Method and system for controlling operating parameter of paint shop, and computer program product

Abstract

The present application provides a method for controlling an operating parameter of a paint shop, the method comprising the following steps: monitoring movement feature information of a workpiece (15) on a conveying apparatus (16) of a paint shop; and controlling an operating parameter of one or more process subsystems (17) of the paint shop, at least on the basis of the movement feature information of the workpiece (15). The present application further provides a system for controlling an operating parameter of a paint shop, and a computer program product. According to embodiments of the present application, movement feature information of respective workpieces (15) on a conveying apparatus (16) of a paint shop is introduced as a control factor, which can effectively increase the flexibility and intelligence of a process subsystem (17) of a paint shop, and increases the energy operating efficiency of the paint shop.

Description

[0001] Method and system for controlling operating parameter of paint shop, and computer program product

[0002] The present application relates to the technical field of automobile painting, in particular a method for controlling an operating parameter of a paint shop, a system for controlling an operating parameter of a paint shop, and a computer program product, used for at least helping to implement steps of the method according to the present application.

[0003] In a paint shop of an automobile production line, during production, from body-in-white welding to coloured vehicle body assembly, various painting processes must be performed, comprising degreasing, surface conditioning, phosphating, passivation, sealing, underbody protection, polishing, intermediate coat application, adhesive application, top coat application, clear coat application, touchup and / or waxing, etc.

[0004] Since these painting processes have different requirements for operating parameters, such as temperature, humidity and airflow, it is necessary, in respective process steps, to turn on a corresponding device in advance and run the device for a period of time before being able to cause a process subsystem to achieve the required production conditions. In addition, coordination and interrelation between respective process subsystems are poor.

[0005] At present, most paint shops use manual monitoring and control to operate devices, which not only wastes a lot of labor power, but also means it is difficult to accurately control suitable on / off times for respective process subsystems, wherein a premature turn-on time wastes energy, and a delayed turn-on time means the operating environment of the process subsystem is unable to satisfy production conditions.

[0006] Moreover, this reliance on manual operation is also inherently prone to human error. An operator may incorrectly judge the necessary ramp-up time based on ambient conditions, forget a step in a complex start-up sequence, or fail to react promptly to an unplanned production stoppage. Such errors directly contribute to inconsistent product quality and significant resource waste.

[0007] To mitigate some of these issues, automated systems have been developed. However, these systems typically suffer from a lack of flexibility and adaptability. A common approach involves using fixed time buffers, where subsystems are turned on a predetermined amount of time before production is scheduled to start. This approach is inherently inefficient, as itdoes not account for real-time production conditions and often leads to unnecessary energy and resource consumption while subsystems idle in a state of readiness.

[0008] Even more advanced systems, such as those controlled by a Manufacturing Execution System (MES), typically employ static, pre-programmed switching sequences. Such sequences are rigid and fail to adapt to the actual production flow, unplanned interruptions, or dynamic workpiece movement data. For example, production breaks are often not taken into account, causing subsystems to continue running in a full-operation state for extended periods, further wasting energy.

[0009] A significant drawback of these existing systems is their lack of integration with dynamic, real-time parameters. They generally do not consider critical information such as the actual conveyor speed, the current occupancy of buffer zones, or the forecasted arrival times of specific workpieces at various processing stations. This lack of real-time awareness means that the control logic cannot make intelligent, predictive decisions to optimize subsystem operations.

[0010] Furthermore, prior art solutions do not typically account for variable ramp-up times that can change with environmental conditions, such as seasonal temperature or humidity fluctuations, which affect how long a system needs to prepare for operation. Similarly, shutdown routines are generally manual or based on fixed timers, failing to factor in the residual heat or inertia of subprocess conditions, which could be leveraged for more efficient power-down cycles.

[0011] Consequently, there is no granular control of energy-saving modes, such as distinct "pause", "standby", "hibernation", "sleep" or "shutdown" modes, based on real-time process data. Subsystems may run idle for extended periods when a short pause would be more appropriate, or are shut down completely when a low-power standby mode would allow for a quicker restart. Finally, existing solutions rarely include a semi-automatic suggestion mode to assist operators in optimizing the management of idle periods, leaving them without the tools to make more efficient decisions in situations that do not warrant full automation.

[0012] Therefore, there is a clear need in the art for an improved control method and system that overcomes these limitations by dynamically and intelligently managing paint shop subsystems based on real-time workpiece and process data to significantly reduce energy consumption and improve operational efficiency.Therefore, there is certain room for improvement for production management of process subsystems of paint shops at present.

[0013] From EP 3095015 B1 a device for operating an automation plant is known, which defines an architecture composed of an automation control system, an energy control system and a superordinate control system and which describes the interfaces and the communication between the systems. In order to control the energy consumption of the automation plant, switching sequences are determined by the energy control system using information from the automation control system and the superordinate control system, and are carried out, wherein the energy control system, in the context of carrying out a switching sequence, gives switching commands to the automation control system, as a result of which equipment items of sub-systems of the automation plant are switched at least temporarily into operating states with reduced energy consumption.

