A road roller roller production line layout simulation method and system

Abstract

The application discloses a road roller roller production line layout simulation method and system, and belongs to the technical field of engineering machinery. The method comprises the following steps: collecting equipment data for producing rollers and constructing a three-dimensional simulation model of a roller production line based on the equipment data; performing parameter calibration on the three-dimensional simulation model to obtain a calibrated three-dimensional simulation model of the roller production line; configuring a plurality of production line differentiation layout schemes for producing rollers in the calibrated three-dimensional simulation model of the roller production line, performing regular working condition simulation and fluctuation working condition simulation, and recording whole-cycle core operation data; taking maximization of production capacity, equalization of equipment load, minimization of logistics conflict and minimization of cost as targets, iteratively optimizing the whole-cycle core operation data through an existing genetic algorithm until optimal operation data are obtained; and obtaining an optimal production line layout scheme through the optimal operation data and outputting the optimal production line layout scheme. The application can solve the problems of blindness and inefficiency of traditional layout design.

Description

Technical Field

[0001] This invention relates to the field of engineering machinery technology, and in particular to a simulation method and system for the layout of a road roller production line. Background Technology

[0002] The core production process of road roller rollers relies on key steps such as wheel rim rolling, multi-station welding, grinding, splicing, stress relief, precision machining, surface hardening, and automatic spraying. This involves multiple core pieces of equipment with highly differentiated functions, including forming equipment, welding equipment, processing equipment, and surface treatment equipment. The process connections are highly constrained; for example, straight seam welding must be performed immediately after rolling, grinding must be done promptly after welding, TOS processing must be completed within 4 hours after vibration aging, and cooling is required before spraying after laser quenching. The logistics and transportation routes are complex; for example, the production of a single roller requires multiple pieces of equipment, and multiple pieces of equipment are used in a single process, with transportation distances exceeding 60 meters. The rationality of the production line layout directly determines the equipment collaboration efficiency, production capacity, and operating costs.

[0003] The traditional layout of road roller roller production lines has the following core problems: Equipment coordination imbalance: Multiple welding workstations (straight seam, circumferential seam, small parts) are scattered, and the welding cycle is not matched, which easily leads to the accumulation of the preceding sequence and the idleness of the following sequence, and the risk of welding operation interference is not avoided; the distance between the plate rolling machine and the straight seam welding workstation is too far, and the transfer time of the plate rolling wheel is too long, which affects the welding quality. Process connection bottlenecks: The failure to accurately simulate the vibration aging treatment time and laser quenching cooling cycle led to material accumulation after aging or waiting for materials in TOS processing. After quenching, no cooling area was reserved, and the coating was directly entered into the spraying process, causing the coating to peel off. Poor adaptability to working conditions: The design is based on ideal normal working conditions only, ignoring fluctuations in core equipment such as welding workstation failures and vibration aging system shutdowns. After production, the capacity fluctuation exceeds 15%, and there is a lack of contingency plans to deal with emergencies. Inefficient optimization: Comparison of multiple solutions relies on manual calculation, which cannot quantify welding efficiency, logistics conflicts, and equipment load differences. Optimization of a single solution takes 7-10 days and it is easy to select the wrong optimal solution. The rectification costs are high: layout defects need to be discovered through actual testing after production begins. The relocation of welding robots and the adjustment of the painting line involve the hoisting of heavy equipment and the renovation of workshop infrastructure. The rectification cost for a single production line exceeds 600,000 yuan, and the rectification period exceeds 15 days, which seriously affects the production schedule. Summary of the Invention

[0004] The purpose of this invention is to provide a simulation method and system for the layout of a road roller production line. Through a closed-loop process encompassing full data acquisition, high-fidelity modeling, multi-condition simulation, intelligent optimization, and practical adaptation, it solves the problems of blindness and inefficiency in traditional layout design, achieving precise and intelligent optimization of the roller production line layout. This invention is achieved through the following technical solutions.

[0005] In a first aspect, the present invention provides a simulation method for the layout of a road roller drum production line, comprising: Collect equipment data for producing pressure rollers and construct a three-dimensional simulation model of the pressure roller production line based on the equipment data; The parameters of the three-dimensional simulation model of the pressure roller production line were calibrated using historical data of pressure roller production to obtain the calibrated three-dimensional simulation model of the pressure roller production line. In the calibrated 3D simulation model of the pressure roller production line, multiple sets of differentiated layout schemes for producing pressure rollers are configured, and multi-condition simulations are performed to record the core operating data of the entire cycle. With the goals of maximizing production capacity, balancing equipment load, minimizing logistics conflicts, and minimizing costs, the core operational data throughout the entire lifecycle is iteratively optimized using existing genetic algorithms until the optimal operational data is obtained. The optimal production line layout scheme is obtained and output by using the optimal operating data; wherein, the optimal production line layout scheme includes the 3D model file of the optimal layout, multi-condition simulation report and parameter optimization details.

