Product production system and method for controlling product production system

Abstract

Disclosed is a product production system comprising: a planning system; an enterprise resource planning (ERP) system; a digital twin system; and a feedback system provided within the digital twin system, wherein the digital twin system generates a processing model on the basis of a correction value generated by the feedback system and performs a simulation for product production in the future to process virtual data related to a virtual robot operation result through the processing model.

Description

Product production system and product production system control method

[0001] The present invention relates to a product production system and a product production system control method, and more particularly, to a product production system and a product production system control method that can reduce differences between a virtual environment and reality that occur according to changes in various variables through feedback control.

[0002] Smart factories, an intelligent manufacturing technology that applies ICT technologies such as AI, robotics, IoT, and big data to existing production processes (assembly, logistics, inspection, etc.), are comprised of multiple cells, each capable of assembling product parts.

[0003] Accordingly, digital twin technology is being promoted as a core task of "smart factories." A digital twin is a simulation device that simulates robot paths in a virtual environment by replicating physical objects and the world in a digital world. This allows for pre-verification and application of these virtual paths to real-world systems.

[0004] At this time, when building a digital twin, various efforts are being made to replicate the real-world situation, such as replicating the exterior through 3D modeling and collecting and linking various data from the manufacturing site through IIoT such as sensors.

[0005] However, in the real world, various forces such as gravity and friction coefficients exist, so simulated results based on values ​​entered into a digital twin are bound to differ from reality. Furthermore, variables such as the coefficient of friction change over time and as equipment and facilities age, the gap between the digital twin and the real world grows. For example, the gap between simulated results of a digital twin (such as AGV movement speed and hourly production volume) and real-world execution results continues to widen, which can lower the usability and reliability of the digital twin.

[0006] Therefore, a system is needed that can reduce the gap between the digital twin and reality that occurs due to changes in various variables such as the coefficient of friction.

[0007]

[0008] The matters described as background technology above are only intended to enhance understanding of the background of the present invention, and should not be taken as an admission that they correspond to prior art already known to those skilled in the art.

[0009]

[0010] The present invention provides a production system for a product and a control method thereof that can reduce differences between a virtual environment and reality that occur according to changes in various variables through feedback control.

[0011]

[0012] The technical problems to be achieved in the present invention are not limited to the technical problems mentioned above, and other technical problems not mentioned can be clearly understood by a person having ordinary skill in the technical field to which the present invention belongs from the description below.

[0013] A product production system according to the present invention includes a planning system that generates an operation plan for a plurality of robots based on information including a parts transport plan required for product production; an ERP system that receives the operation plan for the robots from the planning system and receives performance data regarding actual robot operation results from a production plant; a digital twin system that receives the operation plan for the robots from the ERP system and performs a simulation for product production to produce virtual data regarding virtual robot operation results; and a feedback system that is provided within the digital twin system, receives the performance data from the ERP system, receives the virtual data from the digital twin system, calculates a difference between the performance data and the virtual data, and generates a correction value based on the calculated difference value; wherein the digital twin system generates a processing model based on the correction value generated by the feedback system, and can subsequently process virtual data regarding virtual robot operation results through the processing model by performing a simulation for product production.

[0014] Performance data and virtual data regarding robot operation results may include information regarding the time taken for the robot to perform its work.

[0015] The feedback system can generate a correction value by calculating the difference between the actual data and virtual data regarding the robot's work time.

[0016] The robot's operation plan may include information about the robot's movement path.

[0017] The robot's movement path includes a single or multiple segmented movement section, and the performance data for the robot's operation results and the virtual data for the robot's operation results may include information about the time required for the robot's work for each movement section.

[0018] The feedback system can generate a correction value by calculating the difference between the performance data and virtual data regarding the robot's work time for each movement section.

[0019] The robot's movement path can be divided into multiple movement sections based on whether the robot rotates.

[0020] The robot's operation plan includes information on the standard value of the robot's operation time for each task, and if the digital twin system determines that the virtual robot operation result is outside the error range compared to the standard value, the virtual data may not be transmitted to the feedback system.

[0021] A digital twin system can collect virtual data that determines that the virtual robot's operation results are outside the margin of error.

[0022] The digital twin system further includes a data preprocessing system, which can calculate the difference between actual data and virtual data.