[0014] The present invention is therefore based on the object of providing a method for controlling an operating parameter of a paint shop, a system for controlling an operating parameter of a paint shop, and a computer program product, to at least partially solve the above-mentioned problems of the prior art.

[0015] According to a first aspect of the present application, a method for controlling an operating parameter of a paint shop is provided, the method comprising the following steps:

[0016] monitoring movement feature information of a workpiece on a conveying apparatus of the paint shop; and

[0017] controlling an operating parameter of one or more process subsystems of the paint shop, at least on the basis of the movement feature information of the workpiece.

[0018] The core concept of the present application comprises a method for controlling the operating modes of process subsystems in a paint shop by introducing the movement feature information of a workpiece on a conveying apparatus as a primary control factor. To achieve this, movement data of the workpieces is recorded - such as their position, direction, the timing sequences of previous workpieces, and the number of workpieces in buffer zones -and combined with conveyor system parameters, such as its speed. Based on this data, the system predicts the time axis information, i.e. , when current and upcoming workpieces will reach certain process subsystems. Using these time predictions, the subsystems’ start, stop, and switching times are controlled. This allows for automatically changing operating modes between production (task mode), break (pause mode), and standby (hibernation mode). The calculation for these switching times also considers factors like equipment ramp-up timesand rest capacities (e.g., heat capacities). Furthermore, based on the active operating mode, technical parameters - such as airflow, temperature, humidity, water circulation, or lighting -are automatically adjusted. This approach thus effectively increases the flexibility and intelligence of the paint shop's process subsystems, leading to improved energy operating efficiency.

[0019] The method preferably minimizes repeated switching operations by the operator, reduces labor as well as the risk of human error.

[0020] According to an exemplary embodiment of the present application, all workpieces undergo the same treatment routine.

[0021] According to another exemplary embodiment of the present application, the movement feature information of the workpiece may comprise time axis information of a first workpiece on the conveying apparatus of the paint shop in a process subsystem of the paint shop, position information and movement direction information of a present workpiece on the conveying apparatus of the paint shop, and / or a quantity of workpieces to be painted in a buffer zone of the paint shop, etc.

[0022] Position information data and the production schedule can be retrieved from a MES.

[0023] Position information data can be obtained from or via reading points on the conveying apparatus or a conveying system as well as via incremental encoders or by indirect calculation of the position based on transport times in the conveyor system.

[0024] According to another exemplary embodiment of the present application, time axis information of a workpiece in a process subsystem of the paint shop is predicted at least on the basis of the time axis information of the first workpiece, the position information and movement direction information of the present workpiece on the conveying apparatus and / or an operating parameter of the conveying apparatus, wherein the operating parameter of the conveying apparatus, for example, comprises a conveying speed of the conveying apparatus and / or a process by which the conveying speed of the conveying apparatus changes with time.

[0025] According to another exemplary embodiment of the present application, the predicted time axis information of the workpiece may comprise time axis information of the present workpiece on the conveying apparatus of the paint shop in the process subsystem of thepaint shop, and / or time axis information of a workpiece to be painted in a buffer zone of the paint shop in a process subsystem of the paint shop, wherein the workpiece to be painted in particular is a next workpiece or a final workpiece to be painted in the buffer zone of the paint shop.

[0026] According to another exemplary embodiment of the present application, a turn-on time and a turn-off time of one or more process subsystems of the paint shop are adjusted at least on the basis of the time axis information of the first workpiece and / or the time axis information of a final workpiece.

[0027] By such a means, continuity between the turn-on times and turn-off times of the respective process subsystems is effectively established, achieving a reduction in the overall time of the process flow of the paint shop, saving on the overall energy consumption of the paint shop, and further being able to avoid energy waste due to early turn-on or late turn-off, and the effect of either on production.

[0028] According to another exemplary embodiment of the present application, a switching time of an operating mode of a process subsystem of the paint shop may be controlled at least on the basis of production schedule information of the process subsystem of the paint shop and the predicted time axis information of the workpiece.

[0029] According to another exemplary embodiment of the present application, the operating mode comprises at least one of the following: a task mode, a pause mode, a hibernation mode, a shutdown mode, a maintenance mode, an idle mode and a semi-automatic mode.

[0030] In addition to hibernation mode, standby mode and / or sleep mode may also be provided as operating modes, wherein the standby mode involves a break with a moderate energy consumption, whereas the standby mode involves short idle time of the respective process subsystem.

[0031] It can be provided that operating modes are adjusted automatically based on real-time movement data of workpieces, conveyor parameters, and the production schedule, rather than fixed timers.

[0032] Intelligent and / or predictive activation and / or deactivation of the subsystems' processes can reduce electricity, water, heating, cooling, and ventilation usage.Each operating mode has preferably defined parameter settings (temperature, humidity, airflow, lighting) for maximum efficiency according to process requirements.

[0033] Optionally, an airflow, a painting environment temperature, a painting environment humidity, a circulating water flow and / or an illuminance, etc. of one or more process subsystems of the paint shop may be adjusted at least on the basis of the operating mode of the process subsystem.

