An elevator sheet metal standard, non-standard, expansion special flexible global machining center

Abstract

The application discloses a flexible full-domain machining center special for elevator sheet metal standard, non-standard and expansion, and relates to the technical field of sheet metal automatic machining.The application takes process planning as a top core, divides workpieces into three categories according to structure, process, beat and time period, and configures a priority module, an expansion module and a full-domain scheduling module.The priority module realizes efficient machining of standard parts and collaborative processing of non-standard parts;the expansion module completes bending of expansion parts by reusing equipment resources;and the scheduling module realizes equipment sharing, process splitting and multi-equipment collaboration in a time-sharing and peak-shaving mode, and reduces auxiliary time by combining with transplant optimization.The application solves the pain points of traditional production lines, such as redundancy and inefficiency and insufficient flexibility, greatly improves process value rate, can realize integrated machining of full categories of sheet metal parts of elevator cars, and can be extended and applied to scenes such as electric control cabinets and decorative aluminum veneers, and has the characteristics of low investment, high efficiency and high flexibility.

Description

Specialized terms

[0001] • Module A: Standard punching and bending module (9 pieces on average for standard car wall and front wall), completes the processing of standard ventilation holes, side and top and bottom connecting holes, and continuous bending of side connections.

[0002] • Module B: Non-standard punching and cutting module (1 piece of non-standard car wall and front wall on average), completes the secondary cutting of raw materials, processing of handrail holes and non-standard connection holes.

[0003] • Priority modules: Module A + Module B.

[0004] • Module C: Expands non-standard flexible bending modules for processing a total of 4 expansion parts, including the lintel, control panel, and car door.

[0005] • Module D: Module A + Module B + Module C, a fully integrated scheduling module that enables the processing of all 14 car body sheet metal parts.

[0006] • High-frequency scenarios (130,000 units / year): Module A operates independently during the day shift.

[0007] • Mid-frequency scenario (60,000 units / year): Day shift A+B modules operate in collaboration.

[0008] • Full-category scenario (60,000 units / year): Day shift A+B modules run, night shift C module runs, and D module handles overall scheduling.

[0009] • Production mode: Standard parts are produced during day shifts, and extended parts are produced during night shifts / idle periods.

[0010] • Investment reduction ratio = 1 - Current total investment / Original total investment.

[0011] • Efficiency improvement ratio = 1 - Current production line cycle time / Original production line cycle time.

[0012] • Weighted average investment and efficiency cost ratio = 1 - (1 - investment reduction ratio) × (1 - efficiency improvement ratio).

[0013] • Effective process value rate = the ratio of effective processing time of a process to the processing cycle time of the process. summary

[0014] This invention relates to the field of automated production line technology for sheet metal processing technology and equipment, and discloses a flexible full-domain processing center for elevator sheet metal standard, non-standard, and extended applications. This invention is based on differentiating component structures, optimizing processing technology, adapting equipment, sharing resources, breaking down processing content, optimizing auxiliary transfer, fully utilizing time resources, and system integration to achieve automated full-domain sheet metal processing. It manages full-domain products by considering the number of components in each module, production cycle time, assembly differences, and production periods, setting up standard modules, non-standard modules, priority modules, extended modules, and a full-domain integrated scheduling module. The standard module achieves extreme redundancy elimination and efficient professional processing of standard parts; the non-standard module adds non-standard hole processing and also accommodates secondary cutting processing of non-standard raw material dimensions; the priority module includes both standard and non-standard modules; the extended module adds non-standard flexible bending processing, sharing resources from the priority module; and the full-domain scheduling module enables equipment sharing, time-sharing, and multi-device collaborative processing of extended parts. This invention effectively solves the industry pain points of traditional production lines, such as lack of equipment matching, lack of classification, rigid scheduling, redundant process and equipment functions, repeated investment, idle capacity, and extremely low process value rate. The effective process value rate of traditional production lines is only 3% to 8%, while the core processing section of this invention increases it to 40% to 50%, and the overall value rate of the entire process increases it to 20% to 25%, realizing elevator sheet metal full-domain manufacturing with low investment, high efficiency, high flexibility, and all-time utilization. I. Technical Field

[0015] This invention belongs to the field of automation technology for sheet metal processing techniques and equipment. Specifically, it relates to a flexible, all-domain processing center for elevator sheet metal, centered on the process and integrating product structure, processing technology, compatible equipment, resource sharing, processing content breakdown, assisted transfer optimization, full utilization of time resources, and system integration. It enables separate processing of standard parts, conventional non-standard parts, and extended parts; equipment sharing; time-sharing and peak-shifting; process breakdown; and all-domain collaborative processing. This invention is applicable to the fully automated production of elevator car sheet metal parts, especially suitable for high-volume, multi-variety, and complete-set sheet metal manufacturing scenarios. It can also be extended to the processing of similar sheet metal parts such as electrical control cabinets and decorative aluminum panels.

