0002] In recent years, the discrete manufacturing industry has been undergoing rapid digital transformation. The design of flexible assembly systems is gradually shifting from traditional manual autonomous operation modes to more flexible and efficient human-machine collaboration modes to meet the industry's demands for low-cost, automated, and transparent production. In the manufacturing of rail transit components, the product quality of core components such as traction converters, network control systems, and signaling systems directly affects train operation safety. Therefore, how to achieve low-cost, fully traceable production control while ensuring quality has always been a key research topic in the discrete manufacturing industry.

[0003] The assembly of rail transit components is characterized by its wide variety, small batch sizes, and complex structures. These components typically require multi-directional and multi-process assembly after initial assembly, making fully automated assembly currently impossible and relying primarily on manual labor. However, manual assembly presents numerous challenges: production process guidance cannot directly control on-site operations, quality management lacks equipment and system support, operational data lacks record-keeping and traceability, and resource allocation is untimely, making it difficult to meet the demands for high-quality, end-to-end control. Summary of the Invention

[0004] This invention provides a digital operation assistance method, system, equipment and medium for multi-mode production, which aims to solve the problem of inefficient collaboration, real-time control and data traceability of operation processes under multiple production modes in discrete manufacturing.

[0005] To achieve the above objectives, the first aspect of the present invention provides a digital operation assistance method for multi-mode production, comprising the following steps:

[0006] Obtain production order information, generate a work instruction program based on the production order information, the work instruction program includes process route, operation, work step and steps, and distribute the generated work instruction program to the work terminal;

[0007] Receive the work instruction program, load the first process information in the process route according to the work instruction program, and confirm whether the current operator's qualifications meet the requirements of the process.

[0008] If the operator's qualifications meet the requirements, load the BOM (Bill of Materials) required for the process and guide the operator to pick up the materials. At the same time, verify whether the picked materials meet the requirements through indicator lights or barcode scanners.

[0009] After material verification is completed, the tool operation steps in the process are executed. The tool is activated through the work terminal, and the corresponding tool control parameters are set according to the process parameters of the process to complete the tool operation.

[0010] After the tool operation is completed, the operation data of the current step is collected and recorded in real time, including the operation result, material barcode and tool status, and the operation data is stored in the operation terminal.

[0011] Determine if the process is complete. If not, proceed to the next step and repeat the above steps. If complete, upload and store the operation data of the current process. If the operation data of the current process is the final process of product production, generate and record product history information.

[0012] Furthermore, when a change in process information is detected during the operation, the system server re-edits the operation guidance program for the changed part and sends it to the operation terminal to apply the new process requirements.

[0013] Furthermore, each step is executed in sequence on the work terminal, and step verification is performed upon completion of each step, including verifying the conformity of the work step execution results with preset standards.

[0014] Furthermore, the steps for generating the job instruction procedure include:

[0015] Receive production order information and extract product model, process route number, batch information and order quantity from the production order information;

[0016] Based on the extracted product model, retrieve the corresponding process route template from the database;

[0017] Based on the process route number in the production order information, the process route template is verified for version, and the matching process route version is loaded.

[0018] The information of each process step by step is parsed in the process route to generate a process list containing the process sequence, process content and required operation steps;

[0019] For each process, the required material information and operator qualification requirements are parsed from the production order information to generate a process configuration and associate it with the current process;

[0020] The control parameters and execution instructions of each step are matched one by one with the corresponding steps in the process list to generate a complete work instruction program.

[0021] Set the generated job instruction program as the initial version and distribute it to the job terminal for storage.

[0022] Furthermore, after the work instruction program is generated, the process is divided into configurable task units, which are then assigned to the corresponding operators by the program administrator based on the granularity of the process.

[0023] Furthermore, the work instruction program is set to verification mode when it is first generated. In verification mode, the work instruction program is published to the work terminal step by step, and the work process content that needs to be adjusted is recorded on the work terminal by taking pictures, videos and editing text.

[0024] Furthermore, in processes where multiple operators collaborate in parallel, the work instruction program divides the process content into multiple work units based on the ownership characteristics of the operators and tools. The server then pushes the work program to the corresponding work terminal based on the work unit.

[0025] To achieve the above objectives, a second aspect of the present invention provides a human-machine collaboration system, comprising a system server and at least one client; wherein:

[0026] The system server is used to execute the steps of the method, specifically including generating and managing work instruction programs, connecting to the MES system to obtain order information and personnel qualification information, and interacting with the DDCS, DPS and RCS systems for data.

[0027] The system server also includes a module for receiving feedback information and updating work instructions. This module regenerates the work instructions based on process changes and distributes them to the work terminals. The system server also includes a verification module for verifying the work instructions step by step after process changes and publishing them to the work terminals after successful verification. The system server interfaces with the RCS system to schedule AGVs for material delivery and empty rack recycling in production line mode, and triggers material delivery in advance according to process requirements.

