A curtain rod production process scheduling method and system based on intelligent manufacturing

Abstract

The application discloses a kind of window curtain rod production process scheduling method and system based on intelligent manufacturing, obtains production order and establishes rod body processing task, supporting part task and process sequence relationship;Radial offset data is obtained after the completion of hole site processing or end processing process of rod body to form deformation propagation state, and combined with the clamping, stress and support conditions of candidate processing equipment to form deformation admission task set;According to the historical production and residual information of surface treatment equipment, the device historical residual state is constructed, and the directed residual migration relationship is established, and the application relates to the technical field of intelligent manufacturing production scheduling.The method, according to the historical production and residual state of surface treatment equipment, determines the residual pollution proportion corresponding to different task execution directions respectively, and represents the influence of task switching with directed relationship, so that the task sorting can reflect the actual residual migration difference formed by the previous task to the subsequent task.

Description

Technical Field

[0001] This invention relates to the field of intelligent manufacturing production scheduling, and more specifically, to a method and system for scheduling the production process of curtain rods based on intelligent manufacturing. Background Technology

[0002] As curtain rod products evolve towards parallel production of multiple specifications, small batches, and multiple colors, the task coupling between cutting, hole processing, end processing, straightening, surface treatment, and packaging becomes more intense. Traditional production scheduling methods based on delivery dates, equipment idle time, or equipment load are insufficient to reflect the actual processing status of the rods. CN115222243A discloses an adaptive rescheduling method and system for automated door and window production lines, which reschedules based on production time, production cost, and equipment load, but does not address the deformation propagation state of long rods after continuous clamping and stress. CN114723105B discloses a production scheduling method for automotive parts color spraying, which optimizes the color spraying sequence through color spraying equipment and color data, but does not differentiate residual contamination in different task switching directions based on the historical residual state of the equipment, nor does it utilize actual production tasks to change the subsequent residual state. Therefore, existing technologies still struggle to simultaneously coordinate rod deformation access, surface treatment residue migration, and effective order fulfillment. It is necessary to directly incorporate the actual physical state of the rods and equipment into the task access and dynamic scheduling process. Summary of the Invention

[0003] The purpose of this invention is to provide a method and system for scheduling the production process of curtain rods based on intelligent manufacturing. It solves the problems of existing scheduling methods not taking the propagation of rod deformation and the migration of surface treatment equipment residues as task admission conditions, and making it difficult to implement local rescheduling in conjunction with the effective completeness of orders.

[0004] This invention achieves the above objective through the following technical solution: a curtain rod production process scheduling method based on intelligent manufacturing, the method comprising: Obtain the specifications of the curtain rod production order, including rod body specifications, material type, hole type, surface treatment type, color, and accessory requirements; establish the rod body processing tasks, accessory tasks, and the sequence of processes. After the hole machining or end machining process is completed on the rod body, the deformation propagation state is formed based on the radial offset data of the axial detection position. Combined with the clamping position, clamping direction, machining force direction and support position of the candidate processing equipment, the radial offset after the candidate task is executed is predicted, and a set of deformation admission tasks that meet the radial offset limit specified in the product technical documents is formed. Based on the previous production and residual information of the surface treatment equipment, the historical residual status of the equipment is constructed, the residual pollution ratio when adjacent tasks are switched in different directions is predicted, and a directional residual migration relationship is established. When the residual contamination ratio of the target task exceeds the contamination tolerance threshold, an actual production task that can make the target task meet the threshold after execution is determined from the deformation access task set and used as a residual release task. If there is no residual release task, a device cleaning task is inserted. A production sequence is generated based on the directed residual migration relationship, and the task priority is adjusted according to the effective completeness status of the order. When the production status changes and affects the execution conditions of subsequent tasks, only unexecuted tasks that are related to the changed status are partially rescheduled.

[0005] Furthermore, the establishment of the rod body machining task and the supporting component task includes: Create cutting tasks based on rod specifications and material type, create hole processing tasks based on hole type, create end processing tasks based on end structure, create surface processing tasks based on surface treatment type and color, and set straightening tasks as conditional tasks after end processing tasks and before surface processing tasks. Establish task identifiers for rods, ends, brackets, and connectors within the same order. Connect rod tasks according to the process constraints of cutting, hole machining, end machining, conditional straightening, surface treatment, and packaging. Establish set associations between accessory tasks and corresponding packaging tasks.

[0006] Furthermore, the formation of the deformation propagation state includes: The radial offset and offset direction of each detection position relative to the reference axis are obtained along the axial direction of the rod. The maximum bending position is determined based on the maximum radial offset, and the main bending direction is determined based on the offset direction of the maximum bending position and its adjacent detection positions. The radial offset data after the current process is subtracted from the corresponding data after the previous process to obtain the deformation increment vector at each detection position. The deformation propagation state is characterized by the maximum bending position, the main bending direction, and the deformation increment vector.

[0007] Furthermore, the formation of the deformation admission task set includes: For candidate processing equipment for the rod to be processed, the clamping position, clamping direction, processing force direction and support position are obtained. The processing force direction is established with the main bending direction and deformation increment vector to predict the radial offset of each detection position after the candidate process. Candidate tasks whose predicted radial offset does not exceed the radial offset limit specified in the product technical document are added to the deformation admission task set; for candidate tasks whose predicted radial offset exceeds the limit, the processing equipment, clamping direction or processing time slot is changed, or a straightening task is inserted, and the task is added to the deformation admission task set after the predicted radial offset meets the limit again.

[0008] Furthermore, the historical residual state of the equipment is constructed according to the chronological order of the tasks performed by the surface treatment equipment, including: Record the coating type, processing volume, number of consecutive processing cycles, and cleaning results for each completed task, and obtain the residual amount in the spray gun, feed line, and hanger; The residual amount is associated with the corresponding task identifier and the most recent cleaning result to form the equipment's historical residual status; after each surface treatment task is completed, the equipment's historical residual status is updated with the residual amount generated by that task; after each equipment cleaning is completed, the residual amount before cleaning is replaced with the measured residual amount after cleaning.

