A congestion joint reconstruction self-healing control method for a digital workshop and a related device thereof

Abstract

The application discloses a kind of congestion joint reconstruction self-healing control method of digital workshop and its related equipment, comprising: identifying congestion station, and establishing first initial isolation control area and second initial isolation control area at congestion station and its adjacent station;Extract intermediate station set;Calculate the bidirectional congestion coupling index of each intermediate station;When bidirectional congestion coupling index meets joint reconstruction condition, merged to build joint dynamic isolation control area;According to the abnormal disposal recovery estimation time in joint dynamic isolation control area, calculate the decoupling cost under degraded operation strategy;According to decoupling cost, the production operation tact of each station in joint dynamic isolation control area is corrected and collaborative adjustment instruction is generated;After production line runs according to collaborative adjustment instruction and abnormal disposal is completed, the joint control state of each station in joint dynamic isolation control area is released.

Description

Technical Field

[0001] This invention belongs to the field of digital workshops and relates to a congestion joint reconfiguration self-healing control method and related equipment for digital workshops. Background Technology

[0002] With the development of industrial intelligence and flexible manufacturing, digital workshops are widely used in production scenarios involving multiple varieties, small batches, and dynamically changing cycle times. During the operation of a digital workshop, factors such as short-term equipment downtime, uneven material supply, buffer area backlog, and fluctuations in conveyor cycle time can lead to congestion at local workstations, including waiting times, buffer saturation, or operational stoppages. Because there is a cycle time coupling relationship between workstations in a continuous production line, if local congestion is not identified and controlled in a timely manner, it can easily spread to adjacent workstations, thereby affecting the overall operational stability of the production line.

[0003] Existing technologies typically involve fixed buffer zone control, overall line takt time correction, and pre-production scheduling. Fixed buffer zone control primarily adjusts the operating speed of upstream and downstream equipment based on the material inventory within a pre-defined buffer area, making it difficult to dynamically change the control area according to the direction of congestion spread. Overall line takt time correction mainly addresses the overall capacity coordination of the production line, making it difficult to isolate and reconfigure localized sudden congestion areas in a timely manner. Pre-production scheduling is mainly used for task sequencing and resource allocation before production begins, making it difficult to handle multi-point congestion coupling problems that have already occurred during production line operation. Summary of the Invention

[0004] The purpose of this invention is to overcome the shortcomings of the prior art and provide a congestion joint reconfiguration self-healing control method and related equipment for digital workshops, which can identify the impact of bidirectional congestion in advance, jointly reconfigure adjacent local control areas, and perform step-by-step splitting and progressive load recovery during the recovery phase.

[0005] To achieve the above objectives, the present invention employs the following technical solution: A congestion joint reconfiguration self-healing control method for digital workshops includes: S1, acquire the status data of each workstation on the production line; S2, based on the status data, identify the congested workstations and establish a first initial isolation control zone and a second initial isolation control zone at the congested workstations and their adjacent workstations; S3, extract the workstations located between the first initial isolation control zone and the second initial isolation control zone that have not met the congestion triggering conditions, and generate an intermediate workstation set; S4. Calculate the bidirectional congestion coupling index of each intermediate workstation by using the first-side congestion pressure value generated by the first initial isolation control zone on each intermediate workstation in the intermediate workstation set and the second-side congestion pressure value generated by the second initial isolation control zone on each intermediate workstation. S5, when the bidirectional congestion coupling index meets the joint reconfiguration conditions, the first initial isolation control zone, the second initial isolation control zone and the intermediate workstation set are merged to construct a joint dynamic isolation control zone; S6, calculate the decoupling cost under the degraded operation strategy based on the estimated recovery time of abnormal workstations in the joint dynamic isolation control area; S7, adjusts the production cycle time of each workstation in the joint dynamic isolation control area according to the decoupling cost and generates collaborative adjustment instructions; S8, after the production line operates according to the coordinated adjustment instructions and the abnormality is handled, releases the joint control status of each workstation in the joint dynamic isolation control area.

[0006] Optionally, in S2, after establishing the first initial isolation control zone and the second initial isolation control zone, an elastic adjustment operation is performed on the boundary of the first initial isolation control zone and the second initial isolation control zone according to the direction of congestion spread; when the delivery waiting time of multiple upstream workstations exceeds a preset time threshold, at least one upstream adjacent workstation is incorporated into the control range of the first initial isolation control zone or the second initial isolation control zone; when the congested workstations resume normal operation and the continuous stable operation time of the downstream workstations reaches a preset stable time threshold, the boundary workstations are gradually moved out of the control range of the first initial isolation control zone or the second initial isolation control zone.

[0007] Optionally, in S4, the first-side congestion pressure value is calculated by combining the positive deviation of the cache occupancy in the first initial isolation control area with the upper limit of the cache and a monotonically increasing normalization function; the second-side congestion pressure value is calculated by combining the positive deviation of the material discharge waiting time or material shortage duration in the second initial isolation control area with the preset material discharge threshold and a monotonically increasing normalization function.

[0008] Optionally, in S5, when the bidirectional congestion coupling index of any intermediate workstation is greater than or equal to the joint reconstruction threshold in multiple consecutive sampling periods and the first-order time change rate of the bidirectional congestion coupling index is greater than the preset growth threshold, it is determined that the joint reconstruction condition is met; during the construction of the joint dynamic isolation control area, a unified joint control area identifier is assigned to the joint dynamic isolation control area.

[0009] Optionally, in S6, the total intermediate buffer capacity and bottleneck buffer capacity are calculated based on the buffer limit and current buffer occupancy of each intermediate station in the intermediate station set; the material flow fluctuation demand is obtained based on the estimated recovery time of abnormal handling, the current production cycle time, and the buffer change rate; when the material flow fluctuation demand exceeds the absorption capacity of the total intermediate buffer capacity or the bottleneck buffer capacity, the bottleneck buffer capacity deficiency is obtained according to the difference between the material flow fluctuation demand to be absorbed and the bottleneck buffer capacity; the decoupling cost is obtained by weighting the bottleneck buffer capacity deficiency, the estimated recovery time of abnormal handling, the cumulative cycle time deviation in the joint dynamic isolation control area, and the speed adjustment amplitude.