[0028] The work terminal is used to control the production process and collect operation data. The work terminal includes an industrial all-in-one machine and a mobile terminal. The industrial all-in-one machine is used to execute work instruction programs and control the operation of hardware equipment, including indicator lights, barcode scanners, and smart tools, and communicates with the PLC system. The industrial all-in-one machine in the work terminal is connected to the barcode scanner via a USB interface and connected to the PLC system via a local area network.

[0029] The mobile terminal is used to provide operation guidance content display, data collection, and feedback of operation results in parallel operation scenarios.

[0030] To achieve the above objectives, a third aspect of the present invention provides an electronic device including a memory and a processor, the memory being used to store a program supporting the processor in executing the digital operation assistance method for multi-mode production, and the processor being configured to execute the program stored in the memory.

[0031] To achieve the above objectives, a fourth aspect of the present invention provides a computer-readable storage medium storing a computer program, wherein the computer program, when executed by a processor, performs the steps of the digital operation assistance method for multi-mode production.

[0032] The beneficial effects of this invention are:

[0033] Compared with existing technologies, this invention provides a digital operation assistance method, system, equipment, and medium for multi-mode production. By introducing a series of intelligent operations such as the automatic generation and distribution of digital operation guidance programs, real-time operator qualification verification, material verification, and tool operation control, it greatly improves the collaborative efficiency and quality control capabilities of the operation process. Through real-time data collection and uploading from the operation terminal, the system can automatically record materials, tools, operation results, and process information during the operation, achieving accurate production data traceability. Simultaneously, this invention supports flexible application under different production modes, can meet the needs of various production environments and operation scenarios, ensures efficient control of the operation process and full data traceability, and avoids the problems of resource mismatch, data disconnect, and insufficient quality control in traditional manual operations, thereby improving the transparency, automation, and production efficiency of discrete manufacturing processes. Attached Figure Description

[0034] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below.

[0035] Figure 1 This is a framework diagram of a human-machine collaboration system disclosed in an embodiment of the present invention.

[0036] Figure 2 This is a job instruction program editing process disclosed in an embodiment of the present invention.

[0037] Figure 3 This is a flowchart of a job instruction program version management system disclosed in an embodiment of the present invention.

[0038] Figure 4 This is a system server and client data interaction and synchronization framework diagram disclosed in an embodiment of the present invention.

[0039] Figure 5 This is a parallel job server control flowchart disclosed in an embodiment of the present invention.

[0040] Figure 6 This is a flowchart of a parallel job control process disclosed in an embodiment of the present invention.

[0041] Figure 7This is a hardware framework diagram of a parallel operation system disclosed in an embodiment of the present invention.

[0042] Figure 8 This is a data acquisition flowchart disclosed in an embodiment of the present invention.

[0043] Figure 9 This is a multi-mode control flowchart disclosed in an embodiment of the present invention. Detailed Implementation

[0044] like Figures 1-9 As shown, the present invention provides a digital operation assistance method for multi-mode production, comprising the following steps:

[0045] Step S100: Obtain production order information, generate a work instruction program based on the production order information, the work instruction program includes process route, operation, work step and steps, and send the generated work instruction program to the work terminal;

[0046] On the system server side, the system first interfaces with the factory's MES system to obtain current production order information. Based on this order information, a corresponding work instruction program is generated. This work instruction program contains a complete process route, broken down into processes, steps, and specific procedures. The system server automatically distributes the generated work instruction program to each operator's terminal, such as PCs, PDAs, or mobile devices, ensuring that operators can access the latest work guidelines. The generation process of the work instruction program includes extracting the process route, breaking down processes and steps, and pre-setting qualification verification, bill of materials, and tool parameters to ensure seamless integration throughout the entire production process.

[0047] Step S200: Receive the work instruction program, load the first process information in the process route according to the work instruction program, and confirm whether the current operator's qualifications meet the requirements of the process.

[0048] The operator terminal receives and loads the first process information from the process route. The system server connects to the COA system to import the operator's qualification information. During production, based on the currently loaded process requirements, the system automatically verifies whether the operator's qualifications meet the requirements for that process. If the operator's qualifications meet the requirements, the system will continue executing the process; if the qualifications do not meet the requirements, the system will issue a warning, indicating that the operator does not have the corresponding operating qualifications and that a qualified operator must be replaced to ensure product quality and operational safety.

[0049] Step S300: If the operator's qualifications meet the requirements, load the BOM material list required for the process and guide the operator to pick up the materials. At the same time, verify whether the picked materials meet the requirements through indicator lights or barcode scanners.

[0050] After confirming the operator's qualifications, the system automatically loads the Bill of Materials (BOM) required for the current process. The terminal guides the operator to retrieve materials item by item according to the list, while simultaneously verifying the accuracy of the retrieved materials using indicator lights and a barcode scanner. Indicator lights illuminate at the corresponding material storage locations to help the operator quickly locate the required materials, while the barcode scanner scans the material barcodes to ensure the actual materials match the BOM list. If the material verification fails to meet requirements, the system will immediately issue a warning and prevent further operation, avoiding the impact of using incorrect materials on product quality.