[0006] Optionally, welding temperature field coupling parameters, laser quenching temperature field coupling parameters, and vibration aging electromechanical field coupling parameters can be embedded into the three-dimensional simulation model of the pressure roller production line to recreate the operating state of special processes. The special processes include the straight seam / circumferential seam welding process of the pressure roller, the laser quenching process, and the vibration aging process. The welding temperature field coupling parameters include the welding temperature field attenuation curve, the laser quenching temperature field coupling parameters include temperature control and cooling time, and the vibration aging electromechanical field coupling parameters include the simulated vibration frequency.

[0007] In practical applications, recreating the operating state of special processes can enhance the realism and reliability of the simulation results of the three-dimensional simulation model of the pressure roller production line.

[0008] Optionally, the equipment installation baseline and logistics path marking specifications can be obtained from the optimal layout 3D model file, the fluctuation condition response and adjustment strategy can be obtained from the multi-condition simulation report, and the optimal equipment data for constructing the 3D simulation model of the pressure roller production line can be obtained from the optimal parameter optimization details.

[0009] Optionally, the equipment data for producing the pressure roller includes static basic data and dynamic fluctuation data; The static basic data includes equipment parameters of core equipment, pressure roller product parameters, process connection parameters, logistics and transfer parameters, and workshop site constraint parameters; The dynamic fluctuation data includes equipment fluctuation data of core equipment, material fluctuation data, and manpower fluctuation data; The core equipment includes a wheel rim rolling machine, a pressure roller straight seam welding workstation, a pressure roller straight seam grinding workstation, a pressure roller splicing workstation, a pressure roller circumferential seam welding workstation, a pressure roller small parts welding workstation, a vibration time-effect stress removal system, a TOS machining workstation, a laser quenching surface hardening system, and a pressure roller automatic spraying system.

[0010] In practical applications, while setting differences in core equipment, it is also necessary to set unified benchmark operating parameters (production load, working hours, raw material supply standards).

[0011] Optionally, the equipment parameters of the core equipment include: the rated plate thickness, plate diameter and processing cycle of the wheel rim rolling machine; the welding speed, weld tolerance and processing cycle of the pressure roller straight seam welding workstation; the grinding speed and processing cycle of the pressure roller straight seam grinding workstation; the positioning accuracy and processing cycle of the pressure roller splicing workstation; the welding speed and processing cycle of the pressure roller circumferential seam welding workstation; the load and processing cycle of the pressure roller small part welding workstation; the processing frequency, processing time, load capacity and failure probability of the vibration time-effect stress removal system; the spindle speed, processing accuracy and processing cycle of the TOS machining workstation; the quenching temperature, hardened layer thickness, processing cycle and cooling time of the laser quenching surface hardening system; and the conveying speed, coating thickness, thickness accuracy, processing cycle, floor area and smoke emission of the pressure roller automatic spraying system.

[0012] Optionally, parameter calibration of the three-dimensional simulation model of the pressure roller production line using historical pressure roller production data includes: acquiring historical pressure roller production data for comparison with the initial running data of the three-dimensional simulation model of the pressure roller production line under normal working conditions; during a specific running time of 72 hours for the three-dimensional simulation model of the pressure roller production line, adjusting the parameters of the three-dimensional simulation model of the pressure roller production line for historical pressure roller production data with a deviation exceeding a specific threshold of 3% until the deviation is less than the preset threshold ≤2%, thus completing the calibration; The historical data on pressure roller production includes the utilization rate of core equipment, processing cycle time, and daily production capacity.

[0013] In practical applications, the historical production data of the pressure roller is measured data, and the data obtained from simulation may not be accurate. Therefore, it is necessary to use the historical production data of the pressure roller to calibrate the parameters of the three-dimensional simulation model of the pressure roller production line.

[0014] Optionally, the differences in the production line differentiated layout scheme include the cluster arrangement of core equipment, the collaborative layout of welding workstations, the hierarchical design of logistics channels, the layout of buffer zones between processes, and contingency plans for fluctuating operating conditions.

[0015] Optionally, the equipment load balancing is defined as core equipment utilization fluctuation ≤10%, and the logistics conflict minimization is defined as core equipment congestion duration ≤0.5 hours / day.

[0016] Optionally, the multi-condition simulation includes conventional condition simulation and fluctuating condition simulation, and the full-cycle core operation data includes the layout data of core equipment and the processing cycle data.