[0010] Optionally, before calculating the decoupling cost, the bottleneck buffer capacity shortage, the estimated recovery time for abnormal handling, and the cumulative cycle time deviation are normalized to the same numerical range; when the decoupling cost increases, the deceleration rate of the upstream workstations in the joint dynamic isolation control zone is increased and the target value of the cycle time fluctuation rate of each intermediate workstation in the intermediate workstation set is reduced; when the decoupling cost decreases, the deceleration rate is gradually reduced and each workstation in the joint dynamic isolation control zone is adjusted according to the normal production cycle time.

[0011] Optionally, in S8, the degradation condition is that the maximum value of the bidirectional congestion coupling index of each intermediate workstation in the intermediate workstation set is less than or equal to the degradation threshold within multiple consecutive sampling periods, and the buffer occupancy of each workstation in the joint dynamic isolation control area falls back to the preset stable buffer range; the mapping relationship between some workstations in the joint dynamic isolation control area and the joint control task queue is gradually released in a preset order; the workstations are removed from the joint control task queue and identified as released workstations, and the operating load of each released workstation is adjusted to the normal operating load according to the gradually increasing frequency setpoint or speed setpoint; the joint control area identifier is revoked after all released workstations have completed the operating load adjustment.

[0012] A congestion joint reconfiguration and self-healing control system for a digital workshop includes: The data acquisition module is used to acquire status data of each workstation on the production line; The isolation zone establishment module is used to identify congested workstations based on status data and establish a first initial isolation control zone and a second initial isolation control zone at the congested workstation and its adjacent workstations. The set partitioning module is used to extract workstations located between the first initial isolation control zone and the second initial isolation control zone that have not met the congestion triggering conditions, and generate an intermediate workstation set; The index calculation module is used to calculate the bidirectional congestion coupling index of each intermediate workstation by using the first side congestion pressure value generated by the first initial isolation control zone on each intermediate workstation in the intermediate workstation set and the second side congestion pressure value generated by the second initial isolation control zone on each intermediate workstation. The control area reconstruction module is used to merge the first initial isolation control area, the second initial isolation control area, and the intermediate workstation set to construct a joint dynamic isolation control area when the bidirectional congestion coupling index meets the joint reconstruction conditions. The cost calculation module is used to calculate the decoupling cost under the degraded operation strategy based on the estimated recovery time of abnormal workstations within the joint dynamic isolation control area. The cycle time correction module is used to correct the production cycle time of each workstation in the joint dynamic isolation control area according to the decoupling cost and generate coordinated adjustment instructions. The status release module is used to release the joint control status of each workstation in the joint dynamic isolation control area after the production line is running according to the coordinated adjustment instructions and the abnormality is handled.

[0013] A computer device includes a memory, a processor, and a computer program stored in the memory and executable on the processor, wherein the processor executes the computer program to implement the steps of the congestion joint reconfiguration self-healing control method for the digital workshop.

[0014] A computer-readable storage medium storing a computer program that, when executed by a processor, implements the steps of the congestion joint reconfiguration self-healing control method for the digital workshop.

[0015] Compared with the prior art, the present invention has the following beneficial effects: This invention quantifies the bidirectional pressure exerted on intermediate workstations by adjacent isolation zones by introducing a bidirectional congestion coupling index. When multi-point local congestion creates coupling risks, it breaks through the limitations of traditional fixed buffer sections, logically merging independent initial isolation zones and intermediate workstations into a unified joint dynamic isolation control zone. This eliminates the adjustment lag and interference problems caused by the independent operation of each local control zone. Based on this, the decoupling cost is calculated by combining the estimated recovery time for anomaly handling to correct the production cycle time, achieving a smooth load transition under abnormal operating conditions. Control is released after recovery, effectively curbing the vicious spread of congestion and significantly improving the overall operational stability and self-healing control capability of the continuous production line in the digital workshop.

[0016] Furthermore, the control boundary is reshaped in real time based on the dynamic spatiotemporal evolution of congestion spread. By setting time thresholds and stable time thresholds as the basis for judging expansion and contraction boundaries, the system can know the real situation of upstream material backlog or downstream operation recovery. This avoids excessive or insufficient intervention caused by fixed control range. While effectively accommodating sudden fluctuations in material flow, it maximizes the protection of normal production rhythm of unaffected workstations, thereby improving the production efficiency and control accuracy of the entire production line.

[0017] Furthermore, the positive deviations of buffer occupancy, material discharge waiting time, or material shortage duration are used to characterize material accumulation and supply disruption pressure. By combining this with a monotonically increasing normalization function, calculation errors caused by different dimensions, different equipment operating conditions, and multi-source heterogeneous data are effectively eliminated. This transforms previously difficult-to-measure buffer margins and cycle time anomalies into standardized pressure indicators. This quantification method accurately reveals the actual coupling mapping relationship between abnormal states of upstream and downstream workstations and intermediate workstations, providing robust data support for triggering joint reconfiguration.

[0018] Furthermore, by limiting the continuous sampling period and first-order time rate of change of the bidirectional congestion coupling index, a reconfiguration triggering mechanism with trend prediction capabilities is constructed. This filters transient data noise caused by short-term equipment stagnation or minor cycle fluctuations, accurately pinpointing the truly deteriorating congestion coupling state, thereby avoiding frequent and ineffective topology reconfigurations. Simultaneously, a unified joint control area identifier is assigned to the joint dynamic isolation control area during the construction process, ensuring the uniqueness and synchronization of status data and execution commands at each workstation within the control system, eliminating the risk of command misalignment in collaborative control.