[0051] Step S400: After material verification is completed, execute the tool operation steps in the process, activate the tool through the work terminal, and set the corresponding tool control parameters according to the process parameters of the process to complete the tool operation;

[0052] After material verification, the tools required for the current process are activated via the work terminal, and the corresponding control parameters are set for the tools according to the preset process parameters in the process route. The intelligent tightening tool will be activated, and operating parameters such as torque and angle will be set according to the process requirements to ensure they meet the specifications. The operator then uses the activated tool to complete the designated operation according to the work instruction procedure. This step ensures that each operation is performed according to preset standards, reducing human error and guaranteeing product quality stability.

[0053] Step S500: After the tool operation is completed, collect and record the operation data of the current step in real time, including the operation result, material barcode and tool status, and store the operation data in the work terminal.

[0054] After the tool operation is completed, the operation data for the current step is collected in real time through the work terminal. The data includes the operation result, material barcodes, and tool status. The system stores this data in the work terminal's local database to ensure real-time performance and accuracy. Simultaneously, this data is synchronized with the system server via a WebAPI interface, ensuring complete traceability of the operation data. The collection and storage of operation data enables end-to-end monitoring of quality management, providing data support for subsequent traceability and analysis.

[0055] Step S600: Determine whether the process is completed. If not, proceed to the next step and repeat the above steps. If completed, upload the operation data of the current process and store the uploaded operation data. If the operation data of the current process is the final process of product production, generate and record product history information.

[0056] The system determines the completion status of the current process. If the process is not yet complete, the system automatically proceeds to the next step and repeats steps S300 to S500, ensuring that operational data for each step is collected and stored in real time. Once the process is complete, the work terminal uploads all operational data for the current process to the system server and records it in the server's database. If the current process is the final step in product manufacturing, the system generates and records the product's complete production history, creating a traceable production record including operators, materials, tools, and process parameters. This production history information can be used for factory inspection and quality control, ensuring that each product meets manufacturing standards.

[0057] During the operation, the system server detects changes in process information through periodic checks or event listening. Changes in process information include adjustments to the sequence of operations, modifications to process parameters, and updates to the bill of materials. When the server detects a process change, it immediately interrupts the current job instruction editing process, marks the operation or step that needs to be changed, and ensures that the changes are identified in a timely manner.

[0058] The system server first checks the steps of the current work instruction program. For steps that have not changed, the original configuration remains unchanged to avoid repeated editing. The system then compares the changed content with the current instruction program step by step to identify steps that need to be edited, reducing the workload of updating the work instruction program.

[0059] For the parts marked as requiring change, the server automatically loads the new process requirements and reconfigures the relevant procedures and steps, including adjusting tool parameters, updating work steps, and updating qualification requirements. For the changed steps, the system automatically updates their corresponding control parameters and instructions to ensure that the new process requirements can be correctly executed in the work terminal.

[0060] After the server completes the editing of a new work instruction procedure, it automatically updates the version number of the procedure. The version number is generated based on the product model, process route number, and changes, and is associated with the current process information to ensure that the revised instruction procedure has a unique identifier for version management and traceability.

[0061] After the version update is completed, the system server will automatically distribute the edited new version of the work instruction program to the relevant work terminals. Upon receiving the new program, the work terminals will automatically load the updated process steps and provide operators with real-time updates on the new work instructions. For ongoing processes, the system will instruct operators to start from the updated steps, ensuring that the changed process requirements take effect immediately.

[0062] After the revised work instructions are issued, the work terminal will load the updated steps and verify the operator's execution in real time. The system server will periodically collect data and synchronize with the work terminal to ensure that the revised process information is strictly implemented throughout the entire work process, guaranteeing the process compliance of the production process.

[0063] After receiving the work instruction program, the work terminal loads the steps of each process sequentially. When the operator starts the current process on the work terminal, the system automatically loads the detailed execution content of the first step, including operation instructions, tool parameters, and material requirements, ensuring that the operator executes each step according to the process requirements.

[0064] Before each step begins, the work terminal displays the operating instructions for the current step to the operator, who then performs the specific operations according to the instructions. For example, when a step involves tool operation, the work terminal first activates the tool and sets the corresponding parameters to ensure that the tool operation meets the preset process requirements of the current step.

[0065] After the operator completes this step, the terminal will automatically start the step verification program. The verification includes checking the conformity of the step execution results with the preset standards. For each operation, the system will automatically record the result data, such as torque, angle, material barcode, etc., and compare it with the process standards to determine whether the operation meets the requirements.

[0066] The work terminal compares the actual execution result of the current step with the preset standard value. If the execution result meets the preset standard, the system will prompt "Step qualified" and automatically jump to the next step; if it does not meet the standard, the system will prompt "Step unqualified" and provide the operator with necessary correction guidance, such as re-executing the current step or adjusting the tool parameters, to ensure that the process requirements are met before proceeding to the next step.

[0067] During the step verification process, if a step repeatedly fails to meet the standard or exhibits operational abnormalities, the system will record the abnormal data in the work terminal database and notify the superior administrator or process engineer to ensure data integrity and traceability in subsequent processes. The abnormality record includes the operator ID, operation time, abnormal parameters, and cause of the abnormality, for post-event analysis.