[0017] Secondly, the present invention provides a simulation system for the layout of a road roller drum production line, comprising: The model building module is used to collect equipment data for producing pressure rollers and build a three-dimensional simulation model of the pressure roller production line based on the equipment data. The calibration module is used to calibrate the parameters of the three-dimensional simulation model of the pressure roller production line using historical production data of the pressure roller, so as to obtain the calibrated three-dimensional simulation model of the pressure roller production line. The multi-scheme, multi-condition configuration module is used to configure multiple sets of differentiated layout schemes for producing pressure rollers in the calibrated 3D simulation model of the pressure roller production line, and to perform multi-condition simulations and record core operating data throughout the entire cycle. The iterative optimization module is used to iteratively optimize the core operating data throughout the entire lifecycle with the goals of maximizing production capacity, balancing equipment load, minimizing logistics conflicts, and minimizing costs, until the optimal operating data is obtained. The solution output module is used to obtain and output the optimal production line layout solution from the optimal operating data; wherein, the optimal production line layout solution includes the 3D model file of the optimal layout, multi-condition simulation report and parameter optimization details.

[0018] Compared with the prior art, the beneficial effects of the present invention are as follows: This invention introduces a simulation method for the layout of a road roller production line. By focusing on collecting various parameters from multiple core devices, a three-dimensional simulation model of the roller production line is built, achieving high simulation accuracy. Embedding physical field coupling parameters into the three-dimensional simulation model allows for the accurate reproduction of specific process operation states, thus precisely replicating the collaborative state of the equipment. By configuring multiple differentiated layout schemes for producing rollers on the built three-dimensional simulation model and performing multi-condition simulations, the method can cover fluctuation simulations of core equipment. Compared to traditional layout schemes, this reduces post-production capacity fluctuations and demonstrates strong adaptability to different operating conditions. The method iterates through the full-cycle core operating data obtained from the operating condition simulation under pre-set conditions until the optimal operating data is obtained, leading to the optimal production line layout scheme. This improves the utilization rate of welding workstations, shortens process waiting time, thereby increasing production capacity, reducing logistics and production line costs, and achieving good operational economics. Furthermore, the obtained optimal production line layout scheme has strong feasibility, adapting to the installation and transportation needs of multiple devices, reducing rectification costs by 80%, and achieving targets within one week of production. Attached Figure Description

[0019] Figure 1 The diagram shown is a schematic flowchart of a simulation method for the layout of a road roller production line in one embodiment of the present invention. Detailed Implementation

[0020] The following description, in conjunction with the accompanying drawings and specific embodiments, provides further details. In this description, it should be understood that the terms "first," "second," etc., are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of indicated technical features. Therefore, a feature defined with "first," "second," etc., may explicitly or implicitly include one or more of that feature.

[0021] Example 1 This embodiment introduces a simulation method for the layout of a road roller drum production line, such as... Figure 1 As shown, it includes: Collect equipment data for producing pressure rollers and construct a three-dimensional simulation model of the pressure roller production line based on the equipment data; The parameters of the three-dimensional simulation model of the pressure roller production line were calibrated using historical data of pressure roller production to obtain the calibrated three-dimensional simulation model of the pressure roller production line. In the calibrated 3D simulation model of the pressure roller production line, multiple sets of differentiated layout schemes for producing pressure rollers are configured, and multi-condition simulations are performed to record the core operating data of the entire cycle. With the goals of maximizing production capacity, balancing equipment load, minimizing logistics conflicts, and minimizing costs, a genetic algorithm is used to iteratively optimize the core operational data throughout the entire lifecycle until the optimal operational data is obtained. The optimal production line layout scheme is obtained and output by using the optimal operating data; wherein, the optimal production line layout scheme includes the 3D model file of the optimal layout, multi-condition simulation report and parameter optimization details.

[0022] In this invention, the parameter optimization details are the collected equipment data and operating parameters of the production pressure roller, which are adjusted successively and converged by the genetic algorithm during the iterative optimization process to form a parameter adjustment record and an optimal parameter list.

[0023] Example 2 Based on Example 1, this example introduces the specific implementation process of a simulation method for the layout of a road roller drum production line, including the following: I. Data Acquisition and Preprocessing In one specific embodiment of the present invention, the equipment data for producing pressure rollers includes static basic data and dynamic fluctuation data; Static basic data includes equipment parameters of core equipment, pressure roller product parameters, process connection parameters, logistics and transfer parameters, and workshop site constraint parameters; Dynamic fluctuation data includes equipment fluctuation data for core equipment, material fluctuation data, and manpower fluctuation data; The core equipment includes a wheel rim rolling machine, a pressure roller straight seam welding workstation, a pressure roller straight seam grinding workstation, a pressure roller splicing workstation, a pressure roller circumferential seam welding workstation, a pressure roller small parts welding workstation, a vibration time-effect stress removal system, a TOS machining workstation, a laser quenching surface hardening system, and a pressure roller automatic spraying system.