[0034] Optionally, a drying environment temperature, a drying environment airflow, a pretreatment zone tank liquid circulating flow and / or operating parameters, such as humidity, temperature and airflow, of one or more online / offline repair stations may be adjusted at least on the basis of the operating mode of the process subsystem. In this case, by additionally introducing production schedule information of the process subsystems as a control factor to participate in operating parameter control of the process subsystems, the flexibility and intelligence of the process subsystems of the paint shop can be effectively increased, and the energy operating efficiency of the paint shop is increased.

[0035] According to another exemplary embodiment of the present application, the switching time is determined by a ramp-up time of a process subsystem of the paint shop.

[0036] The calculation of the time for switching an operating mode then results from subtracting the determined ramp-up time from the original calculation. This ensures that the desired production is determined instead of the start of the ramp-up phase.

[0037] Ramp-up times or start-up times can be tailored to each process and thereby can take into account constant or weather-dependent ramp-up characteristics, preventing premature activation and unnecessary energy consumption.

[0038] This allows the activation of processes to be precisely adjusted to the ideal start of production, thereby reducing idle times and wear and tear on the equipment.

[0039] According to another exemplary embodiment of the present application, for a process subsystem with a constant ramp-up time, the ramp-up time is configured by a user.

[0040] Process subsystems having a constant ramp-up time can be coating baths of a paint shop operated under constant hall conditions.According to another exemplary embodiment of the present application, for a process subsystem with a weather-dependent ramp-up time, the ramp-up time is determined using a characteristic map that relates weather conditions to ramp-up times, wherein preferably the determination is based on a predetermined past time including at least the last four seasons.

[0041] If at least one year is used as the basis for determining the ramp-up time, this ensures that the climatic conditions for all seasons are represented in the data set or in the characteristic map.

[0042] According to another exemplary embodiment of the present application, for a process subsystem with an unknown ramp-up time, the ramp-up time is estimated from historical data.

[0043] According to another exemplary embodiment of the present application, the estimation from historical data is based on a predetermined number of last ramp-up times and / or ramp-up times from a predetermined past time.

[0044] According to another exemplary embodiment of the present application, the historical data comprises operating experience data from one or more other paint shops.

[0045] According to another exemplary embodiment of the present application, the estimation from historical data is performed by an artificial intelligence system configured to learn the ramp-up times from the historical data, wherein preferably the learning is repeated iteratively.

[0046] The learning or training of the artificial intelligence system can be based on machine learning and / or statistical evaluation.

[0047] According to another exemplary embodiment of the present application, the ramp-up time is determined independently for transitions from pause mode to task mode, from hibernation mode to task mode, and / or from shutdown mode to task mode.

[0048] According to another exemplary embodiment of the present application, the turn-off time is determined by taking into account a shutdown inertia of the process subsystem.

[0049] This applies to, for example, drying processes, coating processes, and painting processes, i.e. in particular in ovens, baths, and booths.Shutdown routines take into account process inertia and remaining heat which enables deactivation without affecting quality and reducing energy waste.

[0050] According to another exemplary embodiment of the present application, the process subsystem is switched to pause mode, hibernation mode, or shutdown mode at a predetermined time before a final workpiece has exited the process subsystem, wherein the switching is timed such that operating parameters of the process subsystem remain within a predefined production window until the final workpiece has exited.

[0051] According to another exemplary embodiment of the present application, in pause mode, hibernation mode, or shutdown mode, an intermediate temperature of the process subsystem is maintained to achieve a lower total energy consumption.

[0052] According to another exemplary embodiment of the present application, the intermediate temperature is determined by balancing the energy consumption for maintaining the intermediate temperature during an idle period and subsequent ramp-up against the energy consumption for ramping up from an ambient temperature.

[0053] According to another exemplary embodiment of the present application, the process subsystem of the paint shop comprises a pretreatment electrophoresis system, a powder spraying system, an adhesive application system, a paint spraying system, an oven system, a water circulating system, a ventilation system, a lighting system and / or polishing repair station, etc.

[0054] According to another exemplary embodiment of the present application, in pause mode of one or more process subsystems of the paint shop, at least one of the following is applied:

[0055] humidity is reduced, for example, by slower fluid pumping or by decreasing fluid supply, light intensity is dimmed,

[0056] temperature is reduced,

[0057] ventilation is reduced, and

[0058] frequency of recirculating pumps is reduced.

[0059] According to another exemplary embodiment of the present application, in hibernation mode of one or more process subsystems of the paint shop, at least one of the following is applied:

[0060] only fresh air ventilation remains in full operation,

[0061] humidity is reduced, for example, by switching off fluid pumping,

[0062] lighting is turned off, andrecirculating pumps are shut off.

[0063] According to another exemplary embodiment of the present application, in shutdown mode of one or more process subsystems of the paint shop, at least one of the following is applied:

[0064] all painting-related equipment is switched off,

[0065] all drying-related equipment is switched off,

[0066] ventilation is switched off,

[0067] fluid circulation is switched off, and

[0068] all stations and / or systems are switched off.