[0068] For each successful step, the work terminal automatically stores the execution results, including tool parameters, operation time, and operation outcome, and associates the data with the current product's work history. Once a step is confirmed, the work terminal will allow the operator to continue to the next step until all steps in the current process have been verified and completed.

[0069] Once all steps within a process are executed according to standards and pass verification, the work terminal will automatically mark the process as "complete" and synchronously upload the process completion data to the system server to update the product's production history. Simultaneously, the work terminal will automatically load the first step of the next process, continuing until all processes are completed.

[0070] In the specific steps of generating a work instruction program based on production order information, this embodiment parses and transforms the production order information step by step into an executable work instruction program. The steps for generating the work instruction program specifically include:

[0071] The system receives production order information and extracts product model, process route number, batch information, and order quantity from it. Based on the extracted product model, it retrieves the corresponding process route template from the database. According to the process route number in the production order information, it performs version verification on the process route template and loads the matching process route version. It then parses each process step by step within the process route, generating a process list containing the process sequence, step content, and required operation steps. For each process, it parses the required material information and operator qualification requirements from the production order information to generate a step configuration and associates it with the current process. It matches the control parameters and execution instructions of each step with the corresponding steps in the process list to generate a complete work instruction program. The generated work instruction program is set as the initial version and distributed to the work terminal for storage. Through multi-level deconstruction of production order information and dynamic matching of process routes, a highly integrated work instruction program generation process is achieved.

[0072] The following describes a human-machine collaboration system provided in this application through specific embodiments.

[0073] See Figure 1 This is a schematic diagram of a human-computer collaboration system provided in an embodiment of this application. It is intended as an example and not a limitation. Figure 1 As shown, a human-machine collaboration system may include a system server and at least one client; wherein:

[0074] The system server is used to execute the method steps described in the embodiments of this application, specifically including generating and managing work instruction programs, connecting to the MES system to obtain order information and personnel qualification information, and interacting with the DDCS, DPS and RCS systems for data exchange;

[0075] The system server also includes a module for receiving feedback information and updating work instructions. This module regenerates the work instructions based on process changes and distributes them to the work terminals. The system server also includes a verification module for verifying the work instructions step by step after process changes and publishing them to the work terminals after successful verification. The system server interfaces with the RCS system to schedule AGVs for material delivery and empty rack recycling in production line mode, and triggers material delivery in advance according to process requirements.

[0076] The work terminal is used to control the production process and collect operation data. The work terminal includes an industrial all-in-one machine and a mobile terminal. The industrial all-in-one machine is used to execute work instruction programs and control the operation of hardware equipment, including indicator lights, barcode scanners, and smart tools, and communicates with the PLC system. The industrial all-in-one machine in the work terminal is connected to the barcode scanner via a USB interface and connected to the PLC system via a local area network.

[0077] The mobile terminal is used to provide operation guidance content display, data collection, and feedback of operation results in parallel operation scenarios.

[0078] In related technologies, to improve the response speed and stability of human-machine collaborative systems in multi-process, multi-terminal parallel scenarios, multiple independent operation control modules are typically integrated at the workstation. However, existing solutions suffer from problems such as delayed transmission of work instructions and inconsistent operation data collection in multi-device collaborative management. Furthermore, after system updates, real-time synchronization of instructions across various workstations becomes difficult. These issues result in inconsistent data across different terminals during multi-terminal operations, thus affecting the quality and efficiency of parallel work. In addition, existing systems require frequent distribution of production task instructions to various workstations, increasing the burden on the system server and complicating task allocation and resource configuration at the workstation.

[0079] In this embodiment, the system server can not only generate and publish work instructions, but also update and verify process changes in real time, verifying them step by step to ensure that the adjusted instructions meet the latest production requirements. By connecting the system server with the RCS system, this embodiment can trigger material delivery in advance according to the needs of each process in production line mode, ensuring that materials are delivered on demand, achieving real-time allocation of production resources, and reducing the retention of work-in-process. Furthermore, through centralized management of the work terminals by the system server, this embodiment ensures real-time transmission of instructions while reducing the control burden on the work terminals, allowing them to focus on production process execution and data collection. The system server can centrally control material scheduling and work resource scheduling, achieving a more efficient and accurate human-machine collaborative work process, improving the overall production response speed and consistency of work data.

[0080] like Figure 2 , Figure 3 As shown, the human-machine collaboration system comprises two main parts: the system server and the operation terminal. The system server interfaces with various factory systems to acquire production data or upload production result data. The system server interfaces with the factory's MES system, acquiring product order information for production, personnel qualification information for employee qualification verification, and uploading key material collection results, as well as work process start-up and reporting information to the MES system. It also interfaces with the DPS digital process platform system to acquire product operation guidance information, product BOM information, etc., for system operation guidance program generation and configuration. Furthermore, it interfaces with the factory's DDCS system to upload production process data for operation process data traceability. Finally, it interfaces with the RCS system to schedule on-site AGVs for material transfer and empty material cart recovery. In addition to factory system integration, the server implements functions such as operation program generation, operation program version management, intelligent tool configuration, generation mode management, and operation process data acquisition. The work terminals include PC terminals, PDA terminals, and mobile phone / tablet terminals. The PC terminal can connect to sub-terminals for multi-person parallel operation, to intelligent tightening tools for torque control, to label printers for printing product serial number labels, to material indicators for material handling, and to barcode scanners for critical material data collection and verification. Furthermore, in the inspection process, the PC can connect to a mobile phone for online inspection using a photo-visual system. In the testing process, the PC interfaces with the automated testing program to initiate tests and collect product test result data.