[0024] In one specific embodiment of the present invention, after obtaining the equipment data for producing pressure rollers, existing data cleaning algorithms are used to remove outliers and fill in missing values ​​to obtain preprocessed equipment data.

[0025] In one specific embodiment of the present invention, the equipment parameters of the core device include: The rated plate thickness of the wheel rim rolling machine is 20-50mm, the plate diameter is 1.1-1.8m, and the processing cycle is 15-30 minutes / piece. The welding speed of the pressure roller straight seam welding workstation is 0.5-1m / min, the weld tolerance is ±0.5mm, the processing cycle is 90-120 minutes / piece, the working radius is 1.5-1.8m, the failure probability is ≤0.5% / day, and the welding power is 50-80kWh. The grinding speed of the pressure roller straight seam grinding workstation is 0.3-0.6m / min, the grinding accuracy is ±0.2mm, and the processing cycle is 10-12 minutes / piece. For the pressure roller splicing workstation, the positioning accuracy is ±0.2mm, splice strength ≥500MPa, processing cycle time is 15-20 minutes / piece, and fixture load capacity is ≥5T. For the pressure roller circumferential seam welding workstation, the welding speed is 0.4-0.8m / min, weld tolerance is ±0.5mm, processing cycle time is 200-400 minutes / piece, operating radius is 1.5-2m, and failure probability is ≤0.5% / day. For the pressure roller small part welding workstation, the load is 30-50kg, and the welding speed is 0.3-0.5m / min. The vibration-induced stress removal system has a processing frequency of 20-50Hz, a processing time of 40-60 minutes per piece, a load capacity of 5-8T, a stress removal rate of ≥85%, a failure probability of ≤0.3% / day, and a rated input power of 30-50kWh. The TOS machining workstation has a spindle speed of 800-2000rpm, a machining accuracy of IT5-IT6, a processing time of 35-45 minutes per piece, a tool life of ≥100 pieces, and a failure probability of ≤0.4%. The laser quenching surface hardening system has a quenching temperature of 900-1000℃, a hardened layer thickness of 0.5-1mm, a processing cycle of 20-25 minutes / piece, a cooling time of 5-8 minutes, and a laser power of 10-15kW. The automatic spraying system has a conveying speed of 0.2-0.4m / min, a coating thickness of 0.1-0.3mm, a thickness accuracy of ±0.02mm, a processing cycle of 15-20 minutes / piece, a floor area of ​​5-20㎡, a smoke emission of 5000-8000m³ / h, and an energy consumption of 100-150kWh / h.

[0026] In one specific embodiment of the present invention, the product parameters of the core equipment, the roller, include: roller rim blank (width 800-1200mm, thickness 20-30mm, material Q355), finished rim (diameter 1.1-1.7m, width 700-1100mm, machining allowance 5-10mm), total weight of roller 3-5T, welding precision (no cracks, porosity, slag inclusions), hardness after quenching HRC55-60, coating adhesion ≥5MPa, and finished product dimensional accuracy deviation ≤0.2mm.

[0027] In one specific embodiment of the present invention, the process connection parameters of the core equipment include: setting the process according to "wheel rim rolling → straight seam welding → straight seam grinding → splicing → circumferential seam welding → small part welding → vibration aging → TOS processing → laser quenching → automatic spraying → finished product quality inspection → finished product delivery", with the core connection logic as follows: straight seam welding is carried out within 30 minutes after rolling, grinding is carried out immediately after straight seam welding, small part welding is completed within 2 hours after circumferential seam welding, vibration aging is carried out within 1 hour after small part welding, TOS processing is started within 4 hours after vibration aging, and spraying can be carried out after laser quenching and cooling for 5-8 minutes; the rework rate benchmark values ​​are (rolling ≤1%, welding ≤3%, processing ≤1%).

[0028] In one specific embodiment of the present invention, the logistics transfer parameters of the core equipment include: minimum width of the logistics channel (3m in one direction, 4.5m in two directions), transfer load of wheel rims / semi-finished products (≥5T), AGV travel speed of 1.2-1.8m / s, loading and unloading time of 5-8 minutes / time, turning radius ≥3m, location of raw material / finished product warehousing entrance, and material transfer priority of each process (materials after welding are transferred first).

[0029] In one specific embodiment of the present invention, the workshop site constraints of the core equipment include: workshop length 60-80m, width 30-50m, height 8-10m, column position (spacing 8-10m, cross-sectional dimensions 0.5×0.5m), fire passage width ≥4m, power supply interface power (welding equipment ≥80kWh, laser quenching ≥15kW), ground load capacity ≥20T / ㎡, ventilation opening position (suitable for laser quenching and spraying line smoke exhaust), and cooling water source position (suitable for laser quenching cooling).