[0009] Furthermore, the establishment of the directed residual migration relationship includes: Given the current historical residual state of the device, predict the first residual contamination ratio of the first candidate task and its first new residual state after execution. Based on the first new residual state, predict the second residual contamination ratio of the second candidate task and form a first migration edge from the first candidate task to the second candidate task. Given that the second candidate task is executed first, predict the second new residual state after the second candidate task is executed, and predict the proportion of third residual contamination of the first candidate task based on the second new residual state, thus forming a second migration edge from the second candidate task to the first candidate task. The residual contamination ratios corresponding to the first migration edge and the second migration edge are stored separately. The contamination tolerance threshold is determined through task conversion verification. The target product meets the upper limit of color difference or upper limit of coating impurity content specified in the product process document as the qualification condition. The maximum residual contamination ratio corresponding to the qualification is determined as the contamination tolerance threshold.

[0010] Furthermore, the determination of the residual release task includes: When the residual pollution ratio of the target task exceeds the pollution tolerance threshold, candidate production tasks with a residual pollution ratio not exceeding their own pollution tolerance threshold are selected from the deformation access task set. Predict the new residual state after each candidate production task is executed and the residual contamination ratio of the target task in that state. The candidate production task that can make the target task meet its contamination tolerance threshold is identified as the residual release task and placed before the target task. If there are no candidate production tasks that meet the aforementioned conditions, set up an equipment cleaning task before the target task, and update the historical residual status of the equipment based on the measured residual amount after cleaning.

[0011] Furthermore, the adjustment of the order's valid completeness status and task priority includes: A rod that has been processed and whose radial offset does not exceed the radial offset limit specified in the product technical document and whose residual contamination ratio does not exceed the contamination allowable threshold is counted as a valid main rod. The required number of valid main rods, as well as the required and completed quantities of ends, brackets and connectors for the same order, are obtained. When a candidate task is completed and the number of effective main rods, end caps, supports, and connectors simultaneously reaches the corresponding required number, the candidate task is marked as a kitting transition task. Without changing the sequence of processes and meeting the deformation access conditions and contamination tolerance thresholds, the assembly transition task is moved to the first position in the current executable task range.

[0012] Furthermore, the local rescheduling includes: The rod body task, processing equipment, surface treatment equipment, and production order are constructed into a process relationship diagram; when the measured radial offset data, the historical residual status of the equipment, the operating status of the equipment, or the effective completeness status of the order changes, the changed object is used as the status node; Along the process association diagram, identify unexecuted tasks that have subsequent process relationships, equipment occupancy relationships, surface treatment migration relationships, or kitting relationships with the state nodes, and form a set of affected tasks; Keeping the relative execution order of tasks outside the affected task set unchanged, the deformation admission judgment, directed residual migration judgment, and order effective kitting status judgment are re-executed on the affected task set, and the corresponding task segments in the original production sequence are replaced with the re-obtained task order.

[0013] A curtain rod production process scheduling system based on intelligent manufacturing is provided for executing the aforementioned curtain rod production process scheduling method based on intelligent manufacturing. The system includes: The order task construction module is used to establish tasks for processing rods, tasks for supporting parts, and the sequence of processes. The deformation state and admission module is used to form the deformation propagation state based on the radial offset data of the rod, combine the clamping position, clamping direction, processing force direction and support position of the candidate processing equipment to predict the radial offset after the candidate task, and form a set of deformation admission tasks. The residual state and migration module is used to construct the historical residual state of the surface treatment equipment based on the historical production information and measured residual amount, and to form a directed residual migration relationship with an execution direction. The sequence generation module is used to determine the residual release task or equipment cleaning task when the residual contamination ratio of the target task exceeds the contamination tolerance threshold, and to generate a production sequence based on the deformation admission conditions and the directed residual migration relationship. The matching adjustment module is used to identify the number of valid main rods and accessories to complete the matching transition task and adjust the execution priority of the corresponding task. The local rescheduling module is used to determine the set of affected tasks based on changes in production status, and update the execution order of the set of affected tasks while keeping the relative execution order of the remaining tasks unchanged.

[0014] The beneficial effects of this invention are as follows: 1. This invention uses the deformation propagation state of the rod as the admission basis for subsequent processing tasks. By establishing a correspondence between the maximum bending position, the main bending direction and the deformation increment and the clamping, stress and support conditions of the candidate equipment, processing combinations that exceed the limits specified in the product technical documents are excluded before the task enters the subsequent process, thereby suppressing the deformation superposition caused by continuous processing.

[0015] 2. Based on the historical production and measured residual status of the surface treatment equipment, this invention determines the residual contamination ratio corresponding to different task execution directions, and uses a directed relationship to characterize the impact of task switching, so that the task order can reflect the actual residual migration difference formed by the preceding task on the subsequent task.

[0016] 3. When the residual contamination ratio of the target task exceeds the contamination tolerance threshold, this invention prioritizes screening residual release tasks from actual production tasks that have met the deformation access conditions, and uses actual order tasks to change the residual state of the equipment; only when there are no production tasks that meet the conditions is the equipment cleaning task inserted, thereby reducing the non-production occupation caused by direct cleaning.

[0017] 4. The present invention determines the effective kitting status of an order by the number of effective main rods that simultaneously meet the deformation and surface quality requirements, as well as the number of completed ends, brackets and connectors, and identifies kitting transition tasks that can transform an order from an incomplete kitting status to a packageable status, thereby reducing work-in-process tasks that have been processed but cannot yet be kitted.

[0018] 5. When changes occur in rod deformation, equipment residue, equipment operating status, or order fulfillment status, affecting the execution conditions of subsequent tasks, this invention identifies the set of affected tasks based on process correlation, recalculates only the corresponding local task segments, and keeps the relative execution order of other tasks unchanged, thereby reducing the impact of local production disturbances on the existing schedule. Attached Figure Description

[0019] The accompanying drawings, which are included to provide a further understanding of this application and form part of this application, illustrate exemplary embodiments and are used to explain this application, but do not constitute an undue limitation of this application. In the drawings: Figure 1 This is a flowchart illustrating the overall method of the present invention; Figure 2A schematic diagram of the deformation admission, residual release, kitting transition and dynamic closed-loop rescheduling process provided in the embodiments of this application; Figure 3 This is a schematic diagram of the system structure of the present invention. Detailed Implementation

[0020] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be noted that the following embodiments are used to illustrate the technical concept and implementation process of the present invention, and are not intended to limit the scope of protection of the present invention. Adaptive adjustments made by those skilled in the art to the number of detection positions, the configuration of processing equipment, the data acquisition method, and the task execution method without departing from the technical concept of the present invention are all applicable to the present invention. Example

[0021] Please see Figures 1-3 This embodiment provides a curtain rod production process scheduling method based on intelligent manufacturing, which is applicable to production scenarios where multiple curtain rod production orders of different specifications, different surface treatment types and different colors enter the production line at the same time.