[0069] According to another exemplary embodiment of the present application, in maintenance mode of one or more process subsystems of the paint shop, operating of one or more predefined process subsystems is temporarily intensified, for example increasing of fresh air ventilation, to allow entry into one or more process subsystems for maintenance purposes.

[0070] According to another exemplary embodiment of the present application, in semi-automatic mode of one or more process subsystems of the paint shop, a control system of the paint shop requests manual approval for operating mode selection and / or activation.

[0071] In semi-automatic mode, suggesting mode changes to the operator preferably combines the benefits of automation with human oversight.

[0072] According to another exemplary embodiment of the present application, in pause mode of the process subsystems, the coating environment humidity of the one or more process subsystems is adjusted by controlling a circulation flow velocity in the pretreatment electrophoresis system, for example, by reducing an operating frequency of a circulating pump of the pretreatment electrophoresis system and / or reducing a water valve opening of the water circulation system to reduce the amount of liquid circulation in the pretreatment electrophoresis system.

[0073] According to another exemplary embodiment of the present application, in pause mode of the process subsystems, the light intensity of the one or more process subsystems is reduced by controlling lighting parameters.

[0074] According to another exemplary embodiment of the present application, in pause mode of the process subsystems, an allowable operating temperature range of the powder spraying system and / or the adhesive application system and / or the paint spraying system is expandedto reduce the air volume of the ventilation system of the powder spraying system and / or the adhesive application system and / or the paint spraying system.

[0075] According to another exemplary embodiment of the present application, in pause mode of the process subsystems, the coating environment temperature of the one or more process subsystems, in particular the temperature of a drying environment of the oven system and / or the temperature of one or more online and offline maintain stations, is reduced by controlling an opening of a cold water valve / hot water valve of the oven system and / or operating parameters of a burner, for example, by reducing an operating power of the burner and / or reducing the opening of the cold water valve / hot water valve.

[0076] According to another exemplary embodiment of the present application, in pause mode of the process subsystems, an operating power of the ventilation system of the one or more polishing repair stations is reduced, for example, by closing a chamber of one or more stations and / or reducing a fan frequency and / or fan speed of the ventilation system of one or more stations.

[0077] According to another exemplary embodiment of the present application, in hibernation mode of the process subsystems, a fan of an internal air flow circulation system of the powder spraying system and / or the adhesive application system and / or the paint spraying system is turned off, and only a fan of a fresh air circulation system is turned on.

[0078] According to another exemplary embodiment of the present application, in hibernation mode of the process subsystems, part of the fans of the ventilation system of the oven system is turned off, and optionally, the speed and / or frequency of other fans of the ventilation system of the oven system are reduced.

[0079] According to another exemplary embodiment of the present application, in hibernation mode of the process subsystems, the coating environment humidity of the one or more process subsystems is reduced by turning off a circulating pump in the pretreatment electrophoresis system.

[0080] According to another exemplary embodiment of the present application, in hibernation mode of the process subsystems, the lighting system of the one or more process subsystems is turned off.According to another exemplary embodiment of the present application, in shutdown mode of the process subsystems, all production devices assigned to the pretreatment electrophoresis system are turned off.

[0081] According to another exemplary embodiment of the present application, in shutdown mode of the process subsystems, the ventilation system of the powder spraying system and / or the adhesive application system and / or the paint spraying system are turned off, the ventilation system comprising an internal air flow circulation system and a fresh air circulation system.

[0082] According to another exemplary embodiment of the present application, in shutdown mode of the process subsystems, the water circulating system, a burner and the ventilation system of the oven system are turned off.

[0083] According to another exemplary embodiment of the present application, in a shutdown mode of the process subsystems, all chambers of the polishing repair stations are closed and the ventilation systems of the polishing repair stations are turned off.

[0084] According to a second aspect of the present application, a system for controlling an operating parameter of a paint shop is provided, wherein the system may comprise the following components:

[0085] at least one monitoring unit, which is configured for monitoring movement feature information of a workpiece on a conveying apparatus of the paint shop; and

[0086] at least one control unit, which is configured for executing the method according to the present application.

[0087] The system preferably responds to changes in conveyor speed, buffer availability, and environmental influences, ensuring optimal process readiness.

[0088] According to another exemplary embodiment of the present application, the system further comprises a workpiece tracking system with one or more human-machine interfaces, in particular one or more touch screens, to visualize, track, and / or control the workpieces within the paint shop.

[0089] According to another exemplary embodiment of the present application, the workpiece tracking system is configured to provide an operator with workpiece-related information and / or information related to one or more process subsystems, in particular one or more paint application or drying stations of the paint shop.The workpiece tracking system can preferably provide the operator with the locationsof the workpieces, the directions of the workpieces, and / or estimated arrival times of the workpieces at predetermined process stations. Preferably, the workpiece tracking system may also provide or display for each workpiece the applied paint or the paint to be applied.