[0016] Based on a related patent filed on the same day, this invention adds a C-type extended flexible bending module and a D-type full-domain integrated scheduling module to the existing multi-level decreasing automatic feeding library and priority module. This completes the bending capability for non-standard heads of extended components such as door lintels, control panels, and car doors, enabling integrated processing of all 14 sheet metal parts for a single elevator car. The C-type extended module reduces the processing cycle time from 90 seconds / piece to 45 seconds / piece, resulting in a reduction of over 60% in investment, a 50% increase in efficiency, and an 80% reduction in weighted investment and efficiency costs. The D-type full-domain module reduces the processing cycle time from 65 seconds / piece to 20 seconds / piece, reduces the number of manufacturing units by 60%, reduces investment by over 40%, improves efficiency by 69%, and reduces weighted investment and efficiency costs by 81%. This invention addresses the industry pain points of low integration, resource waste, and imbalance between efficiency and flexibility in traditional production lines through equipment sharing, staggered scheduling, process splitting, and redundancy elimination, adapting to the needs of large-volume, multi-variety automated production of elevator sheet metal. II. Background Technology

[0017] Currently, in the field of large-scale mass production of elevator car sheet metal, the mainstream production systems in the industry are mainly divided into three categories: the Salvagnini universal integrated production line mode, the robotic automated bending assembly line mode, and the traditional manual single-machine scattered production mode. All three types of technologies are based on general-purpose equipment, with processes passively adapted to hardware. They only achieve minor optimizations at the automation level and have not completed fundamental paradigm innovations. They are unable to balance production efficiency, production costs, production flexibility, and capacity output, and the industry has long been trapped in a development state of high investment, resource redundancy, and low effective output.

[0018] (a) Salvagnini's imported, universally applicable, integrated production line model The production line hardware has the ability to flexibly process multiple categories of products. However, when applied to the large-scale mass production scenarios of leading enterprises, it is constrained by three factors: time efficiency, line changeover costs, and delivery inventory. The flexible functions built into the hardware cannot be practically implemented, exhibiting the characteristics of pseudo-flexibility.

[0019] Firstly, there is the constraint of time efficiency. The Salvagnini production line adopts a general redundant architecture, resulting in long material transfer paths, cumbersome equipment verification processes, and an average processing cycle of approximately 55 seconds per piece for standard modules, leading to low overall processing efficiency. Elevator car sheet metal products have a high structural concentration, with Class A standard parts accounting for 70% of total output, making them the core product category. Even if a single Salvagnini production line operates at full capacity continuously for 8 hours, its maximum daily capacity is insufficient to meet the batch delivery requirements of leading companies for Class A core parts.

[0020] To compensate for the huge capacity gap, leading companies in the industry can only ensure delivery by adding multiple Salvagnini production lines or extending production hours. Under this production model, all effective working hours and capacity load of the equipment are occupied by a single A-type main product category. Just ensuring the production of the main components is already a challenge for capacity and delivery, leaving no spare working hours or capacity to utilize the equipment's flexibility to carry out the production of B-type non-standard parts and C-type extended parts. This creates a typical vicious cycle in the industry: high equipment redundancy → slow single-piece processing cycle and long processing time → severe shortage of main product category capacity → companies are forced to add equipment and extend production hours → production line product categories become more singular → the flexible functions of equipment hardware remain idle for a long time and cannot be put into practical use.

[0021] Secondly, there are constraints related to material storage during line changes. This equipment, paired with a centralized large material storage unit, requires a 1-2 hour downtime for a single product category change—from category A to category B or C. During this time, materials must be emptied, the storage unit replaced, and equipment parameters recalibrated. In continuous mass production systems, a single line change can directly cause a significant capacity gap and impact delivery schedules. Considering both production efficiency and delivery stability, most companies focus on continuous production of a single product category for extended periods, rarely switching between categories. This lack of flexible equipment is a common application scenario.

[0022] Thirdly, there are constraints related to complete delivery and inventory. Elevator sheet metal is a component that accompanies the entire elevator machine, and the industry generally adopts an operation model of centralized assembly and shipment during the day shift. Workpieces completed during the night shift cannot be assembled and shipped in a timely manner, which can easily lead to inventory backlog, space occupation, product batch confusion, and a series of problems such as workpiece deformation during storage, surface color difference deviation, damage from bumps and knocks during transportation, and difficulty in quality traceability. Due to limitations in inventory management and delivery systems, most companies only adopt a single-shift production model, and equipment is generally idle during the night shift. Flexible production scenarios such as staggered production and production switching during off-peak hours cannot be properly established.

[0023] (ii) Robotic Automated Bending Production Line Mode This model only achieves superficial automation upgrades without systematically restructuring the process paths, sequence of operations, and product category classifications. The production line completely follows the traditional process flow without optimizing the transfer paths or motion flows. Overall, the auxiliary operation time is generally higher than that of manual operation, and the automation upgrade has not achieved substantial efficiency improvements. Furthermore, the production line is built according to general standards without considering the structural and technological differences of standard, non-standard, and extended parts. This makes it impossible to streamline corresponding processes and adapt to the processing of irregularly shaped workpieces and differentiated production needs, resulting in insufficient process matching.

[0024] At the same time, such production lines are also limited by the elevator industry's characteristic of concentrated, complete shipments during the day shift. Mass production during the night shift easily leads to large inventory accumulation, resulting in various batch quality problems, and significantly reducing the effective production time of the equipment. This model suffers from increased investment costs, increased equipment energy consumption and maintenance costs, but with weak production optimization effects. It is a transitional technical solution for the industry and has never been able to break through the inherent limitations of the traditional manufacturing system.

[0025] (III) Traditional manual, single-machine, and fragmented production mode This model centers on the inherent functions of the equipment, with operators passively adapting to equipment parameters, debugging operating programs, and scheduling production. It lacks a systematic approach to category management and process coordination. This model fails to develop categorized production plans for standard, non-standard, and extended parts, and it lacks differentiated process routes, equipment sharing mechanisms, staggered production schedules, and process decomposition optimization methods. Overall, production is highly random, with poor process consistency, significant fluctuations in production cycle time, arbitrary line changeovers, and insufficient product quality stability. It is only suitable for small-batch, sporadic order production scenarios and cannot meet the high-volume, multi-variety, complete-set delivery, and high-stability requirements of modern elevator sheet metal mass production for leading companies.