[0022] Obtain curtain rod orders to be produced, and establish corresponding processing tasks and process relationships based on the production orders.

[0023] Specifically, obtain the required quantities of rod length, rod cross-section specifications, material type, hole type, end structure, surface treatment type, color, and ends, brackets, and connectors from the production order or the product bill of materials associated with the production order.

[0024] Create cutting tasks based on rod length, rod cross-section specifications, and material type; create hole machining tasks based on the number of holes, hole location, and hole type; create end machining tasks based on the rod end structure; create surface treatment tasks based on surface treatment type and color; and create corresponding accessory tasks based on the end caps, brackets, and connectors requirements in the production order.

[0025] Link the rod body task, end task, bracket task, connector task and packaging task within the same production order through order identification, and establish the process sequence relationship between cutting, hole processing, end processing, condition straightening, surface treatment and packaging according to the actual processing technology.

[0026] The straightening task is a conditional task and is not a fixed process that every rod must perform. When subsequent deformation admission judgments indicate that the rod can directly enter the next processing step, the straightening task remains inactive; the straightening task is activated only when it is predicted that the radial displacement of the rod will exceed the allowable range after entering the candidate processing equipment.

[0027] This embodiment uses a length of 2400. The outer diameter is 28 Taking aluminum alloy curtain rods as an example, each production order includes two main rods, two end pieces, three brackets, and one connector. Both main rods need to be cut, hole-making, end-processing, and surface-treatment completed sequentially, and a straightening process is required depending on the actual deformation during processing.

[0028] The aforementioned length, outer diameter, and required quantity of accessories are all directly read from the production order or product bill of materials, and are not set by the scheduling system based on experience.

[0029] After completing the order process task construction, the deformation state of the rod body after the preset processing steps is detected.

[0030] In this embodiment, radial offset data of the rod body is obtained after the hole machining is completed and after the end machining is completed.

[0031] Place the rod in the preset testing support state, take the product's theoretical center axis or the calibrated testing axis as the reference axis, set multiple testing positions along the rod axis, and measure the radial offset and radial offset direction of each testing position relative to the reference axis.

[0032] For a length of 2400 In this embodiment, the rod body has 7 detection positions along the axial direction, with an axial interval of 400 mm between adjacent detection positions. .

[0033] The number of inspection locations is determined based on the length of the pole and the company's pole straightness inspection procedures. When the pole length varies, the inspection location interval should not exceed 400 mm. As a rule for this embodiment, the number of detection locations is increased or decreased accordingly. Therefore, the 7 detection locations only correspond to the 2400 in this embodiment. The number of poles is not a fixed number applicable to all pole specifications.

[0034] Radial offset data is acquired through a laser displacement sensor, and all radial offset values ​​are uniformly represented using... As a unit of length.

[0035] For example, after the hole machining of a certain rod is completed, the radial offset measured at 7 detection positions is 0.20. 0.34 0.58 0.76 0.62 0.38 and 0.18 The radial offset will then be 0.76. The detection location is determined as the current maximum bending position of the rod.

[0036] The current main bending direction of the rod is further determined based on the radial offset direction of the maximum bending position and its adjacent detection positions before and after it.

[0037] If the position of maximum bending and its adjacent detection positions are mainly along the positive direction of the detection coordinate system If the direction deviates, then it will be positive. The direction is determined as the current main bending direction of the rod.

[0038] Simultaneously, the radial offset data of the same rod body after the previous processing step is read, and the radial offset data of each detection position after the current process is compared with the corresponding radial offset data after the previous process to obtain the deformation increment and deformation increment direction of each detection position between two adjacent processing steps.

[0039] The deformation propagation state of the rod is constituted by the maximum bending position, the main bending direction, and the deformation increment direction corresponding to each detection position.

[0040] To ensure that the deformation state of the rod directly influences the selection of subsequent processing equipment, this embodiment further predicts the radial offset state of the rod after it enters different candidate processing equipment.

[0041] For the After the first processing step is completed, the rod body enters the... When the candidate processing equipment performs the next processing step, the first... The predicted radial offset vector for each detection location is determined according to formula (1): In the formula, Indicates the first After the first processing step is completed, the second The actual radial offset vector of each detection position, in units of ; The rod body adopts the first When a candidate processing equipment and its corresponding clamping method execute the next processing step, in the first... The process deformation increment vector formed by each detection location, in units of ; The rod body adopts the first After the candidate processing equipment completes the next processing step, the first... The predicted radial offset vector at each detection location, in units of .

[0042] Formula (1) uses vector relationships for calculation, retaining both the magnitude and direction of the radial offset during the calculation process. When When the direction is opposite to the current main bending direction, the candidate processing equipment may have a counteracting effect on the existing deformation; when the two directions are the same, the candidate processing equipment may have a superimposed effect on the existing deformation.

[0043] Process deformation increment vector The weights are not determined by artificial settings, but by actual processing data corresponding to the same material, the same bar cross-section specifications, the same candidate processing equipment, and the same clamping method.

[0044] Specifically, before a new specification of rod is put into mass production, no less than 20 test rods of the same material and the same cross-sectional specifications are selected and trial processing is completed under the corresponding candidate processing equipment and clamping method. The radial offset vectors before and after processing at each detection position are recorded respectively, and the difference between the radial offset vector after processing and the radial offset vector before processing is used as the sample deformation increment at the corresponding detection position.

[0045] After removing invalid samples corresponding to equipment alarms, detection failures, or tooling malfunctions, the median value of the deformation increment at the same detection position of the remaining samples is taken as the baseline process deformation increment vector for the candidate processing equipment and clamping method. Using the median value reduces the impact of abnormal processing data on the baseline value. In subsequent batch production, after each production batch is completed, the baseline process deformation increment vector is updated based on the detection data before and after actual processing of the same specification rod.

[0046] In this way, the parameters in formula (1) are derived from the actual processing process, and there is no need to set deformation prediction weights.

[0047] After obtaining the predicted radial offset vectors corresponding to each candidate processing equipment, deformation admission judgment is performed on the rod.