[0090] According to a third aspect of the present application, a computer program product is provided, such as a computer readable program carrier, including a computer program instruction, when executed by a processor, causing the processor to carry out the steps of the method of the present application.

[0091] Below, the present application is described in further detail with reference to the accompanying drawings, such that the principles, characteristics and advantages of the present application can be better understood. In the accompanying drawings:

[0092] Fig. 1 shows a workflow diagram of a method for controlling an operating parameter of a paint shop according to an exemplary embodiment of the present application;

[0093] Fig. 2 shows a schematic block diagram of a system for controlling an operating parameter of a paint shop according to an exemplary embodiment of the present application;

[0094] Fig. 3 shows a schematic block diagram of a workpiece tracking system; and

[0095] Fig. 4 shows the workpiece tracking system of Fig. 3 after an operator selected a specific workpiece and a specific process subsystem.

[0096] To clarify the technical problem to be solved, technical solutions and beneficial technical effects of the present application, the present application is explained in further detail below in view of the accompanying drawings and multiple exemplary embodiments. It should be understood that the particular embodiments described here are provided only to explain the present application, rather than limiting the scope of protection of the present application.

[0097] Fig. 1 shows a workflow diagram of a method for controlling an operating parameter of a paint shop according to an exemplary embodiment of the present application. Below, exemplary embodiments describe the method according to the present application in more detail.As shown in Fig. 1, the method may comprise steps S1 and S2. In step S1, movement feature information of a workpiece on a conveying apparatus in a paint shop may be monitored.

[0098] In the present embodiment of the present application, a paint shop of an automobile production line is fitted with a conveying apparatus, and, using the conveying apparatus, a workpiece to be painted, in particular a vehicle body to be painted, may be sequentially conveyed through various process subsystems of the paint shop, and corresponding painting process are performed on the workpiece on the conveying apparatus at the respective process subsystems, comprising degreasing, surface conditioning, phosphating, passivation, sealing, underbody protection, polishing, intermediate coat application, top coat application, clear coat application, touchup and / or waxing, etc.

[0099] The process subsystems of the paint shop may be adjusted according to workpiece production processes and, for example, comprise a pretreatment electrophoresis system, a powder spraying system, an adhesive application system, a paint spraying system, an oven system, a water circulating system, a ventilation system, a lighting system and / or polishing repair station, etc.

[0100] A monitoring unit 11 is provided at intervals of fixed distance, for example, on the production line of the paint shop, and can monitor and record time information and movement direction information of a workpiece passing through the monitoring unit 11, thereby acquiring movement feature information of the painted present workpiece on the conveying apparatus of the paint shop, comprising the position information and movement direction information thereof, wherein the position information is used for representing the position of the present workpiece on the production line, and the movement direction information is used for representing the conveying direction of the present workpiece between the respective process subsystems.

[0101] After a painted first workpiece on the conveying apparatus has been conveyed through all the process subsystems of the paint shop, time information of the first workpiece passing through the respective monitoring units 11 is recorded by all the monitoring units 11 arranged on the production line of the paint shop, and time axis information of the first workpiece in the process subsystem of the paint shop may be determined on the basis of the recorded time information and an operating parameter of the conveying apparatus, wherein the operating parameter of the conveying apparatus may be stored in a control unit 12 of a system 1 for controlling an operating parameter of the paint shop.The operating parameter of the conveying apparatus, for example, is a conveying speed of the conveying apparatus, and also may be a process by which the conveying speed of the conveying apparatus changes with time.

[0102] In addition, a monitoring unit 11 may also be mounted in a buffer zone of the paint shop, and a quantity of workpieces to be painted in the buffer zone of the paint shop may be acquired by means of the monitoring unit 11; these workpieces to be painted are all sequentially conveyed through the respective process subsystems of the paint shop in subsequent painting processes.

[0103] In step S2, an operating parameter of one or more process subsystems of the paint shop may be controlled at least on the basis of the movement feature information of the workpiece.

[0104] In this case, time axis information of a workpiece in respective process subsystems of the paint shop may be predicted at least on the basis of the time axis information of the first workpiece, the position information and movement direction information of the painted present workpiece on the conveying apparatus and / or an operating parameter of the conveying apparatus, wherein the operating parameter of the conveying apparatus may likewise comprise a conveying speed of the conveying apparatus and / or a process by which the conveying speed of the conveying apparatus changes with time.

[0105] In this case, not only is it possible to predict the time axis information of the painted present workpiece on the conveying apparatus of the paint shop in the respective process subsystems of the paint shop, but it is also possible to predict the time axis information of a workpiece to be painted in a buffer zone of the paint shop in the respective process subsystems of the paint shop, which in particular comprises the time axis information of a next workpiece to be painted in the buffer zone - i.e. the next workpiece after the painted presented workpiece in the production line of the paint shop - in the respective process subsystems of the paint shop and / or the time axis information of a final workpiece to be painted in the buffer zone - i.e. the final painted workpiece of this batch of workpieces to be painted planned in the production line of the paint shop - in the respective process subsystems of the paint shop.