[0030] In one specific embodiment of the present invention, the equipment fluctuation data of the core equipment includes: downtime of each welding workstation failure is 2-4 hours / time, downtime of the vibration time stress removal system failure is 3-5 hours / time, maintenance response time of the TOS processing workstation is 30-60 minutes, and equipment performance degradation coefficient (production capacity decrease ≤5% after 30 days of operation).

[0031] In one specific embodiment of the present invention, the material fluctuation data of the core equipment includes: delayed supply of coil blanks by 1-2 hours / time, increased transfer cycle of welding rework materials by 50%, and raw material size deviation rate ≤1%.

[0032] In one specific embodiment of the present invention, the manpower fluctuation data of the core equipment includes: response time of manpower allocation for welding process is 15-30 minutes, fluctuation range of manpower configuration for single process is ±1 person and manpower operation error rate is ≤0.3%.

[0033] II. Constructing a 3D Simulation Model of the Pressure Roller Production Line In one specific embodiment of the present invention, a three-dimensional simulation model of the pressure roller production line is built using the preprocessed equipment data obtained above, and the parameters of the three-dimensional simulation model of the pressure roller production line are calibrated.

[0034] 2.1 Construction of a 3D Simulation Model for the Pressure Roller Production Line Based on simulation tools such as FlexSim and SolidWorks Simulation, and combined with the preprocessed equipment data, a high-fidelity 3D simulation model is built, focusing on the collaborative logic of multiple core devices. Accuracy is ensured through calibration using historical data. The 3D simulation model of the pressure roller production line includes equipment modules, product modules, process flow modules, logistics path modules, site constraint modules, and fluctuating working condition modules.

[0035] The site constraint module serves as the spatial boundary, connecting and constraining the layout and access range of the equipment module and the logistics path module; The process flow module serves as the core scheduling hub, establishing command-driven and status feedback connections with the equipment module, product module, and logistics path module respectively, to achieve the coordinated flow of processes, equipment, products, and logistics. The fluctuation condition module establishes a global disturbance connection with the other five modules, injects fluctuation signals in real time, and drives the dynamic response of each module. The six modules are interconnected and logically interlocked, together forming a complete 3D simulation system for the pressure roller production line.

[0036] Equipment Module: Model multiple core devices at a 1:1 scale to restore the appearance, structure and operation logic of the equipment, and embed rules for switching between equipment start-up, processing, standby, fault and maintenance states; the welding workstation additionally embeds welding temperature field attenuation curve and operation interference detection algorithm, the laser quenching system embeds temperature control and cooling logic, and the vibration aging system embeds vibration frequency and stress removal simulation logic.

[0037] Product module: Model the actual dimensions and weight of the pressure roller blank, semi-finished product and finished product, and mark the processing accuracy and process attributes of each stage (such as marking the cooling requirements of "laser quenched semi-finished product").

[0038] Process flow module: Build the connection logic according to the production process corresponding to multiple equipment, embed the cycle time and rework rules of each process, and focus on optimizing the core connection (roll plate - straight seam welding, vibration aging - TOS processing, laser quenching - automatic spraying) to avoid timing conflicts.

[0039] Logistics route module: Based on site constraints, it plans hierarchical channels, marks AGV driving routes and loading and unloading points, adapts to the heavy-load transfer needs of wheel rims / semi-finished products, and embeds AGV path planning algorithms (prioritizing the transfer of materials after welding and avoiding logistics intersections between multiple devices).

[0040] Site constraint module: 1:1 replica of workshop columns, fire exits, power / water supply interfaces, and ventilation openings to ensure that the layout meets equipment installation (such as smoke exhaust from the spraying line) and fire protection requirements.

[0041] Fluctuation Condition Module: Embedded with fault triggering logic for core equipment such as welding workstations and vibration aging systems, it sets the probability and duration of fluctuation scenarios to reproduce dynamic production fluctuations.

[0042] In one specific embodiment of the present invention, welding temperature field coupling parameters, laser quenching temperature field coupling parameters, and vibration time-effect electromechanical field coupling parameters are embedded in the three-dimensional simulation model of the pressure roller production line to restore the operating state of special processes. The special processes include the pressure roller straight seam / circumferential seam welding process, laser quenching process, and vibration time-effect electromechanical field coupling parameters. The welding temperature field coupling parameters include the welding temperature field attenuation curve, the laser quenching temperature field coupling parameters include temperature control and cooling time, and the vibration time-effect electromechanical field coupling parameters include the simulated vibration frequency.