[0081] During the production and configuration of work procedures, the server automatically receives product process information from the DPS system, including product process routes (processes, steps, work qualifications), work step information, material information, and control elements, and converts this process information into an initial version of the work procedure. The work procedure structure consists of process routes, in the order of process, steps under the process, and steps under the steps. Each step is the smallest granularity of the work procedure, corresponding to the actual actions of the employee. Types include: material picking, barcode collection, tool operation, photography, inspection items, testing, and custom steps. Different types of steps correspond to different control elements: material picking steps correspond to material information control; barcode collection steps correspond to material information and traceability information control; tool operation steps correspond to tool information and fastening parameters control; photography steps correspond to visual inspection and traceability information control; inspection item steps correspond to quality inspection requirements and traceability information control; testing steps correspond to test requirements and traceability information control; and custom steps support custom logical combinations of multiple control items, such as combining material and tool information control. The initial version of the program can also be created manually if not imported from the DPS system.

[0082] After the initial program is created, the program administrator assigns it to the corresponding personnel for configuration at the process level. Only the person receiving the task has the authority to configure and modify it. When configuring the work program, programs already configured in the system can be reused at the process, step, and step levels, further reducing the workload of program development. Furthermore, if it is the first time a work program for a new platform product is created and there is no reference work program, it can be referenced from the component program library at the component level (the component program library is created by setting the relationship between steps and components; one component can correspond to multiple steps). After all steps of a process are configured, the process is assigned to the corresponding workbench type by group (the workbench type maintains rack information and tool information). The above is the product work program editing process. After editing and publishing, it can be used for actual production control on-site.

[0083] For newly created product work procedures, the initial configuration must be in verification mode for on-site physical assembly verification of the procedure's correctness. In verification mode, the work procedure creators (process engineers) must participate in the verification process alongside on-site production verification personnel and modify the work procedure in real time. Unlike the order-based mode applicable to mass production scenarios, where the entire process route work procedure is released to the work terminal, verification mode allows for release at the process-level granularity, facilitating rapid iterative modifications. During verification, if production personnel identify areas requiring adjustment, they can provide online feedback via photos, videos, and text editing on the work terminal. After receiving the feedback on the server side, process engineers adjust the work procedure content. Once all processes under the process route have been verified and revised, the work procedure is submitted for review at the process-level granularity, and then released after approval by the approver.

[0084] Once the program version has been verified and released, any changes to the process information necessitate a synchronized upgrade and editing of the work procedures. Upon receiving process information changes, the system automatically matches the configuration content of unchanged steps and marks the steps requiring modification. Process engineers then reconfigure the changed steps before submitting the revised version for approval. To standardize program version management, version numbers are automatically updated and created, categorized by product drawing number and process route number, and managed continuously to ensure traceability accuracy. Furthermore, the upgrade and editing process will not affect the production of in-process products. After a new version is successfully released, it will automatically be used for production of new orders.

[0085] as follows Figure 4As shown, after process engineers compile and publish the work instruction program on the system server, the work terminal will download the program data and files to the work terminal database in real time. The work terminal program contains multiple scheduled task programs. Product work instruction data and system basic data are obtained from the system server via a WebAPI interface and downloaded to the work terminal database through these scheduled task programs. The process for production process history data is the reverse; it uses the work terminal's scheduled task programs to query incompletely uploaded data rows locally and update them to the system server database via a WebAPI interface. Downloading product work instruction media files and uploading production process media files are done via FTP protocol, using point-to-point network transmission of images and videos.

[0086] In single-person serial operations, the work instruction program controls the hardware to start and instructs the employee to perform the work according to the program steps. However, in parallel operations, multiple employees need to work collaboratively on different steps within the same process. In this case, there is only one main terminal, and parallel operators can log in to their respective employee IDs through mobile terminals (phones, tablets, PDAs) to perform the work.

[0087] If it is identified that the production process requires parallel operation, refer to... Figure 5 The server-side control process first requires setting the process to a multi-person operation mode when editing the job instruction program on the server side, dividing the process steps into multiple different group units according to the characteristics of the person and the work tools, and then submitting them to the job instruction program release process.

[0088] During production operations, refer to Figure 6 The work terminal control process involves the work terminal's work instruction program being activated. The team leader then assigns the work content to different workers. Multiple groups can be assigned to the same worker based on the current production cycle and the number of workers, or one group can be assigned to one worker. After assignment, workers can automatically operate their respective mobile terminals to perform the work according to the assigned group's work content.