[0026] In summary, existing elevator sheet metal manufacturing systems generally follow an equipment-centric design approach, relying on general hardware functions to define production processes. They have consistently failed to integrate the unique product structure, technological characteristics, assembly logic, complete set delivery schedules, and available time slots of the elevator car sheet metal to establish a customized production management system. The three mainstream technologies have only undergone minor iterations at the automation level, such as manual operation, robotic work, and the application of imported complete lines, without achieving fundamental paradigm shifts.

[0027] Currently, the industry faces a common technical challenge: regardless of the mainstream production equipment used, the overall effective process value rate remains only 3% to 8%, with over 90% of production time consumed in non-value-added processes such as line changeover downtime, material handling, equipment idle time, production waiting, inventory transfer, batch processing, and quality rework. The industry has long faced multiple structural problems, including redundant equipment investment, wasted space resources, low production efficiency, high manufacturing costs, difficulty in implementing hardware flexibility, unbalanced equipment utilization rates, significant inventory management pressure, and insufficient stability in complete set delivery. These issues prevent the industry from meeting the core demands of the elevator sheet metal industry for high-efficiency, low-cost, multi-variety, large-volume, all-day capacity utilization, and stable complete set delivery for large-scale mass production. III. Summary of the Invention

[0028] This patent is the third core patent in a series of patented technologies, forming a complete progressive technical support system with Patents 1 and 2, which were filed on the same day. Patent 1 is a multi-level decreasing automatic feeding warehouse, which arranges the raw material specifications of three categories of core components (A, B, and C) according to the weight of PQ (Product Quality), solving the pain points of insufficient warehouse capacity, waiting for material changes and line stoppage, and inability to supply materials synchronously, thus providing stable material support for the entire module. Patent 2 constructs a standard module A + a non-standard module B to achieve efficient punching and bending processing of main components such as car walls and front walls, but it cannot cover the non-standard head bending requirements of extension components such as door lintels, control panels, and car doors. To address this, this patent 3 adds an extended flexible bending module C and a full-domain integrated scheduling module D, sharing all resources of A and B, utilizing spare time and night shifts for staggered production, ultimately achieving full-category, high-efficiency, low-investment, and integrated processing of 14 sheet metal parts for the elevator car.

[0029] This invention discloses a standard, non-standard, and extended-specific flexible full-domain machining center for elevator sheet metal, which reverses the traditional industry's production model centered on fixed equipment and constructs a new sheet metal manufacturing paradigm led by the optimal process system and with equipment actively adapting to the process.

[0030] Traditional elevator sheet metal production generally follows an equipment-first operational logic: companies first purchase general-purpose processing equipment with fixed functions, and all subsequent product structures, processes, and production cycles passively accommodate the inherent performance and limitations of the existing equipment. This model fails to create optimal process routes and investment solutions, resulting in widespread equipment redundancy and significant waste in process layout and workpiece transfer. When faced with a wide variety of non-standard products and fluctuating production capacity, the internal process optimization space is nearing saturation, forcing the industry to rely on continuously adding and piling up equipment to compensate for capacity and process shortcomings. Whether it's single-machine manual production lines, robotic bending production lines, or complete specialized production lines like Salvagnini, none have escaped this drawback, resulting in long-term problems such as equipment accumulation, redundant hardware investment, rigid processes, high proportion of auxiliary time, and low effective process value rate.

[0031] Addressing the aforementioned industry pain points, this invention takes process planning as its core. First, it categorizes elevator sheet metal products by process hierarchy, considering factors such as product structure, production quantity weight, assembly differences, production cycle time, and time-of-day attributes. These categorizes parts into three main types: standard parts, non-standard parts, and extended parts. For each type of part, a customized optimal process solution is developed. This involves process merging, process splitting, eliminating redundant processes, and reasonably reserving functional redundancy to form a differentiated process system. Then, equipment resources are integrated, reorganized, and reused, with corresponding priority modules, extended modules, and a comprehensive integrated scheduling module configured. This invention, relying on pre-process planning, optimal process route design, equipment adaptation to processes, optimized transfer processes, all-time resource sharing, and off-peak scheduling, achieves efficient, low-cost, and high-capacity flexible processing of all types of elevator sheet metal.

[0032] The priority module is configured with standard punching and bending units and non-standard punching and cutting units, matching equipment according to the optimal process routes for standard and non-standard parts, adapting to the working conditions of mass production of standard parts, non-standard hole processing, and secondary cutting processing of non-standard raw materials. For the standard parts production process, by integrating processes and eliminating redundant links, the simplest process path is used with the least equipment investment to maximize capacity, while reserving sufficient spare capacity and idle time. For the non-standard parts production process, the non-standard processes share standard mature process units, prioritizing the use of standard modules to complete core processing such as punching and bending; the matching punching and bending integrated machine is adapted to standard working conditions, adding non-standard hole processing and non-standard raw material laser cutting functions, and appropriately retaining equipment functional redundancy according to actual working conditions. At the same time, the entire line loading and unloading and transfer process is optimized, universal transfer parameters are unified, auxiliary time is significantly reduced, and the overall processing efficiency of non-standard parts is improved.