[0043] 2.2 Calibration of the 3D Simulation Model of the Pressure Roller Production Line In one specific embodiment of the present invention, parameter calibration of the three-dimensional simulation model of the pressure roller production line using historical pressure roller production data includes: acquiring historical pressure roller production data from the past three months for comparison with the initial operating data of the three-dimensional simulation model of the pressure roller production line under normal operating conditions; and adjusting the parameters of the three-dimensional simulation model of the pressure roller production line for historical pressure roller production data whose deviation from the comparison exceeds a specific threshold of 3% within a specific 72-hour period of operation of the three-dimensional simulation model of the pressure roller production line until the deviation is less than a preset threshold of 2%, thus completing the calibration. The historical data on pressure roller production includes the utilization rate of core equipment, processing cycle time, and daily production capacity.

[0044] III. Multiple Schemes and Multiple Operating Conditions Configuration 3.1 Multi-differentiated layout scheme for production lines In one specific embodiment of the present invention, a differentiated layout scheme is configured for the calibrated three-dimensional simulation model of the pressure roller production line. The differences in the differentiated layout scheme include the cluster arrangement of core equipment, the collaborative layout of welding workstations, the hierarchical design of logistics channels, the layout of inter-process buffer areas, and contingency plans for fluctuating operating conditions.

[0045] In one specific embodiment of this invention, based on daily production capacity requirements (50-100 units), three differentiated layout schemes are designed, focusing on the arrangement and coordination of 11 core pieces of equipment. A unified baseline operating condition parameter needs to be set, including production load, working hours, and raw material supply standards. In this embodiment, the unified settings are: 8 hours of work per day, sufficient raw material supply, core equipment failure probability based on baseline values, rework rate based on baseline values, and sufficient manpower. Based on the established unified baseline operating conditions, differentiated design of the schemes is considered from four aspects: cluster arrangement of core equipment, layout of inter-process buffer zones, hierarchical design of logistics channels, and contingency plans for fluctuating operating conditions. Equipment Cluster Layout: Option 1 (Dispersed Layout): 11 core equipment units are arranged sequentially along the length of the workshop, with welding workstations dispersed in different areas; Option 2 (Welding Cluster Layout): Straight seam, circumferential seam, and small part welding workstations are centrally arranged (spaced 3-5m apart), with the plate rolling machine adjacent to the straight seam welding workstation; Option 3 (Functional Modular Layout): Divided into "Forming Module (Plate Rolling + Straight Seam Welding + Grinding), Welding Module (Point Assembly + Circumferential Seam + Small Part Welding), Processing Module (Vibration Aging + TOS Processing + Laser Quenching), and Spraying Module (Automatic Spraying)," with equipment within each module compactly connected; Buffer layout: Option 1 (single buffer area): a total buffer area is set up in the middle of the workshop; Option 2 (inter-process buffer area): a dedicated buffer area is added after welding and aging (capacity of 10-15 pieces); Option 3 (dynamic buffer area): a cooling buffer area is added after laser quenching to meet the cooling requirements before spraying. Logistics channel optimization: Option 1 (fixed channel), uniform channel width; Option 2 (dynamic channel), the channel for welding module and spraying module is extended to 4.5m; Option 3 (intelligent channel), embedding AGV avoidance logic to optimize the transfer path between multiple devices; Contingency plans for fluctuating operating conditions: Plan 1 (no plan); Plan 2 (welding backup), with one backup device for each straight seam and circumferential seam welding workstation; Plan 3 (full plan), with welding backup + redundant configuration of vibration aging system + multiple batches of raw materials in reserve.

[0046] 3.2 Multi-condition simulation In one specific embodiment of the present invention, multi-condition simulation includes conventional condition simulation and fluctuating condition simulation. Based on a three-dimensional simulation model of the pressure roller production line configured with a differentiated production line layout, conventional condition simulation and fluctuating condition simulation are performed, recording the full-cycle core operating data of 11 core devices. The following are the data records for conventional and fluctuating conditions: The operating cycle under normal working conditions is no less than 72 hours: every 10 minutes, record capacity (daily output, process compliance rate), efficiency (equipment utilization rate, process waiting time, logistics congestion time), and cost (equipment energy consumption, logistics cost).

[0047] The operating cycle of fluctuating conditions shall not be less than 24 hours: triggering a 3-hour shutdown of the straight seam welding workstation + a 4-hour shutdown of the vibration aging system + a 1.5-hour delay in raw materials, and recording the capacity recovery time, cost increase, and process stagnation duration.

[0048] Simulation control: Supports pause and rollback. If welding interference or logistics congestion occurs for more than 2 hours, the above layout data will be adjusted in real time and the local simulation will be restarted.