[0019] Furthermore, the abstract system decoupling objective is transformed into a multi-dimensional cost quantification model. By calculating the absorption limits of the total intermediate buffer capacity and the bottleneck buffer capacity, the insufficient bottleneck buffer capacity is determined, and a weighted calculation is performed considering anomaly recovery time, cumulative cycle time deviation, and speed adjustment amplitude. This multi-dimensional weighting mechanism balances the risk cost of downtime caused by material accumulation with the equipment wear cost caused by frequent and significant speed adjustments. This allows the system to accurately assess its current buffer absorption capacity under degraded operating conditions, thereby providing the production line with an optimal collaborative adjustment strategy that balances time efficiency and equipment health.

[0020] Furthermore, based on the trend of decoupling cost changes after normalization, differentiated upstream and downstream cycle time correction strategies are implemented. When the cost increases, the upstream speed reduction is increased to cut off material input at the source, and the target value of cycle time fluctuation rate at intermediate stations is reduced to force the absorption of accumulated material; when the cost decreases, the speed reduction is gradually reduced to guide the production line to smoothly transition to normal cycle time. This control mechanism based on real-time cost feedback forms a synergistic effect of upstream flow restriction, intermediate buffering, and downstream material discharge, strictly confining material flow fluctuations within the joint dynamic isolation control zone and preventing local disturbances from maliciously propagating to the entire line.

[0021] Furthermore, a dual criterion of a declining bidirectional congestion coupling index and sufficient buffer occupancy is introduced to ensure that the production line only initiates the unbinding process after it has escaped the danger of congestion. By demapping the relationships in a preset sequence and sending progressively increasing frequency or speed setpoints to the released workstations, mechanical rigidity shocks and secondary congestion caused by a sudden surge in material speed after anomaly resolution are avoided. This gradual recovery mechanism significantly reduces the damage to actuators caused by sudden changes in electrical load, ensuring a smooth transition from the workshop's self-healing phase to normalized production. Attached Figure Description

[0022] Figure 1 This is a schematic diagram of the overall structure of the digital workshop intelligent control and decision-making system of the present invention; Figure 2 This is a schematic diagram of bidirectional congestion coupling and joint dynamic isolation control area reconstruction of adjacent initial isolation control areas according to the present invention; Figure 3 This is a flowchart of the joint dynamic isolation control zone degradation splitting and load progressive recovery process of the present invention.

[0023] The components include: 1. Field data acquisition assembly; 2. Edge control terminal; 3. Main control PLC controller; 4. Workstation controller; 5. Variable frequency actuator; 6. Conveyor detection sensor; 7. Buffer status detection switch; 8. Equipment status acquisition terminal; 9. Industrial communication bus; 10. Data acquisition module; 101-110, Workstation 1 to Workstation 10; A. First initial isolation control zone; B. Second initial isolation control zone; C. Joint dynamic isolation control zone. Detailed Implementation

[0024] Embodiments of the present invention are described in detail below, examples of which are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0025] The following disclosure provides many different embodiments or examples for implementing various structures of the invention. To simplify the disclosure, specific examples of components and arrangements are described below. These are merely examples and are not intended to limit the invention. Furthermore, reference numerals and / or letters may be repeated in different examples; such repetition is for simplification and clarity and does not in itself indicate a relationship between the various embodiments and / or arrangements discussed. In addition, examples of various specific processes and materials are provided in this invention, but those skilled in the art will recognize the application of other processes and / or the use of other materials.

[0026] Example 1 This embodiment provides a digital workshop intelligent control and decision-making system.

[0027] The system includes a field data acquisition assembly 1, an edge control terminal 2, a main control PLC controller 3, multiple workstation controllers 4, multiple variable frequency actuators 5, an industrial communication bus 9, and a data acquisition module 10 set up independently of the edge control terminal 2. The field data acquisition assembly 1 includes a conveyor detection sensor 6, a buffer status detection switch 7, and an equipment status acquisition terminal 8. The data acquisition module 10 is used to receive multi-source status data uploaded by the field data acquisition assembly 1, and to perform standardization processing and time scale alignment on it.

[0028] The edge control terminal 2 communicates with the main control PLC controller 3, multiple workstation controllers 4, and data acquisition module 10 via the industrial communication bus 9, and is used to execute the congestion joint reconfiguration self-healing control method described in Embodiment 1. The main control PLC controller 3 and the workstation controllers 4 control the corresponding variable frequency actuators 5 according to the coordinated adjustment instructions issued by the edge control terminal 2, so that the variable frequency actuators 5 adjust the operating load of the workstation conveyor drive mechanism.

[0029] When edge control terminal 2 addresses the risk of congestion spreading from adjacent local control areas, its bidirectional congestion coupling calculation and logical topology reconstruction process for state data is as follows: Figure 2 As shown. In Figure 2 In the pre-reconstruction phase on the left, when multiple localized congestion points occur on the production line, edge control terminal 2 will establish an initial isolation control zone at the congested workstation and its adjacent workstations, for example... Figure 2 The isolation zones are respectively controlled by control task A (covering workstations 3 to 5) and control task B (covering workstations 8 to 10). At this time, for intermediate workstations (such as workstations 6 and 7) between isolation zone A and isolation zone B that have not yet reached the congestion triggering condition but have abnormal cycle time fluctuations, the edge control terminal 2 will use the intermediate workstation data collected from the underlying layer, combined with the first-side congestion pressure P16 formed by isolation zone A on the intermediate workstations and the second-side congestion pressure P27 formed by isolation zone B, to calculate the bidirectional congestion coupling indices DI6 and DI7 for each workstation 6 and workstation 7 (intermediate workstations).