[0033] The expansion module adopts a flexible bending unit architecture, reusing the supporting equipment of the priority module to reduce overall equipment investment. This module flexibly combines equipment based on the process characteristics of the expansion parts and the on-site production cycle time. Relying on the shared equipment architecture of the entire production line, it changes the traditional mode of a single machine independently completing the entire processing procedure. Core processes such as punching and bending are decomposed and restructured, using a multi-equipment collaborative operation method to distribute the workload of a single machine, effectively reducing the overall processing cycle time. This mode does not require large-scale new equipment; it can be implemented with only small non-standard units and expansion units. Simultaneously, it is equipped with an optimized transfer mechanism, simplifying workpiece transfer actions. It uses pressure or magnetic attraction to increase transfer speed and acceleration, prioritizes the transfer path along the workpiece width direction, and adopts a simultaneous in-and-out operation mode, effectively compressing auxiliary processing time and breaking through the cycle time bottleneck caused by traditional fixed equipment.

[0034] The integrated scheduling module communicates with the priority module, extension module, and transfer mechanism. With the whole-domain process timing planning as the core, and combined with the workpiece process classification results, it realizes equipment resource sharing, production timing control, work time allocation, and multi-equipment collaborative scheduling, ensuring the orderly production of the three types of workpieces, achieving peak-shifting and complementary production, and full coverage of the whole-domain capacity.

[0035] This invention establishes a new manufacturing logic where process defines equipment, process drives production, and process determines efficiency. Through a series of systematic improvements, including product category segmentation, end-to-end process optimization, precise equipment adaptation, resource sharing and interoperability, staggered scheduling, process decomposition and reorganization, elimination of redundant steps, optimized transfer processes, and intelligent scheduling across the entire domain, it thoroughly improves the traditional model's problems of equipment overload, rigid processes, resource waste, and idle capacity. Traditional equipment-centric production lines have an effective process value rate of only 3%–8%. This invention, by reconstructing the production system based on optimal processes, increases the process value rate of core standard parts processing sections to 40%–50%, and the overall process value rate to 20%–25%, achieving a significant reduction in equipment investment, a substantial increase in production efficiency, and full utilization of capacity throughout all time periods, forming a technological advantage centered on process innovation.

[0036] 3.1 System Integration and Coordination, and Global Scheduling This invention establishes a PLC+MES integrated control center, managing the entire process sequence and achieving signal synchronization, parameter linkage, fault mutual detection, and intelligent task allocation among priority modules, expansion modules, transfer mechanisms, and the material supply system, ensuring coordinated operation of the entire system. The integrated scheduling module adopts a staggered peak operation mode: during the day shift, the focus is on mass production processes of standard and non-standard parts, with priority modules operating at full capacity; utilizing surplus time during the day shift and idle equipment resources during the night shift, the processing of expansion parts is arranged, with expansion modules undertaking production tasks, maximizing the release of daily capacity and eliminating equipment idleness issues.

[0037] For the modular processing of expansion parts, this solution is equipped with a corresponding cycle time division logic. The hole processing process is split and completed by a combination of stamping and cutting equipment, and the bending process is split and completed by a combination of standard bending equipment and flexible expansion bending equipment. This breaks through the cycle time limitation of a single fixed equipment, shortens the processing time of a single part and the overall processing cycle of the expansion parts, and adapts to the flexible production needs of multiple categories and differentiated processes.

[0038] 3.2 Optimization of Assisted Transplanting This invention reconstructs the transfer system based on overall process planning. The system includes an auxiliary feeding unit and a general transfer unit, solving the problems of complex transfer actions, long transfer time, and long equipment waiting time in traditional transfer methods. The eight redundant transfer actions of the traditional frame-type transfer machine are simplified into three core actions: direct feeding and picking, synchronous transfer, and rapid reset, thus shortening the workpiece transfer time.

[0039] The general-purpose transfer mechanism optimizes the operation mode and path according to process requirements: it adopts pressure adsorption or magnetic adsorption to improve the stability and acceleration of workpiece transfer; it shortens the transfer stroke and prioritizes the layout of the transfer path along the width of the workpiece; it adopts the same entry and exit operation mode throughout the process to eliminate equipment waiting gaps, which can meet the continuous transfer requirements of multiple types and specifications of elevator sheet metal workpieces and comprehensively reduce the proportion of auxiliary process time.

[0040] 3.3 Resource Sharing and Delivery Model This invention establishes a modular resource-sharing architecture based on a unified process system: the standard module is equipped with a punching and bending integrated machine, implementing standard punching and bending processes for high-weight core Class A sheet metal parts; non-standard modules and expansion modules reuse the hardware and mature processes of the priority modules. The three types of modules share a set of automatic feeding unit, central control unit, and finished product receiving and dispatching unit. Relying on the integrated platform design, duplicate equipment purchases are avoided, effectively reducing production line construction costs.

[0041] Combining the characteristics of staggered production processes, the workpieces produced by the expansion module are assembled offline, centrally stored, and prepared in a unified manner. They are then shipped together with the standard and non-standard parts produced by the priority module every other day, so as to achieve the complete delivery of all types of workpieces and match the assembly rhythm of the whole machine.

[0042] 3.4 Supply system coordination This invention features a multi-level decreasing intelligent material storage system that strictly matches the overall process layout and processing rhythm. The storage capacity is configured differently based on the usage weight of three types of raw materials (A, B, and C). The feeding rhythm is precisely adapted to the processing technology of each module. It can store and supply 20 or more types of sheet metal raw materials in an orderly manner, breaking through the limitations of traditional material storage systems that have limited storage categories and poor process adaptability.