[0023] The data preprocessing system transmits the difference between the generated performance data and virtual data to the feedback system, and the feedback system can generate a correction value based on the received difference.

[0024]

[0025] A method for controlling a product production system according to the present invention includes: a step in which a planning system generates an operation plan for a plurality of robots based on information including a parts transport plan required for product production; a step in which a digital twin system receives the operation plan for the robots from an ERP system and performs a simulation for product production to produce virtual data regarding virtual robot operation results; a step in which a feedback system receives performance data from the ERP system, receives virtual data from the digital twin system, calculates a difference between the performance data and the virtual data, and generates a correction value based on the calculated difference; a step in which the digital twin system generates a processing model based on the correction value generated by the feedback system; and a step in which the digital twin system performs a simulation for future product production to process virtual data regarding virtual robot operation results through the processing model.

[0026] Performance data and virtual data regarding robot operation results may include information regarding the time taken for the robot to perform its work.

[0027] The robot's operation plan includes information on the standard value of the robot's operation time for each task, and if the digital twin system determines that the virtual robot operation result is outside the error range compared to the standard value, the virtual data may not be transmitted to the feedback system at the stage of generating the correction value.

[0028] The digital twin system includes a feedback system and a data preprocessing system, and the step of generating a correction value includes the data preprocessing system calculating a difference between performance data and virtual data, the data preprocessing system transmitting the calculated difference between performance data and virtual data to the feedback system, and the feedback system can generate a correction value based on the received difference.

[0029]

[0030] According to the production system of the present invention and its control method, differences between a virtual environment and reality that occur due to changes in various variables can be reduced through feedback control.

[0031]

[0032] The effects that can be obtained from the present invention are not limited to the effects mentioned above, and other effects not mentioned can be clearly understood by a person having ordinary skill in the art to which the present invention belongs from the description below.

[0033] Figure 1 illustrates a configuration diagram of a product production system according to one embodiment of the present invention.

[0034] Figure 2 illustrates the movement path of a robot within a production plant according to tasks A and B.

[0035] Figure 3 is a graph showing the simulation results of tasks A and B and the time required for actual task results.

[0036] Figure 4 is a flowchart illustrating a method for controlling a product production system according to one embodiment of the present invention.

[0037] Hereinafter, embodiments disclosed in this specification will be described in detail with reference to the attached drawings. Regardless of the drawing numbers, identical or similar components are given the same reference numbers and redundant descriptions thereof will be omitted.

[0038] The suffixes "module" and "part" used for components in the following description are given or used interchangeably only for the convenience of writing specifications, and do not have distinct meanings or roles in themselves.

[0039] In describing the embodiments disclosed in this specification, if it is determined that a detailed description of related known technology may obscure the gist of the embodiments disclosed in this specification, the detailed description thereof will be omitted. In addition, the attached drawings are only intended to facilitate easy understanding of the embodiments disclosed in this specification, and the technical ideas disclosed in this specification are not limited by the attached drawings, and it should be understood that they include all modifications, equivalents, and substitutes included in the spirit and technical scope of the present invention. Terms including ordinal numbers, such as first, second, etc., may be used to describe various components, but the components are not limited by the terms. The terms are used only for the purpose of distinguishing one component from another.

[0040] When a component is referred to as being "connected" or "connected" to another component, it should be understood that it may be directly connected or connected to that other component, but that there may be other components intervening. Conversely, when a component is referred to as being "directly connected" or "connected" to another component, it should be understood that there are no other components intervening.

[0041] Singular expressions include plural expressions unless the context clearly indicates otherwise.

[0042] In this specification, terms such as “include” or “have” are intended to specify the presence of a feature, number, step, operation, component, part or combination thereof described in the specification, but should be understood not to exclude in advance the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts or combinations thereof.

[0043] In addition, in this specification, “robot” is used as a general concept to refer to smart logistics vehicles such as autonomous mobile robots (AMRs), automated guided vehicles (AGVs), and unmanned forklifts.

[0044] Additionally, the term “product” in this specification means all things that can be produced through production activities, as well as means of transportation such as vehicles and airplanes.