[0030] When edge control terminal 2 detects that the bidirectional congestion coupling index of any intermediate workstation continuously meets the set joint reconfiguration conditions, the system will trigger as follows: Figure 2The right side shows the reconfiguration of the joint dynamic isolation control zone. After reconfiguration, the originally independent isolation zones A and B, along with all intermediate workstations in between, are logically merged into a unified joint dynamic isolation control zone C. The edge control terminal 2 not only assigns a unified joint control zone identifier to the joint dynamic isolation control zone C, but also maps the status data, control parameters, and actuator addresses corresponding to the data in zone A, intermediate workstations, and zone B to the same joint control task queue. This allows the main PLC controller 3 and the related variable frequency actuators 5 to execute coordinated adjustment instructions based on the unified joint control task, effectively avoiding the adjustment lag caused by the independent operation of each initial isolation control zone, and thus identifying and mitigating the risk of coupling and diffusion between adjacent congested areas in advance.

[0031] Example 2 This embodiment, based on the intelligent control and decision-making system for digital workshops in Embodiment 1, provides a congestion joint reconfiguration and self-healing control method for digital workshops. A flexible automated production line with 10 sequentially connected material conveying workstations in a digital packaging workshop is used as a specific industrial application scenario for illustration. These 10 workstations are designated as workstation 1 to workstation 10. The method is executed by an edge control terminal 2 deployed within the workshop and specifically includes the following steps.

[0032] Step S1: Status data acquisition and time scale alignment.

[0033] The edge control terminal 2 acquires the status data of each workstation on the production line in each sampling cycle. The status data includes conveying waiting time, buffer occupancy, buffer change rate, equipment operating status, and cycle time data.

[0034] like Figure 1 As shown, the field data acquisition assembly 1 includes a conveying detection sensor 6 installed between conveying workstations, a buffer status detection switch 7 installed in the workstation buffer area, and an equipment status acquisition terminal 8 connected to the workstation controller 4. The data acquisition module 10 is set independently of the edge control terminal 2 and is used to receive multi-source status data uploaded by the field data acquisition assembly 1, and to perform standardization processing and time scale alignment on the multi-source status data.

[0035] To reduce misjudgments of status caused by upload delays from different data sources, the data acquisition module 10 or the edge control terminal 2 timestamps the multi-source status data based on the data arrival time and network transmission delay of each data source, and maps the corrected data to the same sampling time axis to form a status data set for the corresponding workstation. The network transmission delay can be estimated by communication round-trip time, bus cycle time, or controller local clock deviation.

[0036] Step S2: Establishment of the initial isolation control zone and flexible adjustment of its boundaries.

[0037] The edge control terminal 2 performs online congestion identification based on the status data set generated in step S1. When any workstation meets at least one of the following conditions: the conveying waiting time continuously exceeds a preset time threshold, the buffer status detection switch continuously closes for more than a preset buffer status threshold due to workpiece backlog, or the equipment current data output by the equipment status acquisition terminal is continuously lower than a preset shutdown threshold, the edge control terminal 2 identifies the workstation as a congested workstation.

[0038] When workstation 4 is identified as a congested workstation, edge control terminal 2 establishes a first initial isolation control zone at workstation 4 and its adjacent upstream workstation 3 and downstream workstation 5, denoted as isolation zone A. Subsequently, edge control terminal 2 performs flexible adjustments to the boundary of isolation zone A according to the direction of congestion spread: when the delivery waiting time of multiple consecutive upstream workstations exceeds a preset time threshold, at least one upstream adjacent workstation is incorporated into the control range of isolation zone A; when congested workstation 4 resumes normal operation and the continuous stable operation time of downstream workstations reaches a preset stable time threshold, the boundary workstations that meet the stability conditions are gradually moved out of the control range of isolation zone A.

[0039] Step S3: Online calculation of the bidirectional congestion coupling index of the intermediate workstation.

[0040] like Figure 2 As shown on the left, assuming that workstation 9 at the far end of the production line also triggers a congestion determination, the edge control terminal 2 establishes a second initial isolation control zone at workstation 9 and its adjacent workstations, denoted as isolation zone B. In this embodiment, isolation zone B includes workstations 8, 9, and 10.

[0041] At this time, a first initial isolation control zone A and a second initial isolation control zone B, which are spaced apart and adjacent to each other along the production line direction, coexist on the production line. The workstations located between isolation zones A and B that have not yet reached the congestion triggering condition are defined as the intermediate workstation set S; in this embodiment, S = {workstation 6, workstation 7}. When the cycle time fluctuation rate of the intermediate workstations in set S exceeds the cycle time anomaly warning threshold, the edge control terminal 2 calculates the bidirectional congestion coupling index for each intermediate workstation i in set S. . Figure 2 In and These represent the bidirectional congestion coupling indexes for workstations 6 and 7, respectively.

[0042] The bidirectional congestion coupling index The calculation formula is:

[0043] In the formula, The first side congestion pressure value formed by the first initial isolation control zone on the intermediate workstation i is calculated based on the positive deviation of the buffer occupancy in the first initial isolation control zone relative to the upper limit of the buffer. The second side congestion pressure value formed by the second initial isolation control zone on the intermediate station i is calculated based on the positive deviation of the material discharge waiting time or material shortage duration in the second initial isolation control zone relative to a preset threshold. All are preset monotonically increasing normalized functions; The intermediate workstation The standard deviation or coefficient of variation of the beat within a preset sliding window; These are the influence weights of the corresponding items, and .

[0044] In one implementation, Piecewise linear normalization functions, sigmoid normalization functions, or other monotonically increasing normalization functions can be used to map the corresponding congestion pressure value to a preset numerical range.

[0045] Step S4: Logical topology reconstruction of the joint dynamic isolation control area.

[0046] like Figure 2 As shown, edge control terminal 2 continuously monitors the bidirectional congestion coupling index of each intermediate workstation in the intermediate workstation set S. The maximum value among the bidirectional congestion coupling indices of each intermediate workstation in set S is denoted as... .