[0043] The production process implements a tiered material supply process: standard raw materials with a PQ weight of over 70% are directly fed into the production line for continuous processing; non-standard raw materials are uniformly set up with a secondary cutting pretreatment process, which is closely coordinated with workpiece classification processing and time-sharing staggered scheduling to effectively reduce raw material inventory, improve material utilization rate, and ensure that all types of workpieces are delivered in accordance with process requirements.

[0044] 3.5 Multi-scenario adaptation This invention relies on differentiated process combinations to support flexible switching between various production scenarios. It can match corresponding process solutions according to the enterprise's annual production scale and order structure: the priority module can be activated separately to adapt to the exclusive production process of high-frequency, large-volume standard parts; the priority module can be combined with non-standard processing technology to adapt to medium-frequency, mixed production scenarios of standard and non-standard parts; and the entire module can be linked to adapt to low-frequency production scenarios covering all types of workpieces, which can meet the production needs of different production capacities and different order structures.

[0045] 3.6 Processing Scope and Extended Applications This invention can complete the processing of all sheet metal parts of an elevator car, including the car wall, car door front wall, door lintel, control panel, and car door, achieving integrated production of approximately 14 core sheet metal parts per elevator. The invention's unique core architecture, which includes process classification and management, equipment-adapted processes, staggered scheduling, and process decomposition and collaboration, can also be applied to the large-scale, flexible production of electrical control cabinets, decorative aluminum panels, and various general-purpose sheet metal parts, making it widely applicable.

[0046] 3.7 Scope of Protection Statement This invention belongs to the top-level innovation of manufacturing process architecture and production principle. The core protection scope is: the underlying operating principle of category division and governance, global process optimization, equipment adaptation to process, process splitting and reorganization, time-sharing staggered peak arrangement, transfer process optimization, and full-domain process scheduling built around the process, as well as the overall system architecture adapted to multiple scenarios. It is not limited to the specific embodiments, processing parameters, operating cycle time, numerical ratios and hardware models recorded in the specification.

[0047] The theoretical deduction values, actual performance data, investment reduction, efficiency improvement ratio, material weight ratio, process adaptation parameters, etc. recorded in the specification are all examples and preferred implementation schemes for verifying the innovative effect, and do not constitute a limitation or narrowing of the scope of protection of this invention.

[0048] Any conventional substitutions, equivalent adjustments, and local optimizations made by those skilled in the art to the equipment model, processing parameters, numerical ratios, and module combination methods without departing from the core concept and overall architecture of this invention centered on the process are all within the protection scope of this invention. IV. Detailed Implementation

[0049] This invention aims to process all types of sheet metal for elevator cars. Based on a multi-level decreasing automatic feeding warehouse, it sets up a priority module, an expansion module, and a full-domain integrated scheduling module to form a flexible full-domain processing center centered on the process.

[0050] 4.1 Implementation of workpiece classification Based on five dimensions—equipment structure, processing technology, production cycle, assembly differences, and production time period—workpieces are divided into three categories: standard parts, non-standard parts, and extended parts. Differentiated processing strategies are then matched to each category to achieve differentiated management and precise efficiency improvement.

[0051] 4.2 Priority Module Implementation The priority module consists of a standard punching and bending unit and a non-standard punching and cutting unit. It is designed to eliminate redundancy, simplify processes, and reduce cycle time for standard parts, achieving high-efficiency and low-investment processing. The non-standard punching and cutting unit is adapted to reasonable process and functional redundancy, and is equipped with auxiliary transfer optimization and process splitting and combination to complete the secondary cutting and processing of non-standard holes and non-standard raw materials. The priority module also reserves spare time and equipment resources for the production of extended parts.

[0052] 4.3 Implementation of the Extension Module The expansion module utilizes flexible bending units, fully reusing the material loading, transfer, processing, control, and shipping units of the priority module, eliminating redundant investment in basic equipment. It can be flexibly configured according to the on-site cycle time: for high-efficiency, high-investment, low-cycle conditions, hole processing and bending processing are separated and carried out collaboratively on different equipment; for low-efficiency, low-investment, high-cycle conditions, integrated equipment is used to complete all processing of the expansion parts.

[0053] 4.4 Implementation of Global Integrated Scheduling The integrated scheduling module, centered on PLC+MES, uniformly allocates tasks and timelines: during the day shift, priority is given to the production of standard and non-standard parts; during surplus time periods of the day shift and the night shift, the extended module is automatically scheduled to produce additional parts, achieving full-time capacity utilization. The system has signal synchronization, parameter linkage, and fault linkage capabilities to ensure stable operation throughout the entire process.

[0054] 4.5 Optimized Implementation of Transplanting Non-standard and expansion modules assist the feeding mechanism in carrying out general transfer optimization work, completing the transformation in three aspects: action flow, transfer path, and operating parameters. The eight transfer actions of the traditional frame-type transfer machine are simplified into three core actions: direct feeding and picking, synchronous transfer, and rapid reset; for hinged arm components with a length-to-width ratio of approximately 1:3, the transfer path is preferentially laid out along the width direction of the workpiece; the general transfer mechanism uses mechanical pressure or magnetic adsorption to act on the raw materials, and is equipped with a simultaneous in-and-out operation mode to improve transfer acceleration, movement speed, and operational stability, reduce auxiliary time, and effectively compress the overall processing cycle.