[0106] Since the respective process subsystems of the paint shop must operate for a period of time before being able to achieve a required operating parameter in the process flow thereof -comprising a painting environment temperature and / or a painting environment humidity, etc., which implies that higher time and energy costs are necessary for each machine start process of the process subsystems, the corresponding process subsystem is generally turned off only after the process step is completed for all workpieces of the present batch.

[0107] For this reason, the turn-on time and turn-off time of one or more process subsystems of the paint shop can be adjusted at least on the basis of the time axis information of the first workpiece and / or the time axis information of the final workpiece, thereby automatically coordinating on / off times of the respective process subsystems, in particular effectively establishing continuity between the turn-on times and turn-off times of the respective process subsystems, achieving a reduction in the overall time of the process flow of the paint shop, saving on the overall energy consumption of the paint shop, and further being able to avoid energy waste due to early turn-on or late turn-off, and the effect of either on production.

[0108] Optionally, a safety margin time can further be set for the turn-on times and turn-off times of the respective process subsystems, to eliminate the effect of early turn-on or late turn-off on production as much as possible.

[0109] Given that operators of the respective process subsystems of the paint shop do not work constantly, for example, an operator having to rest at intervals, having to rest during the night when not on shift, further having to rest on statutory holidays, etc., different operating modes may be respectively set for the respective process subsystems of the paint shop, such that the operating states of the respective process subsystems of the paint shop can flexibly adapt to the schedules of the operators, thus increasing the intelligence of the process subsystems of the paint shop.

[0110] As an example, the operating modes may comprise:

[0111] a task mode, the process subsystem maintaining a painting task state in the task mode, for performing a corresponding painting process on a workpiece;

[0112] a pause mode, the process subsystem operating in a pause state for different painting task states in the pause mode, wherein the pause state may last 1 to 24 hours for example; and / or

[0113] a hibernation mode, the process subsystem operating in a hibernation state for different painting task states and pause states in the hibernation mode, wherein the hibernation state may last one day to a number of days for example, etc.In this case, a switching time of an operating mode of a process subsystem of the paint shop may be controlled at least on the basis of production schedule information of the process subsystem of the paint shop and the predicted time axis information of the workpiece.

[0114] The production schedule information not only comprises production arrangements and rest arrangements for respective time periods each day, but also comprises a classification label for whether a respective day is a workday or a holiday, so that the operating mode of the process subsystem can be automatically switched to the pause mode when the operator will be resting, and the operating mode of the process subsystem is automatically switched to the hibernation mode when the operator is on holiday.

[0115] In the different operating modes of the process subsystem, operating parameters of the respective process subsystems of the paint shop are also different. In this case, operating parameters, such as an airflow, a painting environment temperature, a painting environment humidity, a circulating water flow and / or an illuminance of one or more process subsystems of the paint shop may be adjusted at least on the basis of the operating mode of the process subsystem.

[0116] As an example, in the pause mode of the process subsystem:

[0117] an airflow of a ventilation system may be adjusted by means of controlling a fan speed, in particular a drying environment airflow and / or an airflow of one or more online / offline repair stations, etc.;

[0118] a painting environment humidity of one or more process subsystems may further be adjusted by means of controlling a circulating flow speed in a pretreatment device, in particular a humidity of one or more online / offline repair stations, etc.;

[0119] an illuminance of one or more process subsystems may also be adjusted by means of controlling a lamplight parameter;

[0120] a painting environment temperature of one or more process subsystems may also be adjusted by means of controlling an opening degree of a cold water valve / hot water valve of an oven system and / or an operating parameter of a burner, in particular a drying environment temperature and / or a temperature of one or more online / offline repair stations, etc.;

[0121] a circulating water flow of a water circulating system may also be adjusted by means of controlling an opening degree of a water valve of the water circulating system, in particular a pretreatment zone tank liquid circulating flow, etc.By means of adjusting these parameters, the energy consumed by a process subsystem in the pause mode may be saved on, and the process subsystem is caused to maintain a standby state that is able to quickly enter the task mode, thereby saving on energy cost and time cost of the process subsystem, in particular able to greatly reduce the overall energy consumption of the paint shop at low production line utilization.

[0122] Compared to operating parameters in the task mode of the process subsystem, in the hibernation mode of the process subsystem, an airflow of a ventilation system may be reduced by means of controlling a fan speed; a painting environment humidity may also be reduced by means of turning off a circulating pump in a pretreatment device; lamplight and unneeded functional modules may also be turned off, etc. By means of adjusting these parameters, energy consumption of the process subsystem in the hibernation mode may be saved on as much as possible.

[0123] According to an embodiment of the present application, movement feature information of a workpiece on a conveying apparatus of a paint shop is introduced as a control factor, and time axis information of the workpiece in respective process subsystems of the paint shop can be predicted, and an operating parameter of the respective process subsystems of the paint shop is adjusted on the basis of the predicted time axis information.

[0124] Additionally, production schedule information of the respective process subsystems may further be introduced as a control factor to participate in operating parameter control of the respective process subsystems.