[0047] When any intermediate workstation The threshold is greater than or equal to the joint reconstruction threshold within N consecutive sampling periods. And the When the first-order time change rate is greater than the preset growth threshold, the edge control terminal 2 determines that the joint reconstruction condition is met and triggers the joint dynamic isolation control area reconstruction.

[0048] In this embodiment, when station 6 When the joint reconstruction conditions are met continuously, the edge control terminal 2 logically merges the isolation zone A, the isolation zone B, and the intermediate workstation set S to form a joint candidate zone A∪M∪B; subsequently, the edge control terminal 2 reconstructs the joint candidate zone A∪M∪B into a joint dynamic isolation control zone C.

[0049] During the reconfiguration process, edge control terminal 2 assigns a unified joint control area identifier to the joint dynamic isolation control area C, and maps the status data, control parameters, and actuator addresses of the corresponding workstations in joint dynamic isolation control area C to the same joint control task queue. Through this mapping, the originally separately controlled isolation areas A and B, as well as the intermediate workstation set S, are incorporated into the same joint control task, enabling edge control terminal 2 to generate coordinated adjustment instructions based on unified status data and control objectives.

[0050] In one implementation, the status data and control parameters are stored in corresponding registers, data tables, or control task buffers; the actuator address includes the communication address or control address of the frequency converter 5 corresponding to each station within the joint dynamic isolation control area C.

[0051] Step S5: Decoupling cost weighting calculation and collaborative adjustment.

[0052] Within the joint dynamic isolation control zone C, edge control terminal 2 obtains the estimated recovery time for abnormal workstations based on the same joint control task. In this embodiment, the abnormal workstations include workstation 4 and workstation 9. The estimated recovery time for the abnormality handling is... This includes at least one of the following: mechanical failure repair time, material blockage clearing time, conveying restoration time, and control reset time.

[0053] For each intermediate station i in the intermediate station set S, the edge control terminal 2 calculates the remaining available buffer capacity based on the cache limit of that intermediate station and the current cache usage. The total capacity of the intermediate buffer is determined according to the following formula. and bottleneck buffer capacity : ; .

[0054] Edge control terminal 2 determines the material flow fluctuation demand based on the buffer change rate and cycle time data in the status data. In one implementation, the material flow fluctuation demand... Estimated recovery time from abnormal handling The current production cycle time and buffer change rate are used to determine this.

[0055] When material flow fluctuates demand Exceeding the total capacity of the intermediate buffer or bottleneck buffer capacity When considering the bottleneck's absorption capacity, edge control terminal 2 determines the amount of insufficient bottleneck buffer capacity. ,in According to the demand for fluctuations in the flow rate of materials to be consumed With bottleneck buffer capacity The difference between them is determined, and is set to zero when the difference is less than zero. Edge control terminal 2 calculates the decoupling cost under the degraded operation strategy. :

[0056] In the formula, The bottleneck buffer capacity is insufficient. Estimated recovery time for handling anomalies; The cumulative cycle time deviation within the joint dynamic isolation control zone C; This refers to the speed regulation range of the frequency converter 5; to represents the corresponding non-negative weighting coefficient.

[0057] In calculating the decoupling cost Previously, edge control terminal 2 would , and Normalize to the same numerical range to reduce the impact of different dimensions on the weighted calculation results.

[0058] Edge control terminal 2 according to the decoupling cost The production cycle time of each workstation within the joint dynamic isolation control zone C is corrected, and frequency setpoints, speed setpoints, or start / stop control quantities are generated for the corresponding workstations based on the corrected production cycle time. The frequency setpoints, speed setpoints, or start / stop control quantities are sent as coordinated adjustment commands to the corresponding variable frequency actuators 5.

[0059] When decoupling costs When the speed is increased, edge control terminal 2 increases the deceleration rate of the upstream station in the joint dynamic isolation control zone C and reduces the target value of the cycle time fluctuation rate of each station in the intermediate station set S; when the decoupling cost As the speed decreases, edge control terminal 2 gradually reduces the rate of reduction, allowing each workstation within the joint dynamic isolation control zone C to return to its normal cycle time. Thus, through coordinated control of upstream material intake restrictions, intermediate buffering and absorption, and downstream material discharge according to available conveying capacity, material flow fluctuations are confined within the joint dynamic isolation control zone C.

[0060] Step S6: Degradation splitting and progressive load recovery based on dual-threshold hysteresis mechanism.

[0061] After the anomaly handling is completed and the recovery phase begins, edge control terminal 2 continues to monitor the bidirectional congestion coupling index of each intermediate workstation in the intermediate workstation set S. And record the maximum value among them as .like Figure 3 As shown, the system sets a degradation threshold. Less than the joint reconstruction threshold .when Less than or equal to within M consecutive sampling periods When the cache occupancy of each workstation in the joint dynamic isolation control zone C falls back to the preset stable cache range, the edge control terminal 2 determines that the joint dynamic isolation control zone C meets the degradation condition.

[0062] After the degradation conditions are met, edge control terminal 2 initiates a step-by-step degradation and splitting process for the joint control task, and gradually decouples the mapping relationship between some workstations within the joint dynamic isolation control zone C and the joint control task queue according to a preset order. Workstations removed from the joint control task queue are recorded as released workstations.

[0063] For each released workstation, the edge control terminal 2 sends a gradually increasing frequency setpoint or speed setpoint to its corresponding variable frequency actuator 5, so that the operating load of the released workstation gradually recovers from the joint control state to the normal operating load.

[0064] Once all released workstations have completed the gradual load recovery, edge control terminal 2 removes the joint control area identifier. This process reduces electrical load fluctuations and mechanical shocks to the conveyor mechanism during the recovery phase, and lowers the risk of secondary congestion caused by sudden material acceleration.

[0065] This invention calculates a bidirectional congestion coupling index for intermediate workstations between two adjacent initial isolation control zones that are not yet congested but have abnormal cycle time fluctuations. This allows for the identification of coupling and diffusion risks before the intermediate workstations become completely congested, and the early triggering of joint control.