[0045]

[0046] Figure 1 illustrates a configuration diagram of a product production system according to one embodiment of the present invention. Referring to Figure 1, a planning system (100) generates an operation plan for multiple robots based on information including a parts transport plan required for product production.

[0047] Specifically, the planning system (100) may include a production planning system (110) and a logistics planning system (120). The planning system may generate a parts transport plan required for product production based on information included in the production planning system and the logistics planning system, and may generate an operation plan for multiple robots based on the plan.

[0048] The planning system (100) may include other systems (130) for performing other functions in addition to the production planning system (100) and the logistics planning system (100).

[0049] An ERP (Enterprise Resource Planning) system (300) is a system for enterprise-wide resource management, and various information such as factory information related to the layout of a production plant, plan information related to a product production plan, and production data related to product production can be stored in the ERP system (300).

[0050] Meanwhile, the ERP system (300) can receive the robot operation plan from the planning system (100) and can receive performance data on actual robot operation results from the production plant.

[0051] That is, the production plant (700) can transmit information obtained from actual production work through IIoT (Industrial Internet of Things) technology and robots to the ERP system (300) through technologies such as RFID / Sensor / PLC / Zigbee.

[0052] A server (S) is provided in the ERP system (300), and information transmitted to the ERP system (300) through the server (S) can be stored, or information stored in the ERP system (300) can be transmitted to another system.

[0053] The digital twin system (500) receives the robot operation plan from the ERP system (300), performs a simulation of product production, and produces virtual data on the virtual robot operation results.

[0054] A server (S) is provided in the digital twin system (500), and information transmitted from the ERP system (300) can be received through the server (S) and information can be transmitted to other systems.

[0055] Meanwhile, the digital twin system (500) includes a twin model creation module (510), and the twin model creation module (510) creates a virtual factory identical to an actual production factory through information received from the ERP system (300), and through this, a simulation of the operation plan of a robot in the virtual production factory can be performed through the simulation module (530), thereby producing virtual data on the results of robot operation.

[0056] The feedback system (550) receives performance data from the ERP system (300) and virtual data from the digital twin system (500), calculates a difference between the performance data and the virtual data, and generates a correction value based on the calculated difference.

[0057] The feedback system (550) statistically analyzes the difference between performance data and virtual data through data mining, and continuously checks the difference accordingly to check the difference between performance data and virtual data over time.

[0058] That is, in the digital twin system (500), virtual data is produced through simulation of the robot's operation plan, and in the actual production plant, product production-related work is performed through the robot's operation plan to produce performance data.

[0059] The ERP system (300) stores performance data, and the ERP system (300) can transmit this to the feedback system (550). In addition, the feedback system (550) receives virtual data from the digital twin system (500), and can generate a correction value through a comparison of the performance data and the virtual data, i.e., the difference between the two data.

[0060] Meanwhile, a comparison of virtual data and performance data can be performed in the feedback system (550), but a difference value is obtained by comparing performance data and virtual data in the Training Data Set (570) included in the digital twin system (500), and the feedback system (550) can also receive the difference value from the Training Data Set (570).

[0061]

[0062] Meanwhile, the feedback system (550) may be provided within the digital twin system (500). However, the feedback system (550) may also be constructed as a separate system existing outside of the digital twin system (500), and a server (S) may be provided in the feedback system (550) to receive information from other systems or transmit information through the server (S).

[0063] When a correction value is generated in the feedback system (550), the digital twin system (500) generates a processing model based on the correction value. The processing model may be generated in the interface (520) within the digital twin system (500) or within the feedback system (550).

[0064] The digital twin system (500) can process virtual data obtained by performing a simulation for future product production through a processing model generated by an interface (520) or a feedback system (550).

[0065] That is, the digital twin system (500) can increase the usability and reliability of virtual data obtained from a virtual factory by processing virtual data so that the difference between performance data performed in an actual production plant and virtual data approaches 0.

[0066] Specifically, if a processing model is created using virtual data and performance data, the processing value obtained through the virtual data through the processing model can be compared with the performance data, and the processing model can be created to continuously follow the performance data so that the virtual data can become closer to the performance data.

[0067]

[0068] Meanwhile, the performance data for the robot operation results and the virtual data for the robot operation results may include at least one of information regarding the robot collision time, the robot collision location, or the robot's work time.