[0089] like Figure 7As shown in the hardware framework diagram of the parallel operation system, the system server, operation terminal (industrial all-in-one machine), intelligent tool controller, intelligent tightening tool, and operation mobile phone (or Pad tablet, PDA) are all connected to the factory wireless network. The operation terminal (industrial all-in-one machine) is connected to the PLC through the local wired LAN, and the operation terminal (industrial all-in-one machine) is connected to the barcode scanner through the USB bus. The PLC is connected to the tool accessory indicator lights, tri-color lights, and material hopper lights through the extended data I / O. The system server in the diagram provides the necessary work instructions, media file editing, and publishing for parallel operations. The main work terminal, as the core of work process control and execution, downloads work programs and media files, and controls the status of the three-color lights on the equipment during the work process via PLC. Based on the work program, it instructs operators to retrieve corresponding tools, accessories, and product materials according to the light indicators. The main work terminal interacts with the work mobile phone (or tablet, PDA) via a TCP / IP-based AJAX protocol, pushing the work program to each work mobile terminal according to the parallel group scope. The mobile terminal can then display the current work steps, progress, and results, while the operation history data of the mobile terminal is also returned to the main work terminal. Simultaneously, the main work terminal collaborates with the intelligent tool controller and intelligent tightening tool via a TCP / IP-based network protocol. It provides tightening enable signals according to the execution sequence of the work program, provides control parameters and criteria according to the process parameter requirements of the work program, and reads the returned tightening results and data for the operator to display and store on the mobile terminal. The barcode scanner returns the scanned product and material barcode information to the main work terminal for work execution and data collection.

[0090] In actual operation, when the process type is assembly, it needs to be coordinated with intelligent tightening tools. Each operator carries their own mobile phone (or tablet, PDA) terminal and intelligent tightening tool to carry out production assembly work. The mobile phone terminal can indicate the detailed steps of the current operation. The intelligent tightening tool automatically matches the process parameters and enabling data of the current operation through the intelligent tool controller. While the operator is tightening, the tightening result data is transmitted synchronously to the main operation terminal (industrial all-in-one machine) for result value judgment and feedback of the result value to the operator's mobile phone terminal, so that each operator can know the result of the operation in real time and receive the next operation instruction. In the parallel operation process, the operation content of each operator's group unit is independent and does not interfere with each other. The operation result and data collection of one operator will not affect the operation process of other operators. Each operator's intelligent tightening tool can operate simultaneously. The communication and interaction between the intelligent tightening tool, the main operation terminal, and the mobile phone terminal are independent. Only when all group unit operations of each operator are completed will the main operation terminal automatically execute the reporting operation of the current process.

[0091] like Figure 8As shown, a flexible human-machine collaborative system for the discrete manufacturing of rail transit components needs to manage and control the personnel, machines, materials, and methods throughout the entire product manufacturing process. This includes automatic instructions, defect recording, data collection, and step-by-step control during operations, as well as generating post-operation records (product history book, factory inspection record). The system should cover the entire plant, the entire process flow, and multiple operational scenarios, integrating DDCS inspection data and visual inspection data, connecting to MES, RCS, and DPS digital process platforms, and achieving quality data traceability (personnel, machines, materials, and methods) for all production processes in the manufacturing plant.

[0092] Personnel: Management of basic information and access permissions for operators and engineers; management of operator qualifications; management of process step qualifications in product process routes. It integrates with MES and COA systems to download operator qualification information, configures qualification requirements in the process steps of the product engineering workflow, and verifies the matching between the current operator and the current product engineering step during production operations to achieve control over operator qualifications.

[0093] Machine: Basic information management of all hardware (tools, workbenches) associated with the operation, and hardware status management (metering, maintenance, transfer and scrapping). The hardware status is recorded, and the status of all associated hardware is checked when the operation starts. If the status is: metering overdue or faulty, corresponding prompts will be made and the operation will be prohibited from starting. During the operation, the hardware (ID, code) will be associated and collected with the current product information (order, LOT) to achieve the purpose of equipment hardware traceability.

[0094] Materials: Basic data management of product material BOM (Bill of Materials), and collection of key material information. The system imports the product manufacturing BOM and assigns key materials from the BOM to various process steps. During production, the MES (Manufacturing Execution System) downloads the order BOM, verifies material information, and simultaneously provides indicator lights for picking. Once picking is complete, confirmation is received, and key material information barcodes are collected and recorded.

[0095] Method: To digitize and streamline work instructions (SOPs). The entire process, from editing, verification, publishing, to version upgrades, is operated and controlled online. The materials for work instructions include: text descriptions, structured data, images, and videos, and data can be quickly reused across drawing numbers, with synchronized report configuration (product history books, factory inspection records).

[0096] The production process includes assembly, process inspection, debugging and testing, and final inspection. From a production cost perspective, considering the work scenario assessment, processes such as process inspection, debugging and testing, and final inspection generally do not have automated hardware tools (intelligent work vehicles). Furthermore, it is very difficult to implement system operation instructions, control, and data collection at these workstations. However, the work terminal of a flexible human-machine collaborative system can be a regular PC, thin client, mobile phone, tablet, or PDA. As long as it is connected to the factory network, it can serve as a work terminal to execute production, offering flexibility and greatly reducing the cost of system hardware.