[0066] When the intermediate workstation continuously meets the joint reconfiguration conditions, the present invention reconfigures the two initial isolation control zones and the intermediate workstation between them into a joint dynamic isolation control zone and incorporates them into the same joint control task, thereby avoiding the adjustment lag caused by the independent control between adjacent local control zones.

[0067] This invention generates collaborative adjustment instructions based on the estimated recovery time of abnormal handling, buffer capacity, material flow fluctuations, and decoupling costs, enabling each workstation within the joint dynamic isolation control zone to adjust its operating rhythm according to a unified control objective, thereby reducing the impact of congestion spread on the stability of material flow.

[0068] This invention releases the joint control task after the degradation conditions are met and performs a gradual load recovery on the released workstation, reducing the risks of electrical load fluctuations, mechanical shocks and secondary congestion caused by rapid reset.

[0069] Example 3 In this embodiment, a congestion joint reconstruction self-healing control system for a digital workshop is provided. This congestion joint reconstruction self-healing control system for a digital workshop can be used to implement the above-mentioned congestion joint reconstruction self-healing control method for a digital workshop. Specifically, the congestion joint reconstruction self-healing control system for a digital workshop includes a data acquisition module, an isolation zone establishment module, a set partitioning module, an index calculation module, a control zone reconstruction module, a cost calculation module, a cycle time correction module, and a state release module.

[0070] The data acquisition module is used to acquire status data of each workstation on the production line.

[0071] The isolation zone establishment module is used to identify congested workstations based on status data, and to establish a first initial isolation control zone and a second initial isolation control zone at the congested workstation and its adjacent workstations.

[0072] The set partitioning module is used to extract workstations located between the first initial isolation control zone and the second initial isolation control zone that have not met the congestion triggering conditions, and generate an intermediate workstation set.

[0073] The index calculation module is used to calculate the bidirectional congestion coupling index of each intermediate workstation by using the first-side congestion pressure value generated by the first initial isolation control zone on each intermediate workstation in the intermediate workstation set and the second-side congestion pressure value generated by the second initial isolation control zone on each intermediate workstation.

[0074] The control area reconstruction module is used to merge the first initial isolation control area, the second initial isolation control area, and the intermediate workstation set to construct a joint dynamic isolation control area when the bidirectional congestion coupling index meets the joint reconstruction conditions.

[0075] The cost calculation module is used to calculate the decoupling cost under the degraded operation strategy based on the estimated recovery time of abnormal workstations within the joint dynamic isolation control area.

[0076] The cycle time correction module is used to correct the production cycle time of each workstation in the joint dynamic isolation control area according to the decoupling cost and generate coordinated adjustment instructions.

[0077] The status release module is used to release the joint control status of each workstation in the joint dynamic isolation control area after the production line is running according to the coordinated adjustment instructions and the abnormality is handled.

[0078] Example 4 This embodiment provides a computer device including a processor and a memory. The memory stores a computer program, which includes program instructions. The processor executes the program instructions stored in the computer storage medium. The processor may be a Central Processing Unit (CPU), but it can also be other general-purpose processors, digital signal processors (DSPs), application-specific integrated circuits (ASICs), or field-programmable gate arrays (FPGAs). Gate Array (FPGA) or other programmable logic devices, discrete gate or transistor logic devices, discrete hardware components, etc., are the computing and control core of computer equipment, suitable for implementing one or more instructions, specifically suitable for loading and executing one or more instructions to realize corresponding method flows or corresponding functions; the processor described in this embodiment of the invention can be used in the operation of a congestion joint reconfiguration self-healing control method in a digital workshop, including: S1, acquiring the status data of each workstation on the production line; S2, identifying congested workstations based on the status data, and establishing a first initial isolation control zone and a second initial isolation control zone at the congested workstation and its adjacent workstations; S3, extracting workstations located between the first initial isolation control zone and the second initial isolation control zone that have not reached the congestion triggering condition, and generating an intermediate workstation set; S4, utilizing the first S5. Calculate the bidirectional congestion coupling index of each intermediate workstation by considering the first-side congestion pressure value generated by the first initial isolation control zone on each intermediate workstation and the second-side congestion pressure value generated by the second initial isolation control zone on each intermediate workstation; S6. When the bidirectional congestion coupling index meets the joint reconfiguration condition, merge the first initial isolation control zone, the second initial isolation control zone, and the intermediate workstation set to construct a joint dynamic isolation control zone; S7. Calculate the decoupling cost under the degraded operation strategy based on the estimated recovery time of abnormal workstations within the joint dynamic isolation control zone; S8. Correct the production cycle time of each workstation within the joint dynamic isolation control zone based on the decoupling cost and generate a coordinated adjustment instruction; S9. After the production line operates according to the coordinated adjustment instruction and the abnormal handling is completed, deactivate the joint control state of each workstation within the joint dynamic isolation control zone.

[0079] Example 5 This embodiment provides a computer-readable storage medium (Memory), which is a memory device in a computer device used to store programs and data. It is understood that the computer-readable storage medium here can include both the built-in storage medium in the computer device and extended storage media supported by the computer device. The computer-readable storage medium provides storage space that stores the operating system of the computer device. Furthermore, the storage space also stores one or more instructions suitable for loading and execution by a processor. These instructions can be one or more computer programs (including program code). It should be noted that the computer-readable storage medium here can be high-speed RAM or non-volatile memory, such as at least one disk storage device.