[0069] The purpose of the present invention is to reduce the difference between performance data and virtual data, and the present invention is described in detail from the perspective of the work time required by a robot.

[0070] Specifically, when a simulation is completed in a digital twin system (500) according to the robot's operation plan, virtual data on the robot's work time is generated, and when work is performed in an actual production plant according to the robot's operation plan, performance data on the robot's work time is generated.

[0071] Using the above two data, the feedback system (550) calculates the difference between the actual data and the virtual data regarding the robot's work time. Then, a correction value can be generated based on the calculated difference.

[0072] Specifically, as a result of the observation of Task A, when the robot's work time confirmed in the virtual data is 1000 seconds and the robot's work time in the actual production plant is 900 seconds, the difference between the actual data and the virtual data is calculated as -100 seconds, and based on this difference, a correction value of 0.9 can be generated.

[0073] That is, in order for the robot's work time to be shown as 900 seconds in the virtual data as a result of the simulation for future Task A, a correction value of 0.9 is created based on 900 / 1000 = 0.9, and a processing model is created based on this in the digital twin system (500), and when a simulation for future product production is performed, the virtual data for Task A can be processed through the processing model to follow the performance data.

[0074] As described above, it is possible to create a processing model that multiplies the compensation value, or to create a processing model that adds the compensation value. Specifically, a processing model can be created based on the compensation value obtained by subtracting the virtual data from the actual data. Later, when a simulation of product production is performed, the virtual data for Task A can be processed through the processing model to track the actual data.

[0075] That is, based on the difference value of 900 - 1000 = -100, a correction value of -100 can be created, and a processing model can be created based on this.

[0076] Conversely, if the robot's work time confirmed in the virtual data is 900 seconds and the robot's work time in the actual production plant is 1000 seconds, the difference is calculated as +100 seconds, and based on this difference, a correction value of 1.11 (1000 / 900) is created, or a correction value of +100 is calculated, and a processing model is created based on this, and a simulation for future product production is performed, then the virtual data for Task A can be processed through the processing model to track the actual data.

[0077]

[0078] Meanwhile, the operation plan of multiple robots generated by the planning system (100) may include information on the movement path of the robots.

[0079] That is, referring to FIG. 2, there are multiple robots operating in an actual production plant, and the multiple robots can perform multiple tasks, and when performing the tasks, information about the movement paths along which the robots move within the production plant can be included.

[0080] Specifically, by segmenting the robot's movement path, virtual data and performance data can be obtained through simulation for each segment, and it is possible to determine in which segment of the robot's movement path the difference between the virtual data and the performance data is severe, and to generate a correction value to reduce the difference in that segment, and to generate a processing model.

[0081] That is, a robot's path of movement includes a single or multiple segmented movement sections. While a robot's path may be linear, in many cases, the robot may visit multiple work spots (P) while moving from one work spot (P) to another, and may have a path that turns left or right at some point.

[0082] For example, as shown in Fig. 2, the movement path of the robot can be divided into multiple movement sections based on whether the robot rotates, and even if the robot does not rotate, if an event occurs in which it visits another work spot (P), the path can be divided into multiple movement sections based on this.

[0083] Based on this, performance data on robot operation results and virtual data on robot operation results may include information on the robot's work time for each movement section.

[0084] Additionally, the feedback system (550) can generate a correction value by calculating the difference between the performance data and virtual data regarding the robot's work time for each movement section.

[0085] For example, referring to FIGS. 2 and 3, when performing task A, the robot has movement sections of a, b, and c within the production plant (700), and when performing task B, the robot has movement sections of x, y, and z within the production plant (700).

[0086] When performing task A, the work time required in sections a, b, and c is the same as the virtual data and actual data according to the simulation results. On the other hand, when performing task B, the work time required in section x is significantly different between the virtual data and actual data, and there is no difference in the remaining sections y and z. Therefore, the difference value is calculated through the virtual data and actual data in section x, and a correction value is calculated through this, and a processing model can be created using this.

[0087]

[0088] Meanwhile, the robot operation plan generated by the planning system (100) includes information on the standard value of the robot's work time for each task. The standard value of the robot's work time for each task is a value set by the production plant manager and is a value for the general time required for the robot to perform the corresponding task. In other words, if it is assumed that the time required for the robot to perform task A is 1000 seconds, the standard value of the robot's work time for task A is 1000 seconds.