[0055] 4.6 Material Supply and Delivery Implementation The PQ weighted hierarchical full-domain material supply system ensures a continuous and stable supply of standard-sized raw materials for the main standard materials of modules A, B, and C according to their respective cycle time requirements. Non-standard modules rely on laser cutting and shearing processes to complete the secondary cutting and processing of non-standard raw materials, eliminating the need to stockpile large quantities of non-standard sheet metal in advance. This meets the immediate online processing needs of non-standard raw materials, effectively reducing warehouse space investment and non-standard material inventory pressure, and significantly improving the production online rate of non-standard parts. Extended parts are assembled offline and centrally stocked, and shipped together with priority module parts on alternate days to meet the requirements for complete elevator order delivery.

[0056] 4.7 Breakdown of Processing Content By sharing processing equipment resources, multiple sets of equipment can be combined to complete processing tasks that would normally be done independently by a single piece of equipment, reducing investment and lowering the processing time for non-standard and extended modules. Processing tasks such as punching and bending, which were traditionally done centrally, are now completed through secondary combinations, optimizing single-equipment operation into multi-equipment collaborative operation, further reducing the processing time for non-standard and extended modules.

[0057] 4.8 Scenario-based Operation and Implementation High-frequency scenarios: Only enable priority modules to focus on efficient production of standard parts; Mid-frequency scenarios: Priority modules operate in coordination, taking into account both standard and conventional non-standard components; Full-category scenario: Full-module linkage, with day shift producing main components and night shift producing extended components, achieving full coverage processing of 14 car body sheet metal parts. V. Beneficial Effects

[0058] We are building a new manufacturing paradigm centered on processes, deeply integrating equipment and processes to fundamentally solve the underlying defects of the separation between equipment and processes in traditional production lines.

[0059] 5.1 Overall Technical Advantages 5.1.1 Workpieces are managed separately, and processing strategies are precisely matched according to cycle time, process, assembly, and time period, resulting in a more reasonable and flexible process.

[0060] 5.1.2 The equipment is highly shared, with priority modules and expansion modules sharing the same core supporting units, which significantly reduces investment.

[0061] 5.1.3 Shift-based production: day shifts ensure delivery, night shifts maximize capacity, and equipment utilization and all-day production capacity.

[0062] 5.1.4 Process breakdown and multi-equipment collaboration break through the bottleneck of single-machine cycle time, significantly improving overall processing efficiency.

[0063] 5.1.5 The transplanting system has been optimized in all dimensions, with simultaneous upgrades to operation actions, running paths, and working parameters, resulting in a significant reduction in auxiliary working hours and a more compact process.

[0064] 5.1.6 Establish a PQ weight-based hierarchical full-domain material supply system. Relying on the secondary cutting process of non-standard module raw materials, there is no need to stock various non-standard specification plates, which greatly reduces the production line inventory pressure and material warehouse investment costs, and effectively improves the production online rate of non-standard parts. At the same time, the expansion parts adopt an offline assembly, centralized inventory preparation and unified complete set shipment mode, which greatly improves the stability of the whole machine delivery.

[0065] 5.1.7 Supports flexible configuration for multiple scenarios, adapting to different production capacities and order structures, making it highly applicable.

[0066] 5.1.8 The value rate of the process has been significantly improved: the traditional production line is only 3% to 8%, while the core section of this invention reaches 40% to 50%, and the overall value rate reaches 20% to 25%, resulting in a revolutionary improvement in resource utilization and economic benefits.

[0067] 5.1.9 It can cover the processing of all sheet metal parts of elevator cars and can be extended to fields such as electrical control cabinets and aluminum single panels. It has a wide range of applications and high promotion value.

[0068] 5.2 Quantitative Efficiency Improvement Effect of Each Module This invention achieves quantifiable and disruptive technological improvements in each production module and multiple production scenarios through module reconstruction, process simplification, time-sharing scheduling, and equipment sharing. All data corresponds one-to-one with Figures 1-7, and the following cycle time data are the average cycle time of each component.

[0069] 5.2.1 Improved overall efficiency of a single module The overall efficiency of the standard A module is improved by 87%, the overall efficiency of the priority A+B module is improved by 82%, the efficiency of non-standard bending processing of the extended C module is improved by 50%, and the overall efficiency of processing across all categories and domains is improved by 68% to 69%.

[0070] 5.2.2 Single-piece production cycle time optimization The average cycle time per unit of the traditional standard module was 495 seconds, which was reduced to 63 seconds after optimization; the average cycle time per unit of the traditional priority module was 550 seconds, which was reduced to 98 seconds after optimization; the average cycle time per unit of the traditional expansion module was 360 seconds, which was reduced to 180 seconds after optimization; the overall processing time of the 14 sheet metal parts of the car was reduced from 15 minutes to 5 minutes, and the overall production efficiency was improved by more than 67%.

[0071] 5.2.3 Investment and Cost Reduction in Multiple Scenarios 1) High-frequency standard parts production scenario: The weighted average manufacturing cost per unit achieves the largest reduction, with a maximum reduction of 92%; 2) In a standard-plus-non-standard collaborative production scenario for medium-frequency equipment: the overall weighted cost reduction reached 88%; 3) Full-category, full-domain time-sharing production scenario (day shift + night shift): The overall weighted investment and efficiency costs have been reduced by 81%.

