Unmanned intelligent press working system and press working method

Abstract

An unmanned intelligent stamping method and system includes acquiring element data for stamping production, generating a stamping production plan based on the acquired element data, modifying the production plan according to production events during stamping production, and sequentially controlling all processes, including material inventory confirmation, material receiving control, material transport control, mold transport control, end effector transport and installation control, quality inspection control, packing control, basket transport control, and part production control, based on the modified stamping production plan. This realizes unmanned operation of all stamping production processes, reduces labor costs, ensures part consistency in stamping production, and realizes automatic generation and adaptive modification of stamping production plans.

Description

[Technical Field]

[0001] (CROSS-REFERENCE TO RELATED APPLICATIONS) This invention claims priority to a Chinese patent application bearing application number 202310636022.6 and entitled "Unmanned intelligent stamping system and stamping method" filed with the State Intellectual Property Office of the People's Republic of China on June 1, 2023, the entire contents of which are incorporated herein by reference and constitute a part of the present invention for all purposes.

[0002] The present invention relates to the technical field of intelligent control of press working, and in particular to an unmanned intelligent press working system and press working method. [Background technology]

[0003] The description herein merely provides background information related to the present invention and does not necessarily constitute prior art.

[0004] Traditionally, stamping workshops in automobile factories have one to three or even more stamping production lines. Currently, only material loading and unloading, cleaning, oil application, centering, and stamping are automated within automobile production manufacturing plants. Most other operations on stamping lines are still performed manually, such as manual material loading, manual die changing, manual end effector and tooling preparation, manual quality inspection, manual packing, and manual forklift transportation and storage, which results in problems such as low production efficiency, high labor costs, and safety risks.

[0005] For example, during traditional press processing production, manual tasks are performed by a large number of workers, such as one production planning worker per production line per shift, one forklift worker for loading raw materials per two production lines per shift, two workers for lifting and replacing dies per production line per shift, one worker for preparing and replacing end effectors and tooling per production line per shift, one production operation worker per production line per shift, four to eight quality inspection workers per production line per shift, four packing workers per production line per shift, two workers for preparing and replacing baskets per production line per shift, two workers for receiving baskets per production line per shift, and two supervisors and backup workers per production line per shift.

[0006] Therefore, during conventional press production, cooperation from various job types is required, resulting in a large waste of human resources. Furthermore, the cooperation of multiple people with different job types in each work shift cannot ensure consistent quality of parts during press production. Furthermore, production planning during conventional press production requires manual processes, such as manually creating work shifts and manually checking production line data, which makes it impossible to achieve intelligent specification of the production plan or adaptively modify the production plan based on the status of the production line. Summary of the Invention

[0007] To solve the shortcomings of the prior art, the present invention provides an unmanned intelligent stamping system and stamping method, which realizes unmanned operation of the entire stamping production process, reduces labor costs, ensures the consistency of parts in stamping production, realizes automatic generation and adaptive modification of stamping production plans, and further improves the intelligence level of stamping production.

[0008] To achieve the above objectives, the present invention adopts the following technical solutions:

[0009] In a first aspect of the present invention, Acquire element data for press working production, generate a press working production plan based on the acquired element data, and modify the production plan in response to production events during press working production. Based on the revised press processing production plan, all processes including material inventory check, material receiving control, material transport control, mold transport control, end effector transport and installation control, quality inspection control, packing control, basket transport control, and parts production control are controlled in sequence. An unmanned intelligent stamping method is provided, which includes:

[0010] As a further limitation of the first aspect of the present invention, the element data of press working production includes order demand data, production process data, resource constraint data, process constraint data, calendar data, and rule data.

[0011] As a further limitation of the first aspect of the present invention, the order demand data includes sales order data, sales forecast data, planned order data, and production order data; The production process data includes process route data, lead time data, processing time data, and production efficiency data, The resource constraint data includes machine quantity and status data, mold quantity and status data, worker quantity and attendance data, and material inventory data. The process constraint data includes inter-process product batch movement amounts, process interval time data, and yield rate data; The calendar data includes a machine operating calendar, work shifts, and working hours; The rule data includes order rules, equipment rules, optimization rules, and integration rules.

[0012] As a further limitation of the first aspect of the present invention, the production plan includes an order due date forecast, a daily delivery plan, a daily production plan, a production plan based on work shifts, a machine production line plan, and a material procurement plan.

[0013] As a further limitation of the first aspect of the present invention, production events during press production include one or more of equipment breakdown, die breakdown, material inventory, change of month, change of season, change of weather, change in worker health, and change in demand.

[0014] As a further limitation of the first aspect of the present invention, a revised production plan is obtained based on production events during press working production and a preset neural network model, or a revised production plan is obtained based on production events during press working production and pre-stored big data analysis results.

[0015] In a second aspect of the present invention, The system includes a control terminal connected to each of the controllers corresponding to the material multi-level warehouse, the virtual finished parts multi-level warehouse, the rewinding and blanking line, the press processing line, the automatic lifting device, the end effector multi-level warehouse, the automatic quality inspection system, the all-parts automatic packing system, and the unmanned transport device, The control terminal acquires each element data of the press working production, generates a press working production plan based on each acquired element data, and modifies the production plan in response to a production event during the press working production; An unmanned intelligent press processing system is provided that is configured to sequentially perform management control of all processes, including material inventory confirmation, material receiving control, material transport control, mold transport control, end effector transport / attachment control, quality inspection control, packing control, basket transport control, and part production control, based on a revised press processing production plan.