[0048] For the rod to be processed, the clamping position, clamping direction, processing force direction, and support position of each candidate processing equipment are obtained. Based on these equipment parameters, the corresponding equipment is determined. Then, the predicted radial offset after processing at each detection position is calculated using formula (1).

[0049] The predicted radial offset at each detection location is compared with the radial offset limit for the corresponding processing stage. The radial offset limit is taken from the product technical documents; the product technical documents include product drawings, order technical requirements, or enterprise product inspection procedures, and their straightness requirements serve as the basis for judgment at the corresponding processing stage.

[0050] For example, in this embodiment, the length is 2400. For the rod body, before entering the surface treatment process, the product drawings specify that the radial offset of any inspection position relative to the reference axis must not exceed 1.00. Then 1.00 This serves as the radial offset limit for the rod of this specification at this stage of processing.

[0051] If the radial offset of the current maximum bending position of the aforementioned rod is positive Direction 0.76 The deformation increment corresponding to the first candidate processing equipment is positive. Direction 0.35 Therefore, according to formula (1), the predicted radial offset at this position after processing is 1.11. More than 1.00 Therefore, the task corresponding to the first candidate processing equipment does not meet the deformation access requirements.

[0052] If the second candidate processing equipment changes the clamping direction and support position to make the deformation increment of the process corresponding to the detection position negative... Direction 0.28 Therefore, the predicted radial offset after processing is 0.48. Less than 1.00 Therefore, the task corresponding to the second candidate processing equipment meets the deformation admission requirements. In this case, the action corresponding to the first candidate processing equipment is determined to be deformation superposition, and the action corresponding to the second candidate processing equipment is determined to be deformation cancellation.

[0053] Only when the predicted radial offset of all detected positions of the rod does not exceed the corresponding radial offset limit will the candidate machining task be added to the deformation admission task set.

[0054] When the predicted radial offset of a candidate machining task exceeds the radial offset limit at the detection position, the task is re-evaluated by successively changing the candidate machining equipment, changing the clamping direction of the rod, or adjusting the machining time slot. If the rod still cannot meet the deformation access requirements after the above adjustments, the aforementioned conditional straightening task is activated, and a straightening task is inserted between the current machining process and the surface treatment process.

[0055] After straightening is completed, the radial offset data of the rod is re-acquired, and the deformation admission judgment is re-executed using the updated actual radial offset vector.

[0056] After forming a set of deformation-accessible tasks that satisfy deformation constraints, the residual state of the equipment is analyzed for the tasks entering the surface treatment process.

[0057] Acquire historical production records of the target surface treatment equipment arranged by execution time, including coating type, color, processing volume, number of consecutive processing times, and cleaning results for each preceding production task, and acquire residual information for spray guns, feeding pipelines, and hangers.

[0058] This embodiment utilizes mass flow data from the feeding system and discharge detection data after the task is completed to determine the effective residual mass of the product coating that can proceed to the next production task. The effective residual mass is uniformly adopted... As a unit of quality.

[0059] For example, after the surface treatment equipment completes a black coating task, the effective residual mass of black coating in the spray gun and feed line that may enter the product surface with the coating of the next task is detected to be 18. Then 18 This serves as the effective residual mass of the current equipment for the next production task.

[0060] The coating type, color, processing volume, number of consecutive processing cycles, cleaning results, and corresponding effective residual mass of previous tasks are associated according to the task execution sequence to form the historical residual state of the surface treatment equipment. After each new surface treatment task is completed, the coating type, color, processing volume, and actual effective residual mass after the task are written into the equipment's historical residual state.

[0061] After the surface treatment equipment completes cleaning, the residual status of the equipment is not directly recorded as zero. Instead, the actual effective residual quality after cleaning is re-tested, and the historical residual status of the equipment is updated based on the actual test results.

[0062] Based on this, a directed residual migration relationship is established for the surface treatment tasks in the deformation access task set.

[0063] For the preceding task Execute the target task after execution. In this case, the residual contamination ratio is used to represent the impact of previous coating residues in the equipment on the target task. The degree of impact and the proportion of residual pollution are determined according to formula (2): In the formula, Indicates the preceding task After execution, proceed to the target task. The predicted residual pollution percentage at that time is a dimensionless percentage. Indicates task Before stabilizing processing begins, the equipment can enter the task phase. Product coating task Effective residual mass, in units of ; Indicates task The target coating mass input into the equipment from the start of material feeding until the surface treatment state is reached, in units of... .

[0064] Since both the numerator and denominator in formula (2) adopt As a unit of mass, the resulting residual pollution ratio is a dimensionless quantity, and there is no issue of directly calculating between different units of measurement. Determined based on equipment residue detection results before task switching; The values ​​are obtained cumulatively from the mass flow meter of the feeding system, without using human estimation.

[0065] For example, after completing the black coating task, the effective residual mass of black is measured. 18 The next white target task is to input the quality of white coatings from the start of material supply to the point of stable processing. For 300 The predicted residual pollution ratio is calculated according to formula (2). .

[0066] The contamination tolerance threshold is determined based on the surface quality requirements of the target product and the task conversion verification test. Specifically, for a given target color, multiple known residual quality levels are set in the equipment to create different residual contamination ratios for the target task. At least three batches of verification products are continuously processed under each contamination ratio condition, and the color difference value or coating impurity content is tested according to the process document of the target product.

[0067] The maximum allowable residual contamination ratio under the condition that three consecutive batches of verified products meet the corresponding quality standards is determined as the contamination tolerance threshold corresponding to the target color.

[0068] For example, the product process document for a white curtain rod specifies a color difference value. It must not exceed 1.5. This was determined through a task conversion verification test, where the residual contamination ratio does not exceed... At that time, three consecutive batches of white rods all met the requirements. Not greater than 1.5; when the residual pollution ratio reaches At that time, there was at least one batch of products. Exceeding 1.5. Therefore, The permissible pollution threshold for this white product was determined.

[0069] Therefore, in this embodiment It is not preset by the production scheduling procedure, but determined jointly by product quality standards and task conversion verification results. For different target colors or different coating types, the corresponding pollution tolerance thresholds are determined according to the same rules.

[0070] Due to the mission The effective residual quality and task formed after execution The effective residual mass formed after execution is usually different, therefore the preceding tasks Transfer to task corresponding With the task Transfer to task corresponding Calculate and store them separately.