[0049] In one specific embodiment of the present invention, the core operational data throughout the entire lifecycle mainly includes the layout data and processing cycle time data of core equipment, as well as capacity, cost, efficiency, and process downtime. Processing cycle time data is included in capacity. Layout data refers to data involved in the differentiated design of the solution.

[0050] In this invention, the simulation of the changes in the number and location of equipment in the differentiated layout, and the simulation of multiple working conditions including the simulation of abnormal states, will affect the simulation results.

[0051] IV. Iterative Optimization and Verification In one specific embodiment of the present invention, with the goals of maximizing production capacity (production capacity achievement rate ≥ 100%), balancing equipment load (core equipment utilization rate fluctuation ≤ 10%), minimizing logistics conflicts (core equipment congestion time ≤ 0.5 hours / day), and minimizing costs (cost reduction ≥ 12%), the existing genetic algorithm is used to iteratively optimize the core operation data throughout the entire cycle (100 iterations, convergence accuracy ≤ 2%) until the optimal operation data is obtained.

[0052] In one specific embodiment of the present invention, the iterative results can be repeated for 3 rounds of simulation, and the optimal solution is confirmed if the data fluctuation is ≤3%.

[0053] V. Solution Output and Implementation Adaptation In one specific embodiment of the present invention, a 3D model file with optimal layout, a multi-condition simulation report, and parameter optimization details are obtained based on optimal operating data. Specifically, the 3D model file with optimal layout yields equipment installation benchmarks and logistics path marking specifications; the multi-condition simulation report provides adjustment strategies for handling fluctuating operating conditions; and the optimal parameter optimization details provide optimal equipment data for constructing a 3D simulation model of the pressure roller production line.

[0054] Example 3 This embodiment introduces a simulation system for the layout of a road roller drum production line, including: The model building module is used to collect equipment data for producing pressure rollers and build a three-dimensional simulation model of the pressure roller production line based on the equipment data. The calibration module is used to calibrate the parameters of the three-dimensional simulation model of the pressure roller production line using historical production data of the pressure roller, so as to obtain the calibrated three-dimensional simulation model of the pressure roller production line. The multi-scheme, multi-condition configuration module is used to configure multiple sets of differentiated layout schemes for producing pressure rollers in the calibrated 3D simulation model of the pressure roller production line, and to perform multi-condition simulations and record core operating data throughout the entire cycle. The iterative optimization module is used to iteratively optimize the core operating data throughout the entire lifecycle with the goals of maximizing production capacity, balancing equipment load, minimizing logistics conflicts, and minimizing costs, until the optimal operating data is obtained. The solution output module is used to obtain and output the optimal production line layout solution from the optimal operating data; wherein, the optimal production line layout solution includes the 3D model file of the optimal layout, multi-condition simulation report and parameter optimization details.

[0055] The embodiments of the present invention have been described above with reference to the accompanying drawings. However, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention without departing from the spirit and scope of the claims. All of these forms are within the protection scope of the present invention.

Claims

1. A simulation method for the layout of a road roller roller production line, characterized in that, include: Collect equipment data for producing pressure rollers and construct a three-dimensional simulation model of the pressure roller production line based on the equipment data; The parameters of the three-dimensional simulation model of the pressure roller production line were calibrated using historical data of pressure roller production to obtain the calibrated three-dimensional simulation model of the pressure roller production line. In the calibrated 3D simulation model of the pressure roller production line, multiple sets of differentiated layout schemes for producing pressure rollers are configured, and multi-condition simulations are performed to record the core operating data of the entire cycle. With the goals of maximizing production capacity, balancing equipment load, minimizing logistics conflicts, and minimizing costs, a genetic algorithm is used to iteratively optimize the core operational data throughout the entire lifecycle until the optimal operational data is obtained. The optimal production line layout scheme is obtained and output by using the optimal operating data; wherein, the optimal production line layout scheme includes the 3D model file of the optimal layout, multi-condition simulation report and parameter optimization details.

2. The simulation method for the layout of a road roller production line according to claim 1, characterized in that, By embedding welding temperature field coupling parameters, laser quenching temperature field coupling parameters, and vibration time-effect electromechanical field coupling parameters into the three-dimensional simulation model of the pressure roller production line, the operating state of special processes can be reproduced. The special processes include the straight seam / circumferential seam welding process of the pressure roller, the laser quenching process, and the vibration time-effect electromechanical field coupling parameters. The welding temperature field coupling parameters include the welding temperature field attenuation curve, the laser quenching temperature field coupling parameters include temperature control and cooling time, and the vibration time-effect electromechanical field coupling parameters include the simulated vibration frequency.