[0089] If the digital twin system (500) determines that the virtual robot operation result is outside the error range compared to the reference value, the digital twin system (500) determines that this is a special situation and does not transmit virtual data related to this to the feedback system (550).

[0090] That is, in the digital twin system (500), when the error range for task A is set to ±15%, if virtual data exceeding 1150 seconds or less than 850 seconds is obtained, the digital twin system (500) determines that this is a special situation and does not transmit the virtual data to the feedback system (550).

[0091] Meanwhile, the digital twin system (500) can collect virtual data that is determined to be outside the error range of the virtual robot operation result. That is, if virtual data that is outside the error range is continuously obtained as a result of the operation of the product production system according to the present invention, the manager may incorrectly set the reference value itself, and therefore, the manager may refer to the virtual data outside the error range collected by the digital twin system (500), reset the reference value, and reflect this in the planning system (100), thereby changing information on the reference value of the robot's work time included in the robot's operation plan.

[0092]

[0093] Meanwhile, the digital twin system (500) may further include a data preprocessing system (590). The data preprocessing system (590) may be a component of the feedback system (550) included in the digital twin system (500). That is, the data preprocessing system (590) may be included in the feedback system (550).

[0094] A data preprocessing system (590) like this can calculate a difference between performance data and virtual data, transmit this to a feedback system (550), and the feedback system (550) can generate a correction value based on the difference value received.

[0095] The data preprocessing system (590) may be included in the above systems, but it is also possible to construct it as a separate system, and a server may be provided in the data preprocessing system (590) to receive information from other systems or transmit information through the server.

[0096]

[0097]

[0098] Fig. 4 illustrates a flowchart of a method for controlling a product production system according to one embodiment of the present invention. Referring to Fig. 4, a method for controlling a product production system according to one embodiment of the present invention will be described.

[0099] A method for controlling a product production system according to one embodiment of the present invention includes a step (S101) in which a planning system generates an operation plan for a plurality of robots based on information including a parts transport plan required for product production; a step (S103) in which a digital twin system receives the operation plan for the robots from an ERP system and performs a simulation for product production to generate virtual data regarding virtual robot operation results; a step (S105) in which a feedback system receives performance data from the ERP system, receives virtual data from the digital twin system, calculates a difference between the performance data and the virtual data, and generates a correction value based on the calculated difference; a step (S107) in which the digital twin system generates a processing model based on the correction value generated by the feedback system; and a step (S109) in which the digital twin system performs a simulation for future product production to process virtual data regarding virtual robot operation results through the processing model.

[0100] Specifically, the planning system generates an operation plan for the robot (S101) and transmits it to the ERP system (300). The ERP system in turn transmits it to the digital twin system (500). The digital twin system (500) performs a simulation for product production using the received operation plan for the robot and produces virtual data regarding the virtual robot operation results (S103). The feedback system receives performance data from the ERP system (300) (S105-1), receives virtual data from the digital twin system (500), calculates a difference value through the difference between the performance data and the virtual data, and generates a correction value based on the difference value (S105-2).

[0101] The digital twin system receives correction values ​​and creates a processing model based on them (S107).

[0102] Afterwards, the robot operation plan can be regenerated (S201) by the planning system, and the digital twin system can receive it and produce virtual data (S203), and the digital twin system can process the virtual data (S109) using the generated processing model and compare it with the performance data.

[0103] If there is a difference from the actual data, the correction value can be generated again and the processing model can be regenerated so that the virtual data can follow the actual data.

[0104] Meanwhile, performance data on robot operation results and virtual data on robot operation results may include information on the time required for the robot to perform its work.

[0105] In addition, the robot's operation plan includes information on the standard value of the robot's operation time for each task, and if the digital twin system determines that the virtual robot operation result is outside the error range compared to the standard value, in the step (S105-2) of generating a correction value, the virtual data for it may not be transmitted to the feedback system.

[0106] A digital twin system may include a feedback system and a data preprocessing system, and the feedback system may include a data preprocessing system. In this case, the step (S105-2) of generating a correction value may include the data preprocessing system calculating a difference between actual data and virtual data, the data preprocessing system transmitting the calculated difference between actual data and virtual data to the feedback system, and the feedback system generating a correction value based on the received difference.