[0071] For example, when the equipment completes the black coating task first and then performs the white coating task, the predicted residual contamination ratio from black to white is calculated as follows: After the task order is swapped, the equipment executes the white task first, then the black task. Because the effective residual mass after the white task is completed and the stable feeding mass of the black target task changes, the result can be... Different residual contamination ratios. Therefore, the two task execution directions are established as two directed migration relationships, instead of tasks... With the task The pollution impact between them is considered the same.

[0072] For each target task to be entered into the surface treatment equipment, first determine whether the predicted residual pollution ratio when it directly enters the current equipment exceeds its own pollution tolerance threshold according to formula (2).

[0073] If the predicted residual contamination ratio of the target task does not exceed the corresponding contamination tolerance threshold, it will be retained in the current set of executable tasks.

[0074] When the predicted residual pollution ratio of the target task exceeds the corresponding pollution tolerance threshold, the target task will not be directly scheduled for execution. Instead, residual release tasks will be selected from other actual production tasks that have passed the deformation access judgment.

[0075] The residual release task should meet the following conditions simultaneously: First, the task belongs to the actual production order in the current production plan; Second, the task has passed the aforementioned deformation access judgment; Third, the predicted residual pollution ratio corresponding to the task in the current equipment historical residual state does not exceed its own pollution tolerance threshold, and the new equipment residual state after the task is executed can reduce the predicted residual pollution ratio of the target task to within the pollution tolerance threshold corresponding to the target task.

[0076] For example, there are 18 in the current device. Effective residue of black coating; stable feed quality for white target task is 300. The residual pollution ratio was calculated according to formula (2) as follows: More than the corresponding white products Due to the pollution tolerance threshold, white target tasks are not allowed to be executed directly at this time.

[0077] The current set of deformation-related entry tasks also includes an actual production task for a light gray rod. After corresponding task conversion verification tests, the permissible contamination threshold for the light gray product is [value missing]. Under the current conditions of black residue, the predicted pollution proportion corresponding to the light gray task does not exceed [a certain percentage]. Therefore, the light gray task can be executed under the current device state.

[0078] After completing the light gray task, the actual residual state of the equipment was re-acquired, and the effective residual mass that would contaminate subsequent white products was found to have decreased to 4.5. When the target coating quality corresponding to the stable material supply phase of the white target task remains at 300... At that time, the predicted residual pollution ratio was recalculated according to formula (2). Lower than the white target task corresponding Pollution tolerance threshold.

[0079] Therefore, the light gray actual production task is identified as the residual release task of the white target task, forming an execution relationship of "light gray task - white target task". The residual release task itself belongs to the actual production order that needs to be completed, and is not an idle operation task specifically used for cleaning equipment or changing the state of equipment.

[0080] If there is no actual production task that meets the above three conditions in the current deformation access task set, insert the equipment cleaning task before the target task. After the equipment cleaning is completed, re-inspect the actual effective residual mass in the spray gun, feeding pipeline and hanger, write the measured value after cleaning into the equipment historical residual status, and use formula (2) again to determine whether the target task can enter the equipment.

[0081] The above process forms an initial production sequence that satisfies the rod deformation constraints and surface treatment residual constraints.

[0082] Furthermore, to reduce the situation where the main rod processing has been completed but packaging cannot be completed for a long time due to the lack of supporting parts or remaining main rods, this embodiment prioritizes the currently executable tasks based on the effective completeness status.

[0083] For each production order, the number of main rods that have been completed and simultaneously meet the radial offset and surface quality requirements is counted as the effective main rod quantity. Rods with radial offset exceeding the limits specified in the product drawings and rods with surface treatment contamination indicators exceeding the product quality requirements are not included in the effective main rod quantity.

[0084] Simultaneously read the actual completed quantity of end caps, brackets, and connectors, as well as the order demand quantity, from the same production order.

[0085] In this embodiment, the minimum value among the completion ratios of various components is used to represent the effective completeness status of the corresponding order, which is determined according to formula (3): In the formula, Indicates production order The effective homogeneity coefficient is a dimensionless quantity. Indicates order The number of effective main rods that have been completed and simultaneously meet the requirements for deformation quality and surface quality; Indicates the total number of main shafts required in the order; and These represent the number of completed endpoints and the number of endpoints required by the order, respectively. and These represent the number of stents completed and the number of stents requested by order, respectively. and These represent the number of connectors already completed and the number of connectors required by the order, respectively.

[0086] Each ratio is a ratio of quantity to quantity, therefore the parameters in formula (3) do not have dimensional differences. It is a dimensionless quantity. Formula (3) uses the minimum value to judge, instead of the weighted summation of the completion rates of multiple components.

[0087] If any one of the main rod, end cap, bracket, or connector has not yet reached the required quantity, the corresponding completion rate will be less than 1, thus resulting in... <1; Only when all components meet the order requirements is there a =1. Therefore, =1 is used as the criterion for determining whether an order has reached a packageable state. This criterion is derived from the material requirements of the production order itself and is not an artificially set experience threshold.

[0088] For example, a production order requires two main rods, two end caps, three brackets, and one connector. =2、 =2、 =3、 =1. Currently, one effective main rod, two end pieces, three supports, and one connector have been completed. Therefore, the effective kitting coefficient for the current order is determined according to formula (3). The value is 0.5, indicating that the production order has not yet reached the packaging stage.

[0089] If there is currently a surface treatment task for the second main bar of this order, and this task has simultaneously met the deformation admission condition and the contamination tolerance threshold, then it is predicted that after the task is completed, the number of effective main bars will increase from 1 to 2, and the effective matching coefficient of the order will increase. The value changes from 0.5 to 1. Candidate tasks that can change the effective kitting coefficient from less than 1 to 1 are identified as kitting transition tasks. Without altering the original process sequence, exceeding the rod deformation threshold, or violating the surface treatment contamination tolerance threshold, the kitting transition task is moved to the first position in the currently executable task range. Therefore, the order kitting status is only used for adjusting the order between candidate tasks that already meet product quality constraints; it will not allow rods with unqualified deformation or surface quality to enter subsequent processes in pursuit of order kitting.

[0090] After completing the above scheduling, the curtain rod production task is executed according to the determined production sequence, and the status is updated after each production task is completed.