3. The simulation method for the layout of a road roller production line according to claim 1, characterized in that, The equipment installation baseline and logistics path marking specifications are obtained through the optimal layout of the 3D model file. The adjustment strategy for dealing with fluctuating working conditions is obtained through the optimal multi-condition simulation report. The optimal equipment data for building the 3D simulation model of the pressure roller production line is obtained through the optimal parameter optimization details.

4. The simulation method for the layout of a road roller production line according to claim 1, characterized in that, The equipment data for producing the pressure rollers includes static basic data and dynamic fluctuation data; The static basic data includes equipment parameters of core equipment, pressure roller product parameters, process connection parameters, logistics and transfer parameters, and workshop site constraint parameters; The dynamic fluctuation data includes equipment fluctuation data of core equipment, material fluctuation data, and manpower fluctuation data; The core equipment includes a wheel rim rolling machine, a pressure roller straight seam welding workstation, a pressure roller straight seam grinding workstation, a pressure roller splicing workstation, a pressure roller circumferential seam welding workstation, a pressure roller small parts welding workstation, a vibration time-effect stress removal system, a TOS machining workstation, a laser quenching surface hardening system, and a pressure roller automatic spraying system.

5. The simulation method for the layout of a road roller production line according to claim 4, characterized in that, The core equipment parameters include: the rated plate thickness, plate diameter, and processing cycle of the wheel rim rolling machine; the welding speed, weld tolerance, and processing cycle of the pressure roller straight seam welding workstation; the grinding speed and processing cycle of the pressure roller straight seam grinding workstation; the positioning accuracy and processing cycle of the pressure roller splicing workstation; the welding speed and processing cycle of the pressure roller circumferential seam welding workstation; the load and processing cycle of the pressure roller small parts welding workstation; the processing frequency, processing time, load capacity, and failure probability of the vibration time-effect stress removal system; the spindle speed, processing accuracy, and processing cycle of the TOS machining workstation; the quenching temperature, hardened layer thickness, processing cycle, and cooling time of the laser quenching surface hardening system; and the conveying speed, coating thickness, thickness accuracy, processing cycle, floor space, and smoke emission of the pressure roller automatic spraying system.

6. The simulation method for the layout of a road roller production line according to claim 4, characterized in that, The parameter calibration of the three-dimensional simulation model of the pressure roller production line using historical pressure roller production data includes: acquiring historical pressure roller production data and comparing it with the initial running data of the three-dimensional simulation model of the pressure roller production line under normal working conditions; adjusting the parameters of the three-dimensional simulation model of the pressure roller production line for historical pressure roller production data whose deviation from the benchmark exceeds a certain threshold within a specific time period of operation of the three-dimensional simulation model of the pressure roller production line until the deviation is less than the preset threshold, thus completing the calibration. The historical data on pressure roller production includes the utilization rate of core equipment, processing cycle time, and daily production capacity.

7. The simulation method for the layout of a road roller production line according to claim 4, characterized in that, The differences in the production line differentiated layout scheme include the cluster arrangement of core equipment, the collaborative layout of welding workstations, the hierarchical design of logistics channels, the layout of inter-process buffer zones, and contingency plans for fluctuating operating conditions.

8. The simulation method for the layout of a road roller production line according to claim 4, characterized in that, The equipment load balancing is defined as core equipment utilization fluctuation ≤10%, and the logistics conflict minimization is defined as core equipment congestion duration ≤0.5 hours / day.

9. The simulation method for the layout of a road roller production line according to claim 4, characterized in that, The multi-condition simulation includes conventional condition simulation and fluctuating condition simulation, and the full-cycle core operation data includes the layout data of core equipment and the processing cycle data.

10. A simulation system for the layout of a road roller drum production line, characterized in that, include: The model building module is used to collect equipment data for producing pressure rollers and build a three-dimensional simulation model of the pressure roller production line based on the equipment data. The calibration module is used to calibrate the parameters of the three-dimensional simulation model of the pressure roller production line using historical production data of the pressure roller, so as to obtain the calibrated three-dimensional simulation model of the pressure roller production line. The multi-scheme, multi-condition configuration module is used to configure multiple sets of differentiated layout schemes for producing pressure rollers in the calibrated 3D simulation model of the pressure roller production line, and to perform multi-condition simulations and record core operating data throughout the entire cycle. The iterative optimization module is used to iteratively optimize the core operating data throughout the entire lifecycle with the goals of maximizing production capacity, balancing equipment load, minimizing logistics conflicts, and minimizing costs, until the optimal operating data is obtained. The solution output module is used to obtain and output the optimal production line layout solution from the optimal operating data; wherein, the optimal production line layout solution includes the 3D model file of the optimal layout, multi-condition simulation report and parameter optimization details.

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