[0125] Thus, the flexibility and intelligence of the respective process subsystems of the paint shop are effectively increased, and the energy operating efficiency of the paint shop is increased.

[0126] In addition, it should be noted that the step numbers described here do not necessarily represent a sequential order, rather are merely reference numerals; the order can be changed according to particular situations, as long as the technical object of the present application can be achieved.

[0127] Fig. 2 shows a schematic block diagram of a system for controlling an operating parameter of a paint shop according to an exemplary embodiment of the present application.

[0128] As shown in Fig. 2, the system 1 may comprise the following components:monitoring unit 11, which is configured for monitoring movement feature information of a workpiece on a conveying apparatus of a paint shop; and

[0129] a control unit 12, which is configured for executing the method according to the present application.

[0130] If an example comprises a relation of “and / or” between a first feature and a second feature, then it should be interpreted as follows: according to one embodiment, the example not only has the first feature but also has the second feature; and according to another embodiment, the example either only has the first feature or only has the second feature.

[0131] Although the above has described particular solutions, these solutions do not limit the scope of the disclosure of the present application, even when only a single solution is described with respect to a specific feature. The features provided in the disclosure of the present application are cited for the purpose of illustration by example, rather than to limit or eliminate different expressions. In the particular embodiments, according to actual requirements, in technically feasible situations, multiple features may be combined with each other. Without departing from the spirit and scope of the present application, various substitutions, changes and transformations are also conceivable.

[0132] Fig. 3 shows a schematic view of a workpiece tracking system 13 of the system 1, wherein the workpiece tracking system 13 comprises one or more human-machine interfaces 14, for example one or more touchscreens.

[0133] A human-machine interface 14 allows workpieces 15 to be visualized in a schematic representation of the paint shop, whose conveying apparatus 16 and process subsystems 17 are also shown schematically.

[0134] The workpieces 15 can be tracked via the human-machine interface 14 by displaying at least their position and direction, with the direction being indicated, for example, by arrows at the respective workpiece 15.

[0135] Fig. 4 shows a first information box 18 for a selected workpiece 15 and a second information box 19 for selected process subsystem 17. Both boxes 18, 19 can be displayed, for example, by tapping on them on the human-machine interface 14.The first information box 18 may, for example, contain information about the applied paint, the paint to be applied, or the estimated arrival time of the selected workpiece at the next process subsystem.

[0136] The second information box 19 may, for example, contain information about the temperature, humidity, light intensity, ventilation degree, the ramp-up time or the operating mode.

[0137] Reference signs

[0138] I system

[0139] II monitoring unit

[0140] 12 control unit

[0141] 13 workpiece tracking system

[0142] 14 human-machine interface

[0143] 15 workpiece

[0144] 16 conveying apparatus

[0145] 17 process subsystems

[0146] 18 first information box

[0147] 19 second information box

[0148] 51 monitoring

[0149] 52 controlling

Claims

Claims1. Method for controlling an operating parameter of a paint shop, the method comprising the following steps:monitoring (S1) movement feature information of a workpiece (15) on a conveying apparatus (16) of the paint shop; andcontrolling (S2) an operating parameter of one or more process subsystems (17) of the paint shop, at least on the basis of the movement feature information of the workpiece (15).

2. Method according to Claim 1 , wherein the movement feature information of the workpiece (15) comprisestime axis information of a first workpiece (15) on the conveying apparatus (16) of the paint shop in a process subsystem (17) of the paint shop,position information and movement direction information of a present workpiece (15) on the conveying apparatus (16) of the paint shop, and / ora quantity of workpieces (15) to be painted in respective buffer zones of the paint shop.

3. Method according to Claim 2, wherein time axis information of a workpiece (15) in a process subsystem (17) of the paint shop is predicted at least on the basis of the time axis information of the first workpiece (15), the position information and movement direction information of the present workpiece (15) on the conveying apparatus (16) and / or an operating parameter of the conveying apparatus (16), wherein the operating parameter of the conveying apparatus (16), for example, comprises a conveying speed of the conveying apparatus (16) and / or a process by which the conveying speed of the conveying apparatus (16) changes with time.

4. Method according to Claim 3, wherein the predicted time axis information of the workpiece comprises time axis information of the present workpiece (15) on the conveying apparatus (16) of the paint shop in the process subsystem (17) of the paint shop, and / or time axis information of a workpiece (15) to be painted in a buffer zone of the paint shop in a process subsystem (17) of the paint shop, wherein the workpiece (15) to be painted in particular is a next workpiece (15) or a final workpiece (15) to be painted in the buffer zone of the paint shop.

5. Method according to one of Claims 2 to 4, wherein a turn-on time and a turn-off time of one or more process subsystems (17) of the paint shop are adjusted at least on the basis of the time axis information of the first workpiece (15) and / or the time axis information of a final workpiece (15).

6. Method according to one of Claims 3 to 5, wherein a switching time of an operating mode of a process subsystem (17) of the paint shop is controlled at least on the basis of production schedule information of the process subsystem (17) of the paint shop and the predicted time axis information of the workpiece (15).