[0091] Specifically, after the rod body processing task is completed, the actual radial offset data and deformation propagation status of the corresponding rod body are updated; after the surface treatment task is completed, the historical residual status of the corresponding equipment is updated; after the end, bracket, connector or effective main rod is completed, the effective completeness status of the corresponding order is updated; when the processing equipment stops, resumes or changes in processing capacity, the operating status of the corresponding equipment is updated.

[0092] Further establish a process association diagram including pole task nodes, processing equipment nodes, surface treatment equipment nodes, and production order nodes. Establish process sequence associations between adjacent pole processing tasks, establish equipment occupancy associations between production tasks and their available processing equipment, establish directed residue migration associations between surface treatment tasks, and establish kitting associations between pole tasks and component tasks and their corresponding production orders.

[0093] When the measured radial offset data, the historical residual status of the equipment, the operating status of the equipment, or the valid completeness status of the order changes, and the change may affect the execution conditions of subsequent tasks, the changed pole, equipment, or order will be identified as a status node.

[0094] Starting from a state node, retrieve unexecuted tasks along the process association graph that are associated with subsequent processes, equipment occupancy, residual migration, or kitting, and form an affected task set. For production tasks outside the affected task set, do not change their original relative execution order; only re-execute deformation admission judgment, directed residual migration judgment, and order valid kitting judgment for the affected task set.

[0095] For example, the original production sequence includes tasks in sequence. ,Task ,Task ,Task ,Task and tasks When the actual residual state of a surface treatment device changes only affect the task... ,Task and tasks At that time, the task ,Task and tasks The set of tasks has been identified as affected. Keep the tasks running. and tasks Between and tasks The original scheduling relationships outside the affected sections remain unchanged; only the tasks are reassessed. ,Task and tasks The deformation access state, residual migration relationship and homogeneous transition results.

[0096] If the task is determined after recalculation Prioritize the task Execution, task If it remains after both, then the original local task segment "task" will be... -Task -Task "Updated to "Task" -Task -Task This allows for the generation of an updated production sequence. Consequently, when the actual state of a single rod, a single processing machine, or a single production order changes, it is not necessary to rearrange all production tasks, thereby reducing the disturbance of local state changes to the overall production sequence.

[0097] Example 2: This embodiment further illustrates the synergistic relationship between deformation access, directed residual migration, residual release, and effective kitting transition in the context of continuous multi-order production.

[0098] The current production plan includes three production orders, denoted as orders. ,Order and orders .Order For white curtain rods, orders Matching light gray curtain rod, order For the black curtain rods, the rods in all three production orders have been cut, hole-making, and end-processing completed, and are awaiting further processing.

[0099] Obtain the radial offset data of each order's rod. (Order) The maximum radial offset of the middle white rod is 0.76. The product drawings specify that the maximum permissible radial offset before entering the surface treatment process is 1.00. .

[0100] Based on historical trial processing data of the candidate processing equipment, the rod body forms a positive shape at the position of maximum bending after entering the first candidate processing equipment. Direction 0.35 The process deformation increment. According to formula (1), the predicted radial offset after processing is 1.11. Therefore, this candidate processing task does not meet the deformation admission requirements.

[0101] When the rod enters the second candidate processing equipment and is clamped in reverse, a negative signal is generated at the same detection position. Direction 0.28 Based on the process deformation increment, the predicted radial offset after processing is calculated to be 0.48. Therefore, the task corresponding to the second candidate processing equipment meets the deformation access requirements.

[0102] Order and orders The maximum predicted radial offset of the corresponding rod after entering its respective candidate device is 0.67. and 0.71 None of them exceeded 1.00 Therefore, orders The second candidate equipment corresponds to the task and order. Corresponding tasks and orders The corresponding tasks will enter the deformation access task set together.

[0103] The current historical residual status of the surface treatment equipment was then read. Since the previous production task on the surface treatment equipment was a black coating task, the currently detected effective residual mass of the black coating is 18. .

[0104] If order The corresponding white rod directly enters the current surface treatment equipment, and the mass of white target coating required from the start of feeding to entering a stable spraying state is 300. The predicted residual pollution ratio is calculated according to formula (2). .Order The permissible pollution threshold for white products was determined based on the aforementioned conversion verification test. ,therefore Exceed ,Order The white rods cannot be directly inserted into the surface treatment equipment for the time being.

[0105] Continue to assess orders Corresponding to the light gray task. The contamination tolerance threshold for light gray products is determined according to the same conversion verification rules. The predicted pollution proportion of the light gray product caused by the current residual state of the equipment does not exceed [percentage missing]. Therefore, orders The corresponding light gray task can be executed normally.

[0106] Order After the light gray task was completed, the surface treatment equipment was re-tested, and the effective residual mass affecting the subsequent white product was found to be 4.5. Order again Taking the white task as the target task, its predicted residual pollution ratio is calculated according to formula (2). lower than The pollution tolerance threshold. Therefore, orders The corresponding light gray task meets the residual release task conditions, so it will be assigned to the order. This corresponds to the white mission.

[0107] Read more orders Current status of fulfilled orders. The requirements are two main rods, two end caps, three supports, and one connector. Currently, one main rod, two end caps, three supports, and one connector have been completed. Only the second main rod has not yet undergone surface treatment. According to formula (3), the order... Current effective homogeneity coefficient It is 0.5.

[0108] Once the second white main rod has undergone surface treatment and meets quality requirements, the order... The number of effective main rods has increased from 1 to 2, and the quantity of other supporting components has met the order requirements, therefore the order... Effective homogeneity coefficient The value changed from 0.5 to 1. Therefore, the order... The second white main rod corresponds to the mission of the Qi Sui Leap.

[0109] In the current task that satisfies deformation and residual constraints, an "order" is formed. Light gray task - order White Mission - Orders The partial production sequence of the "black task". Among them, orders The light gray task is first executed as an actual order production task, while simultaneously changing the residual state of the surface treatment equipment, thus affecting the order. The white-label task meets the pollution tolerance threshold; then the order is executed. White task, making orders The state changes from incomplete to packageable.

[0110] Therefore, this embodiment does not combine rod deformation, equipment residue, and order fit-up into a single comprehensive score through multiple weight combinations. Instead, it determines the task order according to the sequential constraints of deformation access, residue access, and effective fit-up adjustment, so that product quality constraints take precedence over production fit-up ranking. Example

[0111] This embodiment provides a curtain rod production process scheduling system based on intelligent manufacturing, used to implement the curtain rod production process scheduling method of Embodiment 1 or Embodiment 2 above.