[0080] One or more instructions stored in a computer-readable storage medium can be loaded and executed by a processor to implement the corresponding steps of the congestion joint reconfiguration self-healing control method for digital workshops in the above embodiments; one or more instructions in the computer-readable storage medium are loaded and executed by the processor as follows: S1, acquire the status data of each workstation on the production line; S2, identify the congested workstations based on the status data, and establish a first initial isolation control zone and a second initial isolation control zone at the congested workstation and its adjacent workstations; S3, extract the workstations located between the first initial isolation control zone and the second initial isolation control zone that have not reached the congestion triggering condition, and generate an intermediate workstation set; S4, use the first initial isolation control zone to control the first congestion triggering condition of each intermediate workstation in the intermediate workstation set. S5. Calculate the bidirectional congestion coupling index of each intermediate workstation based on the side congestion pressure value and the second side congestion pressure value generated by the second initial isolation control zone on each intermediate workstation; S6. When the bidirectional congestion coupling index meets the joint reconfiguration condition, merge the first initial isolation control zone, the second initial isolation control zone, and the intermediate workstation set to construct a joint dynamic isolation control zone; S7. Calculate the decoupling cost under the degraded operation strategy based on the estimated recovery time of abnormal workstations within the joint dynamic isolation control zone; S8. Correct the production operation cycle time of each workstation within the joint dynamic isolation control zone based on the decoupling cost and generate a coordinated adjustment instruction; S9. After the production line operates according to the coordinated adjustment instruction and the abnormal handling is completed, deactivate the joint control state of each workstation within the joint dynamic isolation control zone.

[0081] Those skilled in the art will understand that embodiments of the present invention can be provided as methods, systems, or computer program products. Therefore, this application can take the form of a completely hardware embodiment, a completely software embodiment, or an embodiment combining software and hardware aspects. Furthermore, this application can take the form of a computer program product embodied on one or more computer-usable storage media (including, but not limited to, disk storage, optical storage, etc.) containing computer-usable program code.

[0082] This application is described with reference to flowchart illustrations and / or block diagrams of methods, apparatus (systems), and computer program products according to embodiments of this application. It will be understood that each block of the flowchart illustrations and / or block diagrams, and combinations of blocks in the flowchart illustrations and / or block diagrams, can be implemented by computer program instructions. These computer program instructions can be provided to a processor of a general-purpose computer, special-purpose computer, embedded processor, or other programmable data processing apparatus to produce a machine, such that the instructions, which execute via the processor of the computer or other programmable data processing apparatus, generate instructions for implementing the flowchart... Figure 1 One or more processes and / or boxes Figure 1 A device that provides the functions specified in one or more boxes.

[0083] These computer program instructions may also be stored in a computer-readable storage medium that can direct a computer or other programmable data processing device to function in a particular manner, such that the instructions stored in the computer-readable storage medium produce an article of manufacture including instruction means, which are implemented in a process Figure 1 One or more processes and / or boxes Figure 1 The function specified in one or more boxes.

[0084] These computer program instructions may also be loaded onto a computer or other programmable data processing equipment to cause a series of operational steps to be performed on the computer or other programmable equipment to produce a computer-implemented process, thereby providing instructions that execute on the computer or other programmable equipment for implementing the process. Figure 1 One or more processes and / or boxes Figure 1 The steps of the function specified in one or more boxes.

[0085] In the above embodiments of this application, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0086] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

[0087] It should be understood that the above description is for illustrative purposes and not for limitation. Many embodiments and applications beyond the examples provided will become apparent to those skilled in the art upon reading the above description.

[0088] The sequence numbers of the embodiments in this application are for descriptive purposes only and do not represent the superiority or inferiority of the embodiments.

[0089] In the above embodiments of this application, the descriptions of each embodiment have different focuses. For parts not described in detail in a certain embodiment, please refer to the relevant descriptions of other embodiments.

[0090] In the several embodiments provided in this application, it should be understood that the disclosed technical content can be implemented in other ways. The device embodiments described above are merely illustrative; for example, the division of units can be a logical functional division, and in actual implementation, there may be other division methods. For instance, multiple units or components may be combined or integrated into another system, or some features may be ignored or not executed. Furthermore, the displayed or discussed mutual coupling, direct coupling, or communication connection may be through some interfaces; the indirect coupling or communication connection between units or modules may be electrical or other forms.

[0091] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0092] The above description is only a preferred embodiment of this application. It should be noted that for those skilled in the art, several improvements and modifications can be made without departing from the principle of this application, and these improvements and modifications should also be considered within the scope of protection of this application.

[0093] It should be understood that the above description is for illustrative purposes and not for limitation. Many embodiments and applications beyond the provided examples will be apparent to those skilled in the art upon reading the above description. Therefore, the scope of this application should not be determined by reference to the above description, but rather by reference to the foregoing claims and the full scope of their equivalents. For purposes of completeness, all articles and references, including patent applications and publications, are incorporated herein by reference. The omission of any aspect of the subject matter disclosed herein in the foregoing claims is not intended as a waiver of that subject matter, nor should it be construed as an indication that the applicant has not considered that subject matter as part of the disclosed inventive subject matter.

Claims

1. A congestion joint reconfiguration self-healing control method for a digital workshop, characterized in that, include: S1, acquire the status data of each workstation on the production line; S2, based on the status data, identify the congested workstations and establish a first initial isolation control zone and a second initial isolation control zone at the congested workstations and their adjacent workstations; S3, extract the workstations located between the first initial isolation control zone and the second initial isolation control zone that have not met the congestion triggering conditions, and generate an intermediate workstation set; S4. Calculate the bidirectional congestion coupling index of each intermediate workstation by using the first-side congestion pressure value generated by the first initial isolation control zone on each intermediate workstation in the intermediate workstation set and the second-side congestion pressure value generated by the second initial isolation control zone on each intermediate workstation. S5, when the bidirectional congestion coupling index meets the joint reconfiguration conditions, the first initial isolation control zone, the second initial isolation control zone and the intermediate workstation set are merged to construct a joint dynamic isolation control zone; S6, calculate the decoupling cost under the degraded operation strategy based on the estimated recovery time of abnormal workstations in the joint dynamic isolation control area; S7, adjusts the production cycle time of each workstation in the joint dynamic isolation control area according to the decoupling cost and generates collaborative adjustment instructions; S8, after the production line operates according to the coordinated adjustment instructions and the abnormality is handled, releases the joint control status of each workstation in the joint dynamic isolation control area.