7. Method according to Claim 6, wherein the operating mode comprises at least one of the following: a task mode, a pause mode, a hibernation mode, a shutdown mode, a maintenance mode, an idle mode and a semi-automatic mode.

8. Method according to Claim 6 or 7, wherein, at least one the basis of the operating mode of the process subsystem (17), at least one of the following is adjusted for one or more process subsystems (17) of the paint shop:an airflow,a temperature,a humidity,a circulating liquid flow, andan illuminance.

9. Method according to one of Claims 6 to 8, wherein the switching time is determined by a ramp-up time of a process subsystem (17) of the paint shop.

10. Method according to Claim 9, wherein for a process subsystem (17) with a constant ramp-up time, the ramp-up time is configured by a user.

11. Method according to Claim 9, wherein for a process subsystem (17) with a weatherdependent ramp-up time, the ramp-up time is determined using a characteristic map that relates weather conditions to ramp-up times, wherein preferably the determination is based on a predetermined past time including at least the last four seasons.

12. Method according to Claim 9, wherein for a process subsystem (17) with an unknown ramp-up time, the ramp-up time is estimated from historical data.

13. Method according to Claim 12, wherein the estimation from historical data is based on a predetermined number of last ramp-up times and / or ramp-up times from a predetermined past time.

14. Method according to Claim 12 or 13, wherein the historical data comprises operating experience data from one or more other paint shops.

15. Method according to one of Claims 12 to 14, wherein the estimation from historical data is performed by an artificial intelligence system configured to learn the ramp-up times from the historical data, wherein preferably the learning is repeated iteratively.

16. Method according to one of Claims 9 to 15, wherein the ramp-up time is determined independently for transitions from pause mode to task mode, from hibernation mode to task mode, and / or from shutdown mode to task mode.

17. Method according to one of Claims 5 to 16, wherein the turn-off time is determined by taking into account a shutdown inertia of the process subsystem (17).

18. Method according to Claim 17, wherein the process subsystem (17) is switched to pause mode, hibernation mode, or shutdown mode at a predetermined time before a final workpiece (15) has exited the process subsystem (17), wherein the switching is timed such that operating parameters of the process subsystem (17) remain within a predefined production window until the final workpiece (15) has exited.

19. Method according to one of Claims 7 to 18, wherein in pause mode, hibernation mode, or shutdown mode, an intermediate temperature of the process subsystem (17) is maintained to achieve a lower total energy consumption.

20. Method according to Claim 19, wherein the intermediate temperature is determined by balancing the energy consumption for maintaining the intermediate temperature during an idle period and subsequent ramp-up against the energy consumption for ramping up from an ambient temperature.

21. Method according to one of Claims 1 to 20, wherein the process subsystem (17) of the paint shop comprises at least one pretreatment electrophoresis system, at least one powder spraying system, at least one adhesive application system, at least one paint spraying system, at least one oven system, at least one fluid circulating system, atleast one ventilation system, at least one lighting system and / or at least one polishing repair station.

22. Method according to one of Claims 7 to 21 , wherein in pause mode of one or more process subsystems (17) of the paint shop, at least one of the following is applied: humidity is reduced, for example, by slower fluid pumping or by decreasing fluid supply,light intensity is dimmed,temperature is reduced,ventilation is reduced, andfrequency of recirculating pumps is reduced.

23. Method according to one of Claims 7 to 22, wherein in hibernation mode of one or more process subsystems (17) of the paint shop, at least one of the following is applied:only fresh air ventilation remains in full operation,humidity is reduced, for example, by switching off fluid pumping,lighting is turned off, andrecirculating pumps are shut off.

24. Method according to one of Claims 7 to 23, wherein in shutdown mode of one or more process subsystems (17) of the paint shop, at least one of the following is applied: all painting-related equipment is switched off,all drying-related equipment is switched off,ventilation is switched off,fluid circulation is switched off, andall stations and / or systems are switched off.

25. Method according to one of Claims 7 to 24, wherein in maintenance mode of one or more process subsystems (17) of the paint shop, operating of one or more predefined process subsystems (17) is temporarily intensified, for example increasing of fresh air ventilation, to allow entry into one or more process subsystems for maintenance purposes.

26. Method according to one of Claims 7 to 25, wherein in semi-automatic mode of one or more process subsystems (17) of the paint shop, a control system of the paint shop requests manual approval for operating mode selection and / or activation.

27. System (1) for controlling an operating parameter of a paint shop, the system (1) comprising the following components:at least one monitoring unit (11), which is configured for monitoring movement feature information of a workpiece (15) on a conveying apparatus (16) of the paint shop; andat least one control unit (12), which is configured for executing the method according to any one of Claims 1 to 26.

28. System (1) according to Claim 27, wherein the system (1) further comprises a workpiece tracking system (13) with one or more human-machine interfaces (14), in particular one or more touch screens, to visualize, track, and / or control the workpieces (15) within the paint shop.

29. System (1) according to Claim 28, wherein the workpiece tracking system (