[0072] This invention adopts an architecture of "one set of core modules to replace the traditional 10 independent processing units", which completely eliminates the drawbacks of repeated investment and idle equipment in traditional multi-production lines, and greatly reduces the scale of hardware investment.

[0073] 5.2.4 General Transplanting Optimization Special Effects The universal transplanting optimization of this invention systematically improves the traditional transplanting method from three dimensions: streamlined operation process, optimized transplanting path, and improved operating parameters.

[0074] 5.2.4.1 Streamlining and Optimizing Action Flow Traditional frame-type transplanting machines involve eight transplanting actions: transplanter descent → workpiece pickup → transplanter ascent → horizontal translation → transplanter descent → workpiece release → transplanter ascent → reset and return. This solution simplifies this to three core actions: direct feeding and pickup, synchronous transfer, and rapid reset. The number of actions is reduced from eight to three, a 62.5% reduction in steps, significantly lowering transfer time and greatly simplifying the process.

[0075] 5.2.4.2 Optimization of Transplanting Path For hinged arm components with an aspect ratio of approximately 1:3, the transfer path is preferentially laid out along the width direction of the workpiece. Compared to laying it out along the length direction, the transfer distance is shortened to 1 / 3 of the original distance, the stroke is reduced by approximately 66.7%, and the ineffective movement stroke is significantly reduced.

[0076] 5.2.4.3 Improvement and optimization of operating parameters This device can apply pressure to the raw materials using either mechanical pressure or magnetic adsorption. By increasing the friction between the raw materials and the transplanting carrier, it prevents the boards from slipping or shifting, thus ensuring the stable operation of the transplanting equipment under high dynamic conditions.

[0077] Based on this, the motion parameters of the equipment have been significantly improved: the acceleration has been increased from 1~3m / s² in traditional transplanting to 5~10m / s² in this invention; the moving speed has been increased from 200~400mm / s in traditional transplanting to 800~2000mm / s in this invention.

[0078] The range of pressure and magnetic attraction force is F=(2~5)G, where G is the weight of the raw material. It can be used for elevator sheet metal raw materials with a thickness of 0.5~5mm and a single piece weight of ≤50kg, which significantly enhances the efficiency of transfer and transportation and the stability of operation.

[0079] 5.2.5 Quantitative matching of production capacity It can be precisely adapted to three mainstream mass production scenarios in the industry: high-frequency standard parts with an annual production capacity of 130,000 units, medium-frequency non-standard parts with an annual production capacity of 60,000 units, and full-category expansion scenarios with an annual production capacity of 60,000 units, achieving optimal investment, optimal efficiency, and lowest cost matching under different production capacity. VI. Description of the attached drawings

[0080] Figure 1. Traditional equipment-centric manufacturing process for all types of elevator cars This diagram illustrates a traditional dual-production-line manufacturing process, showing two independent production lines that process main components and expansion components respectively. This process suffers from problems such as rigidity, wasted investment, insufficient flexibility, and inefficient collaboration. The effective process value rate is only 3% to 8%, which clearly demonstrates the inherent defects of existing technologies: high investment, high redundancy, and low efficiency.

[0081] Figure 2. Manufacturing Flowchart of the New Elevator Car with Manufacturing Process as the Core This diagram illustrates a new manufacturing paradigm centered on process technology. It employs a multi-level, decremental automated material feeder, dividing the system into priority and extension modules to achieve module sharing, staggered timing, and redundant removal. Standard module efficiency is improved by 87%, priority module by 82%, extension module by 50%, and overall efficiency across all product categories by 68%. The value margin of core processes increases from 3%–8% to 40%–50%, and the overall value margin across all processes increases to 20%–25%, achieving integrated production with high efficiency, high value margin, and low cost.

[0082] Figure 3. Analysis of differences in processes and equipment between old and new paradigms and patent layout. This diagram compares the old and new paradigms and quantifies the patent layout, disclosing core data such as the number of workpieces, weight percentage, variety ratio, efficiency improvement ratio, processing cycle time, process parameters, and equipment matching relationships for modules A (standard), B (non-standard), C (extension), and D (full-domain). The standard module shows an 87% efficiency improvement, the priority module an 82% improvement, the extension module a 50% improvement, and the full-domain improvement a 69% improvement. The diagram clearly defines the division of labor and support relationships of patents 1, 2, and 3: patent 1 provides full-domain material supply support, constructing a PQ weighted hierarchical material library to ensure material supply for all modules; patent 2 is the core of the priority module, enabling efficient processing of standard parts (A) and non-standard parts (B); patent 3 is the core of extension and full-domain scheduling, supplementing the non-standard bending capabilities of module C and achieving collaborative processing of all categories through module D. This diagram comprehensively reflects the direction of process optimization, equipment configuration logic, patent layout structure, and quantified technical effects, providing comprehensive data support for technical solutions.

[0083] Figure 4. Analysis of Investment, Efficiency, Cost, and Manufacturing Methods between New and Old Paradigms This diagram compares the hardware configuration differences between the traditional 10 independent units and the 4 core modules of this invention, clearly illustrating the corresponding relationships between investment reduction, efficiency improvement, cost reduction, and manufacturing paradigm upgrade. Configuration recommendations are provided for three production scenarios: high frequency, medium frequency, and full product range. The maximum reduction in weighted average manufacturing cost per unit is 92%, with 88% reduction in the medium frequency scenario and 81% in the full product range scenario, intuitively demonstrating the significant cost advantages of this invention at different production capacity scales.