[0097] The human-machine collaborative flexible system offers five operating modes to suit different work scenarios and manufacturing plant environments.

[0098] Standalone mode: For manufacturing plants without an MES system, product order information is not retrieved from the factory MES. Instead, the system initiates operation by scanning a product's QR code at the work terminal, and the activated product is recorded on the system server. If the scanned QR code contains product model information, the corresponding product model's work program is automatically loaded. If only the product serial number is available without the product model information, the product model must be manually selected at the work terminal to automatically invoke the product's work program.

[0099] Offline Mode: Primarily suited for remote manufacturing plants where the network or server connection between the remote plant and the headquarters is not yet established. When the system server cannot connect to the field terminals, offline mode is used for production. Production process data is cached on the field terminals, and can be synchronized to the main system server once the network or server connection is restored.

[0100] Verification Mode: When a new product needs to be launched and work procedures need to be developed, the content of the first version of the work instructions has a low degree of conformity and adaptability with the actual work situation. At this time, an intermediate verification version is needed from the development to the final release of the work procedure. Its biggest feature is that the content of the work procedure can be revised and optimized while production is underway so that the work procedure can reach the optimal level.

[0101] Order mode: This is the final release, and the entire process route's operating procedures have reached the optimal version of the operating procedure production mode. This mode has full management, control, data collection and recording of people, machines, materials and methods throughout the production process. The production process route is matched with the MES system, and the process flow control will strictly follow the process route for start-up and reporting.

[0102] Production line mode: Based on the mode adapted to automated and semi-automated production lines, its management, control, and data collection are consistent with the order mode. It adds interaction with the RCS system and adds the AGV delivery function for workstation materials. The production workstation sends the material requirements to the RCS system in advance, which automatically triggers the material AGV delivery. When the materials are consumed in production, the empty rack return process can be executed.

[0103] This invention provides a multi-mode compatible production control system for the diverse production modes in the discrete manufacturing industry. It meets the needs of different production scenarios, ensuring process controllability and traceability in all production stages, covering the entire process management from assembly, process inspection, debugging, and final inspection. By accommodating parallel multi-person operations and serial operations, the system enables job allocation and process data acquisition under the same process route, ensuring the continuity and integrity of data recording throughout the production process and making product assembly data traceability a platform. During the creation of work instruction programs, the system automatically connects to process platform data and associates tool parameter information, automatically converting process data into production control programs. Through step, process step, and operation-level program reuse functions and task assignment processes, program configuration becomes more flexible and efficient. Regarding version management, this invention adopts an online approval process to ensure version traceability, while not affecting normal production during version upgrades and editing. Through a verification mode, all field users can provide online feedback on program issues, forming a closed loop of problem collection, optimization, and recording, ensuring the integrity of program management.

[0104] In addition, this application also provides an electronic device, which includes: at least one processor, a memory, and a computer program stored in the memory and executable on the at least one processor. When the processor executes the computer program, it implements the steps in the control method embodiments of any of the above-described production systems.

[0105] The electronic device may be a desktop computer, laptop, handheld computer, or cloud server, etc. This electronic device may include, but is not limited to, a processor and memory.

[0106] The processor can be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), field-programmable gate arrays (FPGAs), or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc. A general-purpose processor can be a microprocessor or any conventional processor.

[0107] In some embodiments, the memory may be an internal storage unit of the electronic device, such as a hard drive or RAM. In other embodiments, the memory may be an external storage device of the electronic device, such as a plug-in hard drive, Smart Media Card (SMC), Secure Digital (SD) card, or Flash Card. Furthermore, the memory may include both internal and external storage units. The memory is used to store the operating system, applications, boot loader, data, and other programs, such as the program code of the computer program. The memory can also be used to temporarily store data that has been output or will be output.

[0108] This application provides a computer-readable storage medium storing a computer program that, when executed by a processor, implements the digital operation assistance method for multi-mode production described in the above embodiments.

[0109] This embodiment also provides a computer program product, which is a computer-readable storage medium storing program code. When the computer program product is run on a computer, it causes the computer to perform the above-mentioned related steps to realize the digital operation assistance method for multi-mode production in the above embodiment.

[0110] If the integrated unit is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, all or part of the processes in the methods of the above embodiments of this application can be implemented by a computer program instructing related hardware. The computer program can be stored in a computer-readable storage medium, and when executed by a processor, it can implement the steps of the various method embodiments described above. The computer program includes computer program code, which can be in the form of source code, object code, executable files, or certain intermediate forms. The computer-readable medium can include at least: any entity or device capable of carrying computer program code to a device / terminal device, a recording medium, a computer memory, a read-only memory (ROM), a random access memory (RAM), an electrical carrier signal, a telecommunication signal, and a software distribution medium. Examples include USB flash drives, portable hard drives, magnetic disks, or optical disks. In some jurisdictions, according to legislation and patent practice, computer-readable media cannot be electrical carrier signals or telecommunication signals.