[0112] The system includes an order task construction module, a deformation state and admission module, a residual state and migration module, a sequence generation module, a kitting adjustment module, and a local rescheduling module.

[0113] The order task construction module is used to obtain information from curtain rod production orders, including rod length, cross-sectional specifications, material type, hole type, surface treatment type, color, and requirements for ends, brackets, and connectors. Based on this information, it establishes rod processing tasks, accessory tasks, and the corresponding sequence of processes. For straightening processes that require consideration of actual rod deformation, the order task construction module creates conditional straightening tasks and determines whether to activate them based on the deformation status and the judgment results output by the admission module.

[0114] The deformation state and admission module is connected to the rod radial offset detection device to obtain the radial offset vector of each axial detection position and determine the maximum bending position, the main bending direction, and the deformation increment direction between adjacent processes. The deformation state and admission module further reads the clamping position, clamping direction, processing force direction, and support position of the candidate processing equipment, and predicts the radial offset state of each detection position after the rod adopts different candidate processing equipment and clamping methods according to formula (1).

[0115] Using the radial offset limit specified in the product drawings or product inspection procedures as the basis for deformation access judgment, tasks that meet the corresponding radial offset limit are formed into a deformation access task set.

[0116] The residual status and migration module is connected to the data acquisition terminal of the surface treatment equipment to obtain the coating type, color, processing amount, number of consecutive processing times, cleaning results, and effective residual mass in the spray gun, feeding pipeline, and hanger for the preceding production tasks of the equipment. Based on the acquired information, a dynamically updated historical residual status of the equipment is formed, and the predicted residual contamination ratio corresponding to different task execution directions is determined using formula (2).

[0117] For each target product, the corresponding pollution tolerance threshold is determined based on the product quality document and the pre-completed task conversion verification test. The predicted residual pollution ratio under different task directions is compared with the pollution tolerance threshold to form a directed residual migration relationship.

[0118] The sequence generation module receives the set of deformation admission tasks and the directed residual migration relationship. When the predicted residual contamination ratio corresponding to the target task directly entering the equipment exceeds the contamination tolerance threshold, the sequence generation module selects tasks from the actual tasks to be produced that can meet its own contamination constraints and, after execution, can make the target task meet the contamination tolerance threshold again, and identifies the task as the residual release task.

[0119] When there is no actual production task that meets the conditions, the sequence generation module generates a equipment cleaning task and re-evaluates the admission status of the target task after the equipment cleaning is completed and the actual residual amount is updated.

[0120] The kitting adjustment module is used to obtain the actual completed quantity and order requirement quantity of valid main rods, end pieces, brackets and connectors in each production order, and to determine the valid kitting coefficient of the order according to formula (3). When a candidate task is executed, it can increase the effective kitting coefficient of the corresponding order. When the value changes from less than 1 to 1, the candidate task is identified as a set transition task, and its execution order is adjusted within the range of currently executable tasks that meet the deformation admission conditions, residual migration conditions, and process sequence relationships.

[0121] The local rescheduling module is used to maintain the process association diagram between pole tasks, processing equipment, surface treatment equipment, and production orders. When the actual radial offset state of the pole, the historical residual state of the equipment, the operating state of the equipment, or the effective completeness state of the order changes, the changed object is used as a state node. Based on the process association diagram, the unexecuted tasks that have subsequent process associations, equipment occupancy associations, residual migration associations, or completeness associations with that state node are determined, forming a set of affected tasks.

[0122] The local rescheduling module keeps the relative execution order of tasks outside the affected task set unchanged, and only re-performs deformation admission judgment, residual migration judgment and effective matching judgment for the affected task set. It then uses the new local task order to replace the corresponding task segments in the original production sequence, thereby realizing dynamic closed-loop scheduling of the curtain rod production process.

[0123] The above embodiments provide a detailed description of the present invention. Specific examples have been used to illustrate the principles and implementation methods of the present invention. The descriptions of the above embodiments are only for the purpose of helping to understand the method and core ideas of the present invention. At the same time, for those skilled in the art, there will be changes in the specific implementation methods and application scope based on the ideas of the present invention. Therefore, the content of this specification should not be construed as a limitation of the present invention.

Claims

1. A curtain rod production process scheduling method based on intelligent manufacturing, characterized in that, The method includes: Obtain the specifications of the curtain rod production order, including rod body specifications, material type, hole type, surface treatment type, color, and accessory requirements; establish the rod body processing tasks, accessory tasks, and the sequence of processes. After the hole machining or end machining process is completed on the rod body, the deformation propagation state is formed based on the radial offset data of the axial detection position. Combined with the clamping position, clamping direction, machining force direction and support position of the candidate processing equipment, the radial offset after the candidate task is executed is predicted, and a set of deformation admission tasks that meet the radial offset limit specified in the product technical documents is formed. Based on the previous production and residual information of the surface treatment equipment, the historical residual status of the equipment is constructed, the residual pollution ratio when adjacent tasks are switched in different directions is predicted, and a directional residual migration relationship is established. When the residual contamination ratio of the target task exceeds the contamination tolerance threshold, an actual production task that can make the target task meet the threshold after execution is determined from the deformation access task set and used as a residual release task. If there is no residual release task, a device cleaning task is inserted. A production sequence is generated based on the directed residual migration relationship, and the task priority is adjusted according to the effective completeness status of the order. When the production status changes and affects the execution conditions of subsequent tasks, only unexecuted tasks that are related to the changed status are partially rescheduled.

2. The curtain rod production process scheduling method based on intelligent manufacturing according to claim 1, characterized in that, The establishment of the rod body machining task and the supporting component task includes: Create cutting tasks based on rod specifications and material type, create hole processing tasks based on hole type, create end processing tasks based on end structure, create surface processing tasks based on surface treatment type and color, and set straightening tasks as conditional tasks after end processing tasks and before surface processing tasks. Establish task identifiers for rods, ends, brackets, and connectors within the same order. Connect rod tasks according to the process constraints of cutting, hole machining, end machining, conditional straightening, surface treatment, and packaging. Establish set associations between accessory tasks and corresponding packaging tasks.