[0016] As a further limitation of the second aspect of the present invention, the step of checking the material inventory includes: The method includes obtaining the required amount of materials based on the order production information and the number of finished parts in the virtual finished parts three-dimensional warehouse, checking whether the number of stocked materials in the material three-dimensional warehouse is sufficient, and if not, generating a material replenishment instruction or a material replenishment command.

[0017] As a further limitation of the second aspect of the present invention, the material inventory control is If the type of material is blank, generating a material storage command and sending it to a controller corresponding to the material three-dimensional warehouse and the automated guided transport device; if the type of material is coil material, generating a rewinding / blanking command based on the required amount of material and sending it to a controller corresponding to the rewinding / blanking line; and sending the material storage command to the controller corresponding to the material three-dimensional warehouse and the automated guided transport device upon receiving a notification of completion of rewinding / blanking.

[0018] As a further limitation of the second aspect of the present invention, the material transport control comprises: This includes notifying the material multi-story warehouse of the type of material required based on the press processing production plan, so that the material multi-story warehouse transports the material to the exit, and notifying the unmanned transport device to transport the material from the specified exit to a material loading position on the press processing line based on transport completion feedback information from the material multi-story warehouse.

[0019] As a further limitation of the second aspect of the present invention, the mold transport control is This includes sending a die transport control command to an automatic lifting device based on the press working production plan, so that the automatic lifting device lifts the corresponding die onto a workbench of the press working line in accordance with the command.

[0020] As a further limitation of the second aspect of the present invention, the end effector transport and attachment control includes: Based on the press working production plan, a preparation command for the corresponding end effector and tooling is transmitted to a controller corresponding to the end effector multi-story warehouse, and information on the delivery port transmitted from the controller corresponding to the end effector multi-story warehouse is received; Based on feedback information from the end effector multi-story warehouse, an end effector transport and attachment command is sent to a controller corresponding to the unmanned transport device, so that the unmanned transport device follows the command to take out the end effector from the outlet of the end effector multi-story warehouse and attach it to the corresponding tooling, and receives end effector attachment completion information sent from the controller corresponding to the unmanned transport device.

[0021] As a further limitation of the second aspect of the present invention, the basket transport control is Sending a data acquisition command to a controller corresponding to the finished part multi-story warehouse based on the press working production plan, and acquiring empty basket storage positions and finished part storage positions sent from the controller corresponding to the finished part multi-story warehouse; Based on information from the finished parts multi-level warehouse and the all-parts automatic packing system, sending a basket transport command to a controller corresponding to the automated guided transport device, so that the automated guided transport device places the empty basket in the finished parts multi-level warehouse at the corresponding workstation of the all-parts automatic packing system in accordance with the command, and receiving basket transport completion information fed back from the automated guided transport device.

[0022] As a further limitation of the second aspect of the present invention, the part production control comprises: acquiring material shortage information fed back from a controller corresponding to the press working line, and transmitting a material supply command to the controllers corresponding to the material multi-story warehouse and the automatic transport device based on the material shortage information; Obtaining quality information feedback from an automated quality inspection system; When the all-component automatic packing system fills the basket, it acquires information about the basket being full and sends a transport command to the automated guided transport device, causing the automated guided transport device to carry the full basket into the finished parts multi-level warehouse and transport the empty basket from the finished parts multi-level warehouse to a corresponding workstation of the all-component automatic packing system.

[0023] In a third aspect of the present invention, The control terminal obtains the required amount of materials based on the order production information and the number of finished parts in the virtual finished parts multi-level warehouse, communicates with the controller corresponding to the material multi-level warehouse to check whether the number of stocked materials is sufficient, and if not, generates a material replenishment instruction or a material replenishment command; If the supplied material is raw material, the control terminal communicates with a controller corresponding to the raw material multi-story warehouse to specify the storage location after storage, and communicates with a controller corresponding to the automated guided transport device to issue a command, the automated guided transport device follows the command to transport the raw material to a specified entrance of the raw material multi-story warehouse, and the raw material multi-story warehouse transports the raw material to a specified storage location; if the supplied material is coiled material, the control terminal communicates with an automatic lifting device to send a command, and the automatic lifting device follows the command to place the coiled material at a specified storage location on the rewinding and blanking line; The control terminal communicates with a controller corresponding to the rewinding / blanking line based on the required amount of material and issues a command, the rewinding / blanking line rewinds and blanks the coil material according to the command and notifies the control terminal when blanking is complete, the control terminal communicates with controllers corresponding to the material multi-story warehouse and the automated guided transport device based on the blanking completion information, the automated guided transport device transports the material to a specified entrance of the material multi-story warehouse according to the command, and the material is transported to a specified storage position by the material multi-story warehouse, The control terminal notifies the controller corresponding to the material storage unit of the type of material required based on the press processing production plan, the material storage unit transports the material to an exit based on the information and notifies the control terminal, and the control terminal notifies the unmanned transport device to transport the material from a specified exit to a material loading position on the press processing line based on the information from the material storage unit, The control terminal sends a die lifting command to the automatic lifting device according to the stamping production plan, and the automatic lifting device lifts the corresponding die onto the workbench of the stamping line according to the die lifting command; The control terminal notifies the controller corresponding to the end effector multi-level warehouse to prepare the corresponding end effector and tooling based on the press working production plan, and feeds back the delivery port to the control terminal; The control terminal notifies the controller corresponding to the automated guided vehicle based on the feedback information from the end effector multi-story warehouse, and the automated guided vehicle takes out the end effector from the outlet of the end effector multi-story warehouse based on the information and attaches it to the corresponding tooling, and feeds back the information to the control terminal in real time. The control terminal sends a quality inspection command to the automatic quality inspection system based on the press processing production plan, and the automatic quality inspection system controls the quality inspection according to the quality inspection command and feeds back the quality inspection results to the control terminal. The control terminal notifies the automatic packing system based on the press processing production plan, and the automatic packing system adjusts the position of the belt conveyor and switches policies based on the information, and feeds back to the control terminal. The control terminal notifies the finished parts multi-story warehouse based on the press working production plan, and the finished parts multi-story warehouse feeds back the empty basket storage positions and finished part storage positions to the control terminal based on the information; The control terminal notifies the automated guided vehicle according to the information of the finished parts multi-level warehouse and the all-parts automatic packing system, and the automated guided vehicle places the empty basket in the finished parts multi-level warehouse at the corresponding workstation of the all-parts automatic packing system according to the information, and feeds back to the control terminal; The control terminal starts production when the preparation of each mechanism is completed based on feedback information from each component; An unmanned intelligent stamping method is provided, including:

[0024] In one alternative embodiment, when the materials loaded on the press processing line are used up during the production process, the controller corresponding to the press processing line communicates with the control terminal, and the control terminal notifies the material multi-level warehouse and the automated guided transport device to replenish the materials based on the production information; During the production process, the automatic quality inspection system inspects the quality of the parts and communicates with the automatic packing system for all parts, transmitting quality information to the automatic packing system for all parts; the automatic quality inspection system communicates with the control terminal, transmitting quality information to the control terminal; During the production process, the automatic packing system for all parts fills the basket and then communicates with the control terminal, and the control terminal notifies the automatic guided vehicle to transfer the full basket into the finished parts multi-level warehouse and transfer the empty basket from the finished parts multi-level warehouse to the corresponding workstation of the automatic packing system according to the basket fullness information; During the production process, the control terminal exchanges information in real time with the controllers for the material storage, virtual finished parts storage, unwinding and blanking line, press processing line, automatic lifting device, end effector storage, automatic quality inspection system, all-parts automatic packing system, and unmanned transport device, monitors the production status, and based on feedback information from each controller, determines whether the line needs to be stopped for mold inspection and repair or equipment maintenance. During the production process, the control terminal displays or reports production information to the control side corresponding to the worker in real time; During the production process, the control terminal communicates with each controller and initiates production preparation work for the next batch of parts.

[0025] The beneficial effects of the present invention compared with the prior art are as follows:

[0026] 1. The unmanned intelligent stamping system and stamping method described in the present invention realize unmanned control operation of the entire process of material inventory confirmation, material storage control, material transport control, mold transport control, end effector transport and installation control, quality inspection control, packing control, basket transport control, and part production control, thereby reducing labor costs, ensuring part consistency in stamping production, and improving part stamping quality.

[0027] 2. The unmanned intelligent stamping system and stamping method described in the present invention realizes unmanned production planning and material management, unmanned mold lifting and replacement, unmanned end effector and tooling preparation and replacement, unmanned quality inspection of finished parts, unmanned finished part packing, unmanned basket preparation and replacement, and unmanned basket storage.

[0028] 3. In the unmanned intelligent stamping system and stamping method described in the present invention, the ERP system obtains each element data of stamping production, generates a stamping production plan based on each element data obtained, modifies the production plan according to production events during stamping production, and sends the stamping production plan to the control terminal in real time or periodically, thereby realizing the automatic generation and adaptive modification of the stamping production plan and further improving the intelligence level of stamping production.

[0029] Advantages of additional aspects of the invention will be set forth in part in the description that follows, and in part will be obvious from the description, or may be learned by practice of the invention. [Brief explanation of the drawings]

[0030] The drawings in the specification, which form a part of this invention, are intended to provide a further understanding of the invention, and the illustrative embodiments of the invention and their descriptions are intended to interpret the invention and are not intended to unduly limit the invention. [Figure 1] 1 is a structural schematic diagram of an unmanned intelligent stamping system provided in Example 1 of the present invention; FIG. [Figure 2] 1 is a schematic layout diagram of an unmanned intelligent stamping system provided in Example 1 of the present invention; FIG. DETAILED DESCRIPTION OF THE INVENTION

[0031] The present invention will now be further described with reference to the following figures and examples.

[0032] Unless inconsistent, embodiments of the present invention and features of the embodiments may be combined with one another.

[0033] Example 1: As shown in FIG. 1, a first embodiment of the present invention provides an unmanned intelligent stamping system, which includes a raw material multi-level warehouse, a virtual finished parts multi-level warehouse, a rewinding and blanking line, a stamping line, an automatic lifting device, an end effector multi-level warehouse, an automatic quality inspection system, an automatic all-parts packing system, and a control terminal communicatively connected to a controller corresponding to the unmanned transport device, and the control terminal communicatively connected to an ERP system; the ERP system is configured to acquire each element data of press working production, generate a press working production plan based on each acquired element data, modify the production plan in response to a production event during press working production, and transmit the press working production plan to a control terminal in real time or periodically; The control terminal is configured to control all processes based on the press processing production plan, including material inventory confirmation, material receiving control, material transport control, mold transport control, end effector transport and attachment control, quality inspection control, packing control, basket transport control, and parts production control.

[0034] In this embodiment, the element data of press working production includes order demand data, production process data, resource constraint data, process constraint data, calendar data, and rule data. It will be appreciated that in some other embodiments, the data may include external impact data such as power supply and water resource supply data, or internal impact data such as unplanned worker deployment data and unexpected shutdown data due to internal causes.

[0035] In this example, the order demand data includes sales order data, sales forecast data, planned order data, and production order data, but it will be understood that in some other embodiments, it may also include tentative order data, etc.

[0036] The production process data includes process route data, lead time data, processing time data, and production efficiency data, but it will be understood that in some other embodiments, it may also include data on materials required for the process, data on material replenishment times for each process, etc.

[0037] The resource constraint data includes machine quantity and status data, mold quantity and status data, worker quantity and attendance data, and material inventory data; the process constraint data includes inter-process product batch transfer amounts, process interval time data, and yield rate data; the calendar data includes machine operation calendars, work shifts, and work hours; and the rule data includes order rules, equipment rules, optimization rules, and integration rules.

[0038] The production plan includes order due date forecast, daily delivery plan, daily production plan, production plan based on work shifts, machine production line plan, and material procurement plan.

[0039] In this embodiment, production events during press production include equipment breakdowns, die breakdowns, and changes in material inventory and demand.

[0040] In this embodiment, when the system is used for the first time, data within a set period (for example, one year) is collected and analyzed to obtain the changes in equipment failure rate, mold failure rate, or material inventory, as well as the changes in demand, and the production plan is adjusted based on the situation obtained by big data analysis.

[0041] It is understood that after completing the initial adjustment based on historical data, analysis is continuously performed based on data collected in real time, and the production plan is adaptively adjusted based on data that changes over time to achieve a balance between low cost and high profit (here, the plan may be set with the lowest cost as a target, or the highest profit as a target, or a balance control of both may be performed).

[0042] In this embodiment, the ERP system is further configured to generate cost data based on each acquired element data, and the cost data includes cost forecast data, planned total cost data, equipment cost data, material cost data, human cost data, and tooling die cost data.

[0043] In this embodiment, the production events may further include stamping plans for different months, different seasons, or different sets of products, etc., so the automatic modification of the production plan may further be based on different production seasons, different production months (months in the lunar calendar, where the personnel reduction situation is different in different months, and the material supply or sales situation is also different in different months), or different stamping plans (for example, for stamping set products, each set of products includes multiple parts, and one specification of the stamping plan should generally complete the stamping of each part of one set of products), etc., and the above-mentioned different production seasons, months, or stamping plans can be automatically generated for each of the different production seasons, months, or specific stamping plans through big data analysis methods.

[0044] In this embodiment, market data (including market sales status, material supply information, or relevant policy information) is analyzed in real time or periodically based on big data, and adaptive production order adjustment or early warning is performed based on the acquired data.

[0045] In this embodiment, for products that are shown to have good sales (or good future prospects) through big data analysis, the materials of the press-processed products corresponding to those products are allocated preferentially, i.e., set to a priority production level, and other product materials are allocated sequentially according to the importance level or the product's market sales status.

[0046] It will be appreciated that in some other embodiments, the ERP system may be further configured to generate order Gantt charts, process Gantt charts, machine Gantt charts, load and shortage data, and abnormality early warning data based on each acquired element data.

[0047] In this embodiment, any of the raw material multi-story warehouse, virtual finished parts multi-story warehouse, rewinding and blanking line, press processing line, automatic lifting device, end effector multi-story warehouse, automatic quality inspection system, automatic all-parts packing system, and unmanned transport device is provided with a corresponding controller for realizing data collection, data reception, data transmission, and operation control, and the specific controller may be a controller attached to each warehouse that communicates with the control terminal via an integrated protocol interface.

[0048] The respective functions of each specific functional entity are all conventional solutions in this field and are not considered to be the innovative content of this solution. For example, patents such as CN201620059004.1: AGV trolley logistics transportation system for automatic packing at the end of a stamping line, CN201820253101.3: end effector three-dimensional storage device, CN201510337966.9: system and method for automatic packing of all parts at the end of a stamping line, and CN201911228175.7: virtual three-dimensional storage system and method can fully realize the operation of each of the above systems.

[0049] In this example, "raw material" refers to material that has not been pressed and formed, "coil material" refers to rolled steel sheet that needs to be recoiled and blanked to form the raw material, "finished part" refers to parts that have been pressed and formed and can be used for the next welding process, "basket" refers to a container for storing multiple finished parts, and "all parts" refers to all types of finished parts.

[0050] The end effector is a gripper for grasping a part.

[0051] In this embodiment, the control terminal is an upper control terminal, which may be remotely located in the form of a cloud service. Those skilled in the art can select it based on the specific operating conditions, and detailed description will be omitted here.

[0052] In this embodiment, the structures of the raw material multi-level warehouse, virtual finished parts multi-level warehouse, rewinding and blanking line, stamping line, automatic lifting device, end effector multi-level warehouse, automatic quality inspection system, automatic all-parts packing system, and unmanned transport device can all adopt conventional automation solutions, i.e., conventional raw material automation management systems, conventional rewinding and blanking lines, conventional quality inspection systems, etc. Those skilled in the art can select from conventional technologies based on specific operating conditions as long as they can achieve fully automated stamping control of the entire process described in this embodiment, and detailed descriptions will be omitted here.

[0053] In this embodiment, the automatic lifting device may be a fully automatic overhead crane or a fully automatic wireless mold change vehicle. Those skilled in the art can select one based on the specific operating conditions, and detailed description will be omitted here.

[0054] In this embodiment, the unmanned transport device may be an unmanned forklift or an AGV (Automated Guided Vehicle), and a person skilled in the art can select one based on the specific operating conditions, so detailed explanations are omitted here.

[0055] In this embodiment, a solution is provided for a case where there is one production line. A stamping factory may have two or more stamping lines, and this can be achieved by increasing the number of control terminals. However, a stamping factory with two or more stamping lines may have only one material multi-level warehouse or only one finished part multi-level warehouse. In this case, the multiple control terminals can be divided into a master-slave configuration or a single host computer configuration. Those skilled in the art can select one based on the specific operating conditions, and detailed explanations will be omitted here.

[0056] In this embodiment, material inventory check is performed as follows: The method includes obtaining the required amount of materials based on the order production information and the number of finished parts in the virtual finished parts three-dimensional warehouse, checking whether the number of stocked materials in the material three-dimensional warehouse is sufficient, and if not, generating a material replenishment instruction or a material replenishment command.

[0057] In this embodiment, the material receiving control is If the type of material is blank, generating a material storage command and sending it to a controller corresponding to the material three-dimensional warehouse and the automated guided transport device; if the type of material is coil material, generating a rewinding / blanking command based on the required amount of material and sending it to a controller corresponding to the rewinding / blanking line; and sending the material storage command to the controller corresponding to the material three-dimensional warehouse and the automated guided transport device upon receiving a notification of completion of rewinding / blanking.

[0058] In this embodiment, the material transport control is This includes notifying the material multi-story warehouse of the type of material required based on the press processing production plan, so that the material multi-story warehouse transports the material to the exit, and notifying the unmanned transport device to transport the material from the specified exit to a material loading position on the press processing line based on transport completion feedback information from the material multi-story warehouse.

[0059] In this embodiment, the mold transport control is as follows: This includes sending a die transport control command to an automatic lifting device based on the press working production plan, so that the automatic lifting device lifts the corresponding die onto a workbench of the press working line in accordance with the command.

[0060] In this embodiment, the end effector transport and attachment control is as follows: Based on the press working production plan, a preparation command for the corresponding end effector and tooling is transmitted to a controller corresponding to the end effector multi-story warehouse, and information on the delivery port transmitted from the controller corresponding to the end effector multi-story warehouse is received; Based on feedback information from the end effector multi-story warehouse, an end effector transport and attachment command is sent to a controller corresponding to the unmanned transport device, so that the unmanned transport device follows the command to take out the end effector from the outlet of the end effector multi-story warehouse and attach it to the corresponding tooling, and receives end effector attachment completion information sent from the controller corresponding to the unmanned transport device.

[0061] In this embodiment, the basket transport control is as follows: Sending a data acquisition command to a controller corresponding to the finished part multi-story warehouse based on the press working production plan, and acquiring empty basket storage positions and finished part storage positions sent from the controller corresponding to the finished part multi-story warehouse; Based on information from the finished parts multi-level warehouse and the all-parts automatic packing system, sending a basket transport command to a controller corresponding to the automated guided transport device, so that the automated guided transport device places the empty basket in the finished parts multi-level warehouse at the corresponding workstation of the all-parts automatic packing system in accordance with the command, and receiving basket transport completion information fed back from the automated guided transport device.

[0062] In this embodiment, the parts production control is acquiring material shortage information fed back from a controller corresponding to the press working line, and transmitting a material supply command to the controllers corresponding to the material multi-story warehouse and the automatic transport device based on the material shortage information; Obtaining quality information feedback from an automated quality inspection system; When the all-component automatic packing system fills the basket, it acquires information about the basket being full and sends a transport command to the automated guided transport device, causing the automated guided transport device to carry the full basket into the finished parts multi-level warehouse and transport the empty basket from the finished parts multi-level warehouse to a corresponding workstation of the all-component automatic packing system.

[0063] In this embodiment, the quality inspection control is The method includes notifying a controller corresponding to the automatic quality inspection system based on the press processing production plan, so that the automatic quality inspection system switches the corresponding policy based on the information, and the control terminal obtains the quality inspection result feedback sent from the controller corresponding to the automatic quality inspection system.

[0064] In this embodiment, the packing control is Based on the press processing production plan, the automatic all-parts packing system is notified, so that the automatic all-parts packing system adjusts the position of the belt conveyor and switches policies based on the information, and the control terminal obtains a packing completion command sent from the automatic all-parts packing system.

[0065] In this embodiment, the parts production control is During the production process, the control terminal exchanges information with each controller in real time, monitors the production status, and determines whether the line needs to be stopped for mold inspection and repair and equipment maintenance based on feedback information from each mechanism; The method further includes the control terminal displaying or reporting the production information in real time to the control side corresponding to the worker (i.e., the mobile control terminal or the computer terminal device corresponding to the factory manager) during the production process.

[0066] During the production process, the control terminal communicates with each controller and initiates production preparation work for the next batch of parts.

[0067] More specifically, as shown in FIG. 2, the layout of the entire press processing system may include a multi-level material warehouse 1, an unmanned forklift (material transport) 2, a press processing line 3, an automatic quality inspection system 4, an automatic all-parts packing system 5, an unmanned forklift (basket transport) 6, a basket warehouse 7, a rewinding and blanking line 8, and a coil material storage location 9.

[0068] Example 2: Embodiment 2 of the present invention provides an unmanned intelligent stamping method, which includes:

[0069] In S1, the control terminal obtains the required amount of material based on the order production information and the number of finished parts in the virtual finished parts three-dimensional warehouse, communicates with the material three-dimensional warehouse to check whether the number of stocked materials is sufficient, and if not, generates a material replenishment instruction or material replenishment command to prompt the press processing factory manager to prepare the material.

[0070] In S2, materials in the press processing factory are generally divided into coil materials and blanks, and when the materials are transported to the press processing factory, the press processing factory manager inputs the material information into the control terminal.

[0071] Based on the material information, if it is raw material, the control terminal communicates with the raw material multi-story warehouse to specify the storage location after it is received, and also communicates with the unmanned forklift to issue a command, and the unmanned forklift follows the command to transport the material to the designated entrance of the raw material multi-story warehouse, which then transports the material to the designated storage location.If it is coil material, the control terminal communicates with the fully automatic overhead crane, and the fully automatic overhead crane follows the command to place the coil material in the designated storage location on the rewinding and blanking line.

[0072] In S3, the control terminal communicates with the rewinding / blanking line based on the required amount of material and issues commands, and the rewinding / blanking line rewinds and blanks the coil material according to the commands. When blanking is complete, it notifies the control terminal, and the control terminal communicates with the material multi-story warehouse and unmanned forklift based on the blanking completion information. The unmanned forklift transports the material to a specified entrance of the material multi-story warehouse according to the commands, and the material multi-story warehouse transports the material to a specified storage position.

[0073] In S4, the control terminal notifies the material multi-story warehouse of the type of material required based on the press processing production plan, the material multi-story warehouse transports the material to the exit based on the information and notifies the control terminal, and the control terminal notifies the unmanned forklift to transport the material from the specified exit to the material loading position on the press processing line based on the information from the material multi-story warehouse.

[0074] In S5, the control terminal notifies the automatic overhead crane based on the press processing production plan, and the automatic overhead crane hoists the corresponding mold onto the workbench of the press processing line based on the information.

[0075] In S6, the control terminal notifies the end effector multi-story warehouse to prepare the corresponding end effector and tooling based on the press working production plan, and feeds back the delivery port to the control terminal.

[0076] In S7, the control terminal notifies the AGV based on the feedback information from the end effector multi-story warehouse, and the AGV takes out the end effector from the exit of the end effector multi-story warehouse based on the information, attaches it to the corresponding tooling, and feeds back the information to the control terminal in real time.

[0077] In S8, the control terminal notifies the automatic quality inspection system based on the press working production plan, and the automatic quality inspection system switches the corresponding program based on the information and feeds it back to the control terminal.

[0078] In S9, the control terminal notifies the all-parts automatic packing system based on the press processing production plan, and the all-parts automatic packing system adjusts the position of the belt conveyor and switches the program based on the information, and provides feedback to the control terminal.

[0079] In S10, the control terminal notifies the finished parts multi-story warehouse based on the press working production plan, and the finished parts multi-story warehouse feeds back the empty basket storage positions and finished parts storage positions to the control terminal based on the information.

[0080] In S11, the control terminal notifies the unmanned forklift based on the information of the finished parts multi-level warehouse and the all-parts automatic packing system, and the unmanned forklift places the empty basket in the finished parts multi-level warehouse at the corresponding workstation of the all-parts automatic packing system based on the information, and feeds back to the control terminal.

[0081] In S12, the control terminal starts production when the preparation of each mechanism is completed based on feedback information from each component.

[0082] In S13, when the material loaded on the press processing line is used up during the production process, the press processing line communicates with the control terminal, and the control terminal notifies the material multi-story warehouse and the unmanned forklift to replenish the material based on the production information (repeating S4).

[0083] In S14, during the production process, the automatic quality inspection system inspects the quality of the parts, communicates with the all-parts automatic packing system, and transmits quality information to the all-parts automatic packing system, and the automatic quality inspection system communicates with the control terminal and transmits the quality information to the upper system.

[0084] In S15, during the production process, the automatic all-component packing system will communicate with the control terminal after filling the basket, and the control terminal will instruct the unmanned forklift to carry the full basket into the finished parts multi-level warehouse and transport the empty basket from the finished parts multi-level warehouse to the corresponding workstation of the automatic all-component packing system based on the blanking completion information (repeating S11).

[0085] In S16, during the production process, the control terminal exchanges information with each mechanism in real time, monitors the production status, and determines, based on feedback information from each mechanism, whether it is necessary to stop the line for mold inspection and repair, equipment maintenance, etc.

[0086] Specifically, when the automatic quality inspection system detects defective products in a batch (the number of defective products in a batch can be set), the line must be stopped and the molds must be inspected and repaired.Warning ranges are set for signals such as temperature, pressure, and current in the feedback information from each controller, and if they remain within the warning range for a long period of time, equipment maintenance must be performed.

[0087] In S17, during the production process, the control terminal displays or reports the production information in real time to the control side corresponding to the factory manager (ie, the mobile control terminal or the computer terminal device corresponding to the factory manager).

[0088] In S18, during the production process, the control terminal communicates with each mechanism to start production preparation work for the next batch of parts, such as material preparation, mold change preparation, end effector change preparation, basket change preparation, etc. [Explanation of symbols]

[0089] 1. Material storage 2. Unmanned forklift (material transport) 3 Press processing line 4. Automatic quality inspection system 5. Automatic packing system for all parts 6. Unmanned forklift (basket transport) 7. Basket Warehouse 8 Rewinding and blanking lines 9 Coil material storage position

Claims

1. Acquire element data for press working production, generate a press working production plan based on the acquired element data, and modify the production plan in response to production events during press working production. Each element data of the press working production includes order demand data, production process data, resource constraint data, process constraint data, calendar data, and rule data, the calendar data includes a machine operation calendar, a work shift, and working hours, and the production events during the press working production include one or more of equipment failure, die failure, material inventory amount, month change, season change, weather change, change in worker health condition, and change in demand; When modifying the production plan in response to production events during press production for the first time, data within a set period is collected and analyzed to obtain the equipment failure rate, mold failure rate, or changes in material inventory, as well as changes in demand, and the production plan is adjusted based on the situation obtained through big data analysis. After the initial adjustment, analysis is continuously performed based on the data collected in real time, and the production plan is adaptively adjusted based on the data that changes over time, achieving a balance between low cost and high profitability. Based on the revised press processing production plan, all processes including material inventory confirmation, material receiving control, material transport control, mold transport control, end effector transport and installation control, quality inspection control, packing control, basket transport control, and parts production control are controlled in sequence. The order demand data includes sales order data, sales forecast data, planned order data, and production order data; The production process data includes process route data, lead time data, processing time data, and production efficiency data, The resource constraint data includes machine quantity and status data, mold quantity and status data, worker quantity and attendance data, and material inventory data. The process constraint data includes inter-process product batch movement amounts, process interval time data, and yield rate data; The rule data includes an order rule, an equipment rule, an optimization rule, and an integration rule; The production plan includes order delivery date forecast, daily delivery plan, daily production plan, production plan based on work shift, machine production line plan, and material procurement plan. Obtaining a revised production plan based on production events during press production and a preset neural network model, or obtaining a revised production plan based on production events during press production and a pre-stored big data analysis result; An unmanned intelligent press processing method comprising:

2. The system includes a control terminal communicatively connected to each of the controllers corresponding to the material multi-level warehouse, the virtual finished parts multi-level warehouse, the rewinding / blanking line, the press processing line, the automatic lifting device, the end effector multi-level warehouse, the automatic quality inspection system, the all-part automatic packing system, and the unmanned transport device; The control terminal communicates with an ERP system, and the ERP system is configured to execute the unmanned intelligent press working according to claim 1 to modify the production plan, and transmit the modified press working production plan to the control terminal in real time or periodically; An unmanned intelligent press processing system characterized in that the control terminal is configured to sequentially control all processes, including material inventory confirmation, material receiving control, material transport control, mold transport control, end effector transport / attachment control, quality inspection control, packing control, basket transport control, and part production control, based on the revised press processing production plan.

3. To check material inventory, The unmanned intelligent press processing system of claim 2, further comprising obtaining the required quantity of material based on the order production information and the number of finished parts in the virtual finished parts three-dimensional warehouse, checking whether the number of stocked materials in the material three-dimensional warehouse is sufficient, and if not, generating a material replenishment instruction or a material replenishment command.

4. Material inventory control is 3. The unmanned intelligent stamping system of claim 2, further comprising: if the type of material is blank, generating a blank storage command and sending it to the controller corresponding to the blank storage and the unmanned transport device; if the type of material is coil material, generating a rewinding / blanking command based on the required amount of material and sending it to the controller corresponding to the rewinding / blanking line; and, upon receiving a notification of completion of rewinding / blanking, sending a blank storage command to the controller corresponding to the blank storage and the unmanned transport device.

5. Material transport control is 3. The unmanned intelligent stamping system according to claim 2, further comprising: notifying the material multi-story warehouse of the type of material required based on the stamping production plan, so that the material multi-story warehouse transports the material to the exit; and notifying the unmanned transport device to transport the material from the specified exit to the material loading position of the stamping line based on the transport completion feedback information of the material multi-story warehouse.

6. Mold transport control is The unmanned intelligent stamping system of claim 2, further comprising: sending a mold transport control command to the automatic lifting device based on the stamping production plan, so that the automatic lifting device lifts the corresponding mold onto the workbench of the stamping line according to the command.

7. End effector transport and attachment control is Based on the press working production plan, a preparation command for the corresponding end effector and tooling is transmitted to a controller corresponding to the end effector multi-story warehouse, and information on the delivery port transmitted from the controller corresponding to the end effector multi-story warehouse is received; 3. The unmanned intelligent stamping system according to claim 2, further comprising: sending an end effector transport and attachment command to a controller corresponding to the unmanned transport device based on feedback information from the end effector multi-story warehouse, so that the unmanned transport device takes out the end effector from the outlet of the end effector multi-story warehouse and attaches it to the corresponding tooling in accordance with the command, and receiving end effector attachment completion information sent from the controller corresponding to the unmanned transport device.

8. Basket transport control is Sending a data acquisition command to a controller corresponding to the finished part multi-story warehouse based on the press working production plan, and acquiring empty basket storage positions and finished part storage positions sent from the controller corresponding to the finished part multi-story warehouse; 3. The unmanned intelligent stamping processing system of claim 2, further comprising: sending a basket transport command to a controller corresponding to the unmanned transport device based on information from the finished parts multi-level warehouse and the all-parts automatic packing system, so that the unmanned transport device places the empty basket in the finished parts multi-level warehouse at the corresponding workstation of the all-parts automatic packing system according to the command, and receiving basket transport completion information fed back from the unmanned transport device.

9. Parts production control acquiring material shortage information fed back from a controller corresponding to the press working line, and transmitting a material supply command to the controllers corresponding to the material multi-story warehouse and the automatic transport device based on the material shortage information; Obtaining quality information feedback from an automated quality inspection system; 3. The unmanned intelligent stamping processing system of claim 2, further comprising: when the all-component automatic packing system fills the basket, it obtains full basket information and sends a transport command to the unmanned transport device, so that the unmanned transport device carries the full basket into the finished parts multi-level warehouse and transports the empty basket from the finished parts multi-level warehouse to the corresponding workstation of the all-component automatic packing system.

10. The control terminal obtains the required amount of material based on the press working production plan and the number of finished parts in the virtual finished parts multi-level warehouse, communicates with the controller corresponding to the material multi-level warehouse to check whether the number of stocked materials is sufficient, and if not, generates a material replenishment instruction or a material replenishment command, and the production plan is generated based on each element data of the press working production and is corrected according to production events during the press working production, If the supplied material is raw material, the control terminal communicates with a controller corresponding to the raw material multi-story warehouse to specify the storage location after storage, and communicates with a controller corresponding to the automated guided transport device to issue a command, the automated guided transport device transports the raw material to a specified entrance of the raw material multi-story warehouse in accordance with the command, and the raw material multi-story warehouse transports the raw material to a specified storage location; if the supplied material is coiled material, the control terminal communicates with an automatic lifting device to send a command, and the automatic lifting device places the coiled material in a specified storage location on the rewinding and blanking line in accordance with the command; The control terminal communicates with a controller corresponding to the rewinding / blanking line based on the required amount of material and issues a command, the rewinding / blanking line rewinds and blanks the coil material in accordance with the command and notifies the control terminal when blanking is complete, the control terminal communicates with controllers corresponding to the material multi-story warehouse and the automated transport device based on the blanking completion information, the automated transport device transports the material to a specified entrance of the material multi-story warehouse in accordance with the command, and the material is transported to a specified storage position by the material multi-story warehouse, The control terminal notifies the controller corresponding to the material storage unit of the type of material required based on the press processing production plan, the material storage unit transports the material to an exit based on the information and notifies the control terminal, and the control terminal notifies the unmanned transport device to transport the material from a specified exit to a material loading position on the press processing line based on the information from the material storage unit, The control terminal sends a die lifting command to the automatic lifting device according to the stamping production plan, and the automatic lifting device lifts the corresponding die onto the workbench of the stamping line according to the die lifting command; The control terminal notifies the controller corresponding to the end effector multi-level warehouse to prepare the corresponding end effector and tooling based on the press working production plan, and feeds back the delivery port to the control terminal; The control terminal notifies the controller corresponding to the automated guided vehicle based on the feedback information from the end effector multi-story warehouse, and the automated guided vehicle takes out the end effector from the outlet of the end effector multi-story warehouse based on the information and attaches it to the corresponding tooling, and feeds back the information to the control terminal in real time. The control terminal sends a quality inspection command to the automatic quality inspection system based on the press processing production plan, and the automatic quality inspection system controls the quality inspection according to the quality inspection command and feeds back the quality inspection results to the control terminal. The control terminal notifies the automatic packing system based on the press processing production plan, and the automatic packing system adjusts the position of the belt conveyor and switches policies based on the information, and feeds back to the control terminal. The control terminal notifies the finished parts multi-story warehouse based on the press working production plan, and the finished parts multi-story warehouse feeds back the empty basket storage positions and finished part storage positions to the control terminal based on the information; The control terminal notifies the automated guided vehicle according to the information of the finished parts multi-level warehouse and the all-parts automatic packing system, and the automated guided vehicle places the empty basket in the finished parts multi-level warehouse at the corresponding workstation of the all-parts automatic packing system according to the information, and feeds back to the control terminal; The control terminal starts production when each mechanism is ready based on feedback information from each component. During the production process, when the materials loaded on the stamping line are used up, the controller corresponding to the stamping line communicates with the control terminal, and the control terminal notifies the material storage and the automated transport device to replenish the materials based on the production information; During the production process, the automatic quality inspection system inspects the quality of the parts and communicates with the automatic packing system for all parts, transmitting quality information to the automatic packing system for all parts; the automatic quality inspection system communicates with the control terminal, transmitting quality information to the control terminal; During the production process, the automatic packing system for all parts fills the basket and then communicates with the control terminal, and the control terminal notifies the automatic guided vehicle to transfer the full basket into the finished parts multi-level warehouse and transfer the empty basket from the finished parts multi-level warehouse to the corresponding workstation of the automatic packing system according to the basket fullness information; During the production process, the control terminal exchanges information in real time with the controllers corresponding to the raw material storage, virtual finished parts storage, unwinding and blanking line, stamping line, automatic lifting device, end effector storage, automatic quality inspection system, all-parts automatic packing system, and unmanned transport device, monitors the production status, and based on the feedback information from each controller, determines whether the line needs to be stopped for mold inspection and repair or equipment maintenance. During the production process, the control terminal displays or reports production information to the control side corresponding to the worker in real time; During the production process, the control terminal communicates with each controller to initiate production preparation work for the next batch of parts.

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