[0111] In the above embodiments, the descriptions of each embodiment have different focuses. For parts that are not described in detail or recorded in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0112] Those skilled in the art will recognize that the units and algorithm steps of the various examples described in conjunction with the embodiments disclosed herein can be implemented in electronic hardware, or a combination of computer software and electronic hardware. Whether these functions are implemented in hardware or software depends on the specific application and design constraints of the technical solution. Those skilled in the art can use different methods to implement the described functions for each specific application, but such implementation should not be considered beyond the scope of this application.

Claims

1. A digital operation assistance method for multi-mode production, characterized in that, Includes the following steps: Obtain production order information, generate a work instruction program based on the production order information, the work instruction program includes process route, operation, work step and steps, and distribute the generated work instruction program to the work terminal; Receive the work instruction program, load the first process information in the process route according to the work instruction program, and confirm whether the current operator's qualifications meet the requirements of the process. If the operator's qualifications meet the requirements, load the BOM (Bill of Materials) required for the process and guide the operator to pick up the materials. At the same time, verify whether the picked materials meet the requirements through indicator lights or barcode scanners. After material verification is completed, the tool operation steps in the process are executed. The tool is activated through the work terminal, and the corresponding tool control parameters are set according to the process parameters of the process to complete the tool operation. After the tool operation is completed, the operation data of the current step is collected and recorded in real time, including the operation result, material barcode and tool status, and the operation data is stored in the operation terminal. Determine if the process is complete. If not, proceed to the next step and repeat the above steps. If complete, upload and store the operation data of the current process. If the operation data of the current process is the final process of product production, generate and record product history information.

2. The digital operation assistance method for multi-mode production as described in claim 1, characterized in that, When a change in process information is detected during operation, the system server re-edits the operation guidance program for the changed part and sends it to the operation terminal to apply the new process requirements.

3. The digital operation assistance method for multi-mode production as described in claim 1, characterized in that, Each step is executed in sequence on the work terminal, and step verification is performed upon completion of each step, including verifying the conformity of the work step execution results with preset standards.

4. The digital operation assistance method for multi-mode production as described in claim 1, characterized in that, The steps for generating a job instruction procedure include: Receive production order information and extract product model, process route number, batch information and order quantity from the production order information; Based on the extracted product model, retrieve the corresponding process route template from the database; Based on the process route number in the production order information, the process route template is verified for version, and the matching process route version is loaded. The information of each process step by step is parsed in the process route to generate a process list containing the process sequence, process content and required operation steps; For each process, the required material information and operator qualification requirements are parsed from the production order information to generate a process configuration and associate it with the current process; The control parameters and execution instructions of each step are matched one by one with the corresponding steps in the process list to generate a complete work instruction program. Set the generated job instruction program as the initial version and distribute it to the job terminal for storage.

5. The digital operation assistance method for multi-mode production as described in claim 4, characterized in that, After the work instruction program is generated, the process is divided into configurable task units, and the program administrator assigns them to the corresponding operators based on the granularity of the process.

6. The digital operation assistance method for multi-mode production as described in claim 1, characterized in that, The work instruction program is set to verification mode when it is first generated. In verification mode, the work instruction program is published to the work terminal step by step, and the work terminal records the work process content that needs to be adjusted by taking pictures, videos and editing text.

7. The digital operation assistance method for multi-mode production as described in claim 1, characterized in that, In processes where multiple operators collaborate in parallel, the work instruction program divides the process content into multiple work units based on the ownership characteristics of the operators and tools. The server then pushes the work program to the corresponding work terminal based on the work unit.

8. A human-machine collaborative system, characterized in that, It includes a system server and at least one client; wherein: The system server is used to execute the steps of the method described in any one of claims 1 to 7, specifically including generating and managing work instruction programs, connecting to the MES system to obtain order information and personnel qualification information, and interacting with the DDCS, DPS and RCS systems for data exchange; The system server also includes a module for receiving feedback information and updating work instructions. This module regenerates the work instructions based on process changes and distributes them to the work terminals. The system server also includes a verification module for verifying the work instructions step by step after process changes and publishing them to the work terminals after successful verification. The system server interfaces with the RCS system to schedule AGVs for material delivery and empty rack recycling in production line mode, and triggers material delivery in advance according to process requirements. The work terminal is used to control the production process and collect operation data. The work terminal includes an industrial all-in-one machine and a mobile terminal. The industrial all-in-one machine is used to execute work instruction programs and control the operation of hardware equipment, including indicator lights, barcode scanners, and smart tools, and communicates with the PLC system. The industrial all-in-one machine in the work terminal is connected to the barcode scanner via a USB interface and connected to the PLC system via a local area network. The mobile terminal is used to provide operation guidance content display, data collection, and feedback of operation results in parallel operation scenarios.

9. An electronic device, comprising a memory and a processor, characterized in that, The memory is used to store programs that support the processor in executing the digital operation assistance method for multi-mode production according to any one of claims 1-7, and the processor is configured to execute the programs stored in the memory.

10. A computer-readable storage medium storing a computer program thereon, characterized in that, The computer program, when run by a processor, performs the steps of the digital operation assistance method for multi-mode production as described in any one of claims 1-7.

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