3. The curtain rod production process scheduling method based on intelligent manufacturing according to claim 2, characterized in that, The formation of the deformation propagation state includes: The radial offset and offset direction of each detection position relative to the reference axis are obtained along the axial direction of the rod. The maximum bending position is determined based on the maximum radial offset, and the main bending direction is determined based on the offset direction of the maximum bending position and its adjacent detection positions. The radial offset data after the current process is subtracted from the corresponding data after the previous process to obtain the deformation increment vector at each detection position. The deformation propagation state is characterized by the maximum bending position, the main bending direction, and the deformation increment vector.

4. The curtain rod production process scheduling method based on intelligent manufacturing according to claim 3, characterized in that, The formation of the deformation access task set includes: For candidate processing equipment for the rod to be processed, the clamping position, clamping direction, processing force direction and support position are obtained. The processing force direction is established with the main bending direction and deformation increment vector to predict the radial offset of each detection position after the candidate process. Candidate tasks whose predicted radial offset does not exceed the radial offset limit specified in the product technical document are added to the deformation admission task set; for candidate tasks whose predicted radial offset exceeds the limit, the processing equipment, clamping direction or processing time slot is changed, or a straightening task is inserted, and the task is added to the deformation admission task set after the predicted radial offset meets the limit again.

5. The curtain rod production process scheduling method based on intelligent manufacturing according to claim 4, characterized in that, The historical residual status of the equipment is constructed according to the time sequence of tasks performed by the surface treatment equipment, including: Record the coating type, processing volume, number of consecutive processing cycles, and cleaning results for each completed task, and obtain the residual amount in the spray gun, feed line, and hanger; The residual amount is associated with the corresponding task identifier and the most recent cleaning result to form the equipment's historical residual status; after each surface treatment task is completed, the equipment's historical residual status is updated with the residual amount generated by that task; after each equipment cleaning is completed, the residual amount before cleaning is replaced with the measured residual amount after cleaning.

6. The curtain rod production process scheduling method based on intelligent manufacturing according to claim 5, characterized in that, The establishment of the directed residual migration relationship includes: Given the current historical residual state of the device, predict the first residual contamination ratio of the first candidate task and its first new residual state after execution. Based on the first new residual state, predict the second residual contamination ratio of the second candidate task and form a first migration edge from the first candidate task to the second candidate task. Given that the second candidate task is executed first, predict the second new residual state after the second candidate task is executed, and predict the proportion of third residual contamination of the first candidate task based on the second new residual state, thus forming a second migration edge from the second candidate task to the first candidate task. The residual contamination ratios corresponding to the first migration edge and the second migration edge are stored separately. The contamination tolerance threshold is determined through task conversion verification. The target product meets the upper limit of color difference or upper limit of coating impurity content specified in the product process document as the qualification condition. The maximum residual contamination ratio corresponding to the qualification is determined as the contamination tolerance threshold.

7. The curtain rod production process scheduling method based on intelligent manufacturing according to claim 4, characterized in that, The determination of the residual release task includes: When the residual pollution ratio of the target task exceeds the pollution tolerance threshold, candidate production tasks with a residual pollution ratio not exceeding their own pollution tolerance threshold are selected from the deformation access task set. Predict the new residual state after each candidate production task is executed and the residual contamination ratio of the target task in that state. The candidate production task that can make the target task meet its contamination tolerance threshold is identified as the residual release task and placed before the target task. If there are no candidate production tasks that meet the aforementioned conditions, set up an equipment cleaning task before the target task, and update the historical residual status of the equipment based on the measured residual amount after cleaning.

8. The curtain rod production process scheduling method based on intelligent manufacturing according to claim 1, characterized in that, The adjustments to the order's completeness status and task priority include: A rod that has been processed and whose radial offset does not exceed the radial offset limit specified in the product technical document and whose residual contamination ratio does not exceed the contamination allowable threshold is counted as a valid main rod. The required number of valid main rods, as well as the required and completed quantities of ends, brackets and connectors for the same order, are obtained. When a candidate task is completed and the number of effective main rods, end caps, supports, and connectors simultaneously reaches the corresponding required number, the candidate task is marked as a kitting transition task. Without changing the sequence of processes and meeting the deformation access conditions and contamination tolerance thresholds, the assembly transition task is moved to the first position in the current executable task range.

9. The curtain rod production process scheduling method based on intelligent manufacturing according to claim 6, characterized in that, The local rescheduling includes: The rod body task, processing equipment, surface treatment equipment, and production order are constructed into a process relationship diagram; when the measured radial offset data, the historical residual status of the equipment, the operating status of the equipment, or the effective completeness status of the order changes, the changed object is used as the status node; Along the process association diagram, identify unexecuted tasks that have subsequent process relationships, equipment occupancy relationships, surface treatment migration relationships, or kitting relationships with the state nodes, and form a set of affected tasks; Keeping the relative execution order of tasks outside the affected task set unchanged, the deformation admission judgment, directed residual migration judgment, and order effective kitting status judgment are re-executed on the affected task set, and the corresponding task segments in the original production sequence are replaced with the re-obtained task order.

10. A curtain rod production process scheduling system based on intelligent manufacturing, characterized in that, The system is used to execute the curtain rod production process scheduling method based on intelligent manufacturing as described in any one of claims 1 to 9, the system comprising: The order task construction module is used to establish tasks for processing rods, tasks for supporting parts, and the sequence of processes. The deformation state and admission module is used to form the deformation propagation state based on the radial offset data of the rod, combine the clamping position, clamping direction, processing force direction and support position of the candidate processing equipment to predict the radial offset after the candidate task, and form a set of deformation admission tasks. The residual state and migration module is used to construct the historical residual state of the surface treatment equipment based on the historical production information and measured residual amount, and to form a directed residual migration relationship with an execution direction. The sequence generation module is used to determine the residual release task or equipment cleaning task when the residual contamination ratio of the target task exceeds the contamination tolerance threshold, and to generate a production sequence based on the deformation admission conditions and the directed residual migration relationship. The matching adjustment module is used to identify the number of valid main rods and accessories to complete the matching transition task and adjust the execution priority of the corresponding task. The local rescheduling module is used to determine the set of affected tasks based on changes in production status, and update the execution order of the set of affected tasks while keeping the relative execution order of the remaining tasks unchanged.

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