[0084] Figure 5. Schematic diagram of the system logic for adding extended modules, module sharing, and time compensation. This diagram illustrates the system control and full-process linkage. With the PLC control center at its core, it connects multi-level decreasing feeders, non-standard punching and cutting units, standard punching and bending units, priority modules, and expansion modules through a general transfer mechanism. This enables cycle time matching, signal synchronization, information management, and staggered production to ensure stable, efficient, and collaborative operation of the entire process.

[0085] Figure 6. Schematic diagram of the acceleration enhancement method for general transplanting modules This diagram illustrates the principle of general-purpose transplanting speed-up. It uses mechanical pressure or magnetic adsorption, with a magnetic force F=(2~5)G, to increase the acceleration of raw materials to 5~10m / s², and the transplanting speed to 800~2000mm / s. It is suitable for sheet metal parts with a thickness of 0.5~5mm and a weight of ≤50kg, which greatly shortens the auxiliary time of process connection and improves the overall cycle time.

[0086] Figure 7. Schematic diagram of manufacturing cycle time and time allocation for each component of a single unit. This diagram compares the processing cycle times and timing allocation for various components of a single elevator car before and after the upgrade. The standard module's cycle time decreased from 495 seconds to 63 seconds, the priority module from 550 seconds to 98 seconds, and the extension module from 360 seconds to 180 seconds. The overall car cycle time decreased from 15 minutes to 5 minutes, representing an efficiency improvement of over 67%. The diagram clearly illustrates the day / night shift staggered production rules, precise time scheduling logic, and cycle time adaptation relationships, visually demonstrating the effects of efficiency improvement, capacity activation, and value optimization.

[0087] All specific values ​​are illustrative and used only to illustrate the technical principles; actual values ​​may be adjusted according to application scenarios. For specific structural details of the feeding silo, refer to Figure 1 of Patent 1 (Title: A Multi-Level Decreasing Automatic Feeding Silo for an Automatic Sheet Metal Processing Line), filed on the same day. For specific structural details of the processing equipment, refer to Figures 1-17 of Patent 2 (Title: A Sheet Metal Processing Method Based on Processing Technology with Dedicated and Flexible Considerations), also filed on the same day. The technical content corresponding to the above figures is incorporated into this specification. The terms "core method," "core defect," and "core advantage" marked in each figure are intuitive supplements to the technical logic of this invention and have the same explanatory effect as the textual description in the specification, jointly defining the scope of protection of this invention.

[0088] The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A flexible, all-domain machining center for elevator sheet metal, encompassing standard, non-standard, and extended applications, characterized in that: It includes a priority module, an extension module, and a global integrated scheduling module; The priority module enables the processing of standard parts and non-standard parts, and the expansion module enables the non-standard bending processing of expansion parts. Each module shares hardware resources and a supply system, and the global integrated scheduling module performs time-sharing and peak-shifting scheduling and task coordination. By breaking down processes, enabling multi-equipment collaborative operations, and optimizing general transfer methods, auxiliary time is reduced, processing efficiency is improved, and equipment investment is reduced.

2. The machining center according to claim 1, characterized in that: The priority module includes a standard punching and bending unit and a non-standard punching and cutting unit; the standard punching and bending unit completes standard hole and standard bending processing, and the non-standard punching and cutting unit completes non-standard hole processing and secondary cutting of raw materials.

3. The machining center according to claim 1, characterized in that: The expansion module is a flexible, non-standard bending unit that fully reuses the equipment and resources of the priority module and does not require separate punching equipment.

4. The machining center according to claim 1, characterized in that: The global integrated scheduling module adopts a time-sharing operation mode, with the day shift prioritizing the module and utilizing the spare time of the priority module and the night shift to run the extension module.

5. The machining center according to claim 1, characterized in that: The general transplanting optimization significantly reduces auxiliary time by simplifying transplanting steps, shortening moving distances, and improving operating parameters.

6. The machining center according to claim 5, characterized in that: The transplanting process has been simplified from multiple traditional actions into three core actions: direct transplanting, synchronous transplanting, and rapid repositioning.

7. The machining center according to claim 5, characterized in that: The method of applying pressure or magnetic attraction to the surface of raw materials is adopted to increase the friction and improve the transplanting acceleration and speed. Combined with the simultaneous entry and exit mode, it reduces the auxiliary transplanting time and improves the stability of operation.

8. The machining center according to claim 1, characterized in that: The priority module and the expansion module share the automatic feeding unit, raw material library, control unit and finished product delivery unit.

9. The machining center according to claim 1, characterized in that: The hole machining of the extension parts is completed in conjunction with the punching and cutting equipment of the priority module, and the bending machining is completed by a combination of standard bending equipment and extension bending equipment.

10. The machining center according to claim 1, characterized in that: The workpieces processed by the expansion module are assembled offline, centrally stocked, and shipped together with the workpieces of the priority module on the same day.

11. The machining center according to claim 1, characterized in that: The global integrated scheduling module adopts a PLC+MES integrated control center to realize signal synchronization, parameter linkage and fault mutual detection of each module.

12. The machining center according to any one of claims 1 to 10, characterized in that: It can perform integrated processing of all types of car body sheet metal parts, including car walls, front walls, door lintels, control panels, and car doors, and can be adapted to three production scenarios: high frequency, medium frequency, and full range of products, depending on production capacity and demand.

13. The machining center according to claim 1, characterized in that: The machining center is also suitable for the automated processing and production of electrical control cabinets, decorative aluminum panels, and various large general-purpose sheet metal parts.

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