2. The congestion joint reconfiguration self-healing control method for digital workshops according to claim 1, characterized in that, In S2, after establishing the first and second initial isolation control zones, the boundaries of the first and second initial isolation control zones are flexibly adjusted according to the direction of congestion spread. When the waiting time of multiple upstream workstations exceeds a preset time threshold, at least one upstream adjacent workstation is incorporated into the control range of the first or second initial isolation control zone. When the congested workstations resume normal operation and the continuous stable operation time of the downstream workstations reaches a preset stable time threshold, the boundary workstations are gradually moved out of the control range of the first or second initial isolation control zone.

3. The congestion joint reconfiguration self-healing control method for digital workshops according to claim 1, characterized in that, In S4, the first-side congestion pressure value is calculated by combining the positive deviation of the cache occupancy in the first initial isolation control area with the upper limit of the cache and a monotonically increasing normalization function; the second-side congestion pressure value is calculated by combining the positive deviation of the material discharge waiting time or material shortage duration in the second initial isolation control area with the preset material discharge threshold and a monotonically increasing normalization function.

4. The congestion joint reconfiguration self-healing control method for digital workshops according to claim 1, characterized in that, In S5, when the bidirectional congestion coupling index of any intermediate workstation is greater than or equal to the joint reconstruction threshold in multiple consecutive sampling periods and the first-order time change rate of the bidirectional congestion coupling index is greater than the preset growth threshold, the joint reconstruction condition is determined to be met; during the construction of the joint dynamic isolation control zone, a unified joint control zone identifier is assigned to the joint dynamic isolation control zone.

5. The congestion joint reconfiguration self-healing control method for digital workshops according to claim 1, characterized in that, In S6, the total intermediate buffer capacity and bottleneck buffer capacity are calculated based on the buffer limit and current buffer occupancy of each intermediate station in the intermediate station set. The material flow fluctuation demand is obtained based on the estimated recovery time of abnormal handling, the current production cycle time, and the buffer change rate. When the material flow fluctuation demand exceeds the absorption capacity of the total intermediate buffer capacity or the bottleneck buffer capacity, the bottleneck buffer capacity shortage is obtained according to the difference between the material flow fluctuation demand to be absorbed and the bottleneck buffer capacity. The decoupling cost is obtained by weighting the bottleneck buffer capacity shortage, the estimated recovery time of abnormal handling, the cumulative cycle time deviation in the joint dynamic isolation control area, and the speed adjustment amplitude.

6. The congestion joint reconfiguration self-healing control method for digital workshops according to claim 5, characterized in that, Before calculating the decoupling cost, the bottleneck buffer capacity shortage, the estimated recovery time for abnormal handling, and the cumulative cycle time deviation are normalized to the same numerical range. When the decoupling cost increases, the deceleration rate of the upstream station in the joint dynamic isolation control zone is increased and the target value of the cycle time fluctuation rate of each intermediate station in the intermediate station set is reduced. When the decoupling cost decreases, the deceleration rate is gradually reduced and each station in the joint dynamic isolation control zone is adjusted according to the normal production cycle time.

7. The congestion joint reconfiguration self-healing control method for digital workshops according to claim 1, characterized in that, In S8, the degradation condition is that the maximum value of the bidirectional congestion coupling index of each intermediate workstation in the intermediate workstation set is less than or equal to the degradation threshold in multiple consecutive sampling periods, and the cache occupancy of each workstation in the joint dynamic isolation control area falls back to the preset stable cache range. The mapping relationship between some workstations and the joint control task queue within the joint dynamic isolation control zone is gradually removed in a preset order; the workstations are moved out of the joint control task queue and identified as released workstations; the operating load of each released workstation is adjusted to the normal operating load according to the gradually increasing frequency setpoint or speed setpoint; and the joint control zone identifier is removed after all released workstations have completed the operating load adjustment.

8. A congestion joint reconfiguration self-healing control system for a digital workshop, characterized in that, include: The data acquisition module is used to acquire status data of each workstation on the production line; The isolation zone establishment module is used to identify congested workstations based on status data and establish a first initial isolation control zone and a second initial isolation control zone at the congested workstation and its adjacent workstations. The set partitioning module is used to extract workstations located between the first initial isolation control zone and the second initial isolation control zone that have not met the congestion triggering conditions, and generate an intermediate workstation set; The index calculation module is used to calculate the bidirectional congestion coupling index of each intermediate workstation by using the first side congestion pressure value generated by the first initial isolation control zone on each intermediate workstation in the intermediate workstation set and the second side congestion pressure value generated by the second initial isolation control zone on each intermediate workstation. The control area reconstruction module is used to merge the first initial isolation control area, the second initial isolation control area, and the intermediate workstation set to construct a joint dynamic isolation control area when the bidirectional congestion coupling index meets the joint reconstruction conditions. The cost calculation module is used to calculate the decoupling cost under the degraded operation strategy based on the estimated recovery time of abnormal workstations within the joint dynamic isolation control area. The cycle time correction module is used to correct the production cycle time of each workstation in the joint dynamic isolation control area according to the decoupling cost and generate coordinated adjustment instructions. The status release module is used to release the joint control status of each workstation in the joint dynamic isolation control area after the production line is running according to the coordinated adjustment instructions and the abnormality is handled.

9. A computer device comprising a memory, a processor, and a computer program stored in the memory and executable on the processor, characterized in that, When the processor executes the computer program, it implements the steps of the congestion joint reconfiguration self-healing control method for digital workshops as described in any one of claims 1 to 7.

10. A computer-readable storage medium storing a computer program, characterized in that, When the computer program is executed by the processor, it implements the steps of the congestion joint reconfiguration self-healing control method for digital workshops as described in any one of claims 1 to 7.

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