[0107]

[0108] Although the present invention has been illustrated and described with respect to specific embodiments thereof, it will be apparent to those skilled in the art that the present invention may be variously improved and modified without departing from the technical spirit of the present invention as defined by the following claims.

[0109]

[0110] [Explanation of symbols]

[0111] 100: Planning System

[0112] 300: ERP system

[0113] 500: Digital Twin System

[0114] 700: Production plant

Claims

1. A planning system that generates an operation plan for multiple robots based on information including a parts transport plan required for product production; An ERP (Enterprise Resource Planning) system that receives robot operation plans from the planning system and performance data on actual robot operation results from the production plant; A digital twin system that receives the robot operation plan from the ERP system, performs a simulation for product production, and produces virtual data on the virtual robot operation results; and A feedback system is provided within the digital twin system, receives performance data from the ERP system, receives virtual data from the digital twin system, calculates the difference between the performance data and the virtual data, and generates a correction value based on the calculated difference; A digital twin system is a product production system that creates a processing model based on the correction values generated by the feedback system, performs simulations for future product production, and processes virtual data on the results of virtual robot operation through the processing model.

2. In claim 1, A product production system characterized in that performance data on robot operation results and virtual data on robot operation results include at least one of information on the work time of the robot.

3. In claim 2, A product production system characterized in that the feedback system generates a correction value by calculating the difference between performance data and virtual data regarding the work time of the robot.

4. In claim 1, A product manufacturing system, characterized in that the robot's operation plan includes information about the robot's movement path.

5. In claim 4, A product production system, characterized in that the movement path of the robot includes a single or multiple segmented movement section, and the performance data on the robot operation result and the virtual data on the robot operation result include information on the work time required by the robot for each movement section.

6. In claim 5, A product production system characterized in that the feedback system generates a correction value by calculating the difference between performance data and virtual data regarding the work time of the robot for each moving section.

7. In claim 5, A product production system, characterized in that the movement path of the robot is divided into multiple movement sections based on whether the robot rotates.

8. In claim 1, A product production system characterized in that the robot's operation plan includes information on the standard value of the robot's operation time for each task, and the digital twin system does not transmit virtual data to the feedback system if the virtual robot operation result is judged to be outside the error range compared to the standard value.

9. In claim 8, A digital twin system is a product production system characterized by collecting virtual data in which the virtual robot operation results are judged to be outside the error range.

10. In claim 1, A digital twin system further includes a data preprocessing system, and the data preprocessing system is a product production system characterized by calculating the difference between performance data and virtual data.

11. In claim 10, A product production system characterized in that the data preprocessing system transmits the difference between the generated performance data and virtual data to the feedback system, and the feedback system generates a correction value based on the received difference value.

12. A step in which the planning system generates an operation plan for multiple robots based on information including a parts transport plan required for product production; A step in which the digital twin system receives the robot operation plan from the ERP system, performs a simulation for product production, and produces virtual data on the virtual robot operation results; A step in which the feedback system receives performance data from the ERP system and virtual data from the digital twin system, calculates the difference between the performance data and the virtual data, and generates a correction value based on the calculated difference; A step in which the digital twin system generates a processing model based on the correction value generated by the feedback system; and A method for controlling a product production system, comprising: a step of processing virtual data on the results of virtual robot operation through a processing model by having a digital twin system perform a simulation for future product production; 13. In claim 12, A method for controlling a product production system, characterized in that performance data on robot operation results and virtual data on robot operation results include information on the work time of the robot.

14. In claim 12, The robot's operation plan includes information on the standard time required for each robot task. The digital twin system determines that the virtual robot operation results are outside the error range compared to the reference value. At the stage of generating the correction value, A method for controlling a product production system, characterized in that virtual data therefor is not transmitted to a feedback system.

15. In claim 12, The digital twin system includes a feedback system and a data preprocessing system. The steps to generate the correction value are: A method for controlling a product production system, characterized in that a data preprocessing system calculates a difference between performance data and virtual data, the data preprocessing system transmits the calculated difference between performance data and virtual data to a feedback system, and the feedback system generates a correction value based on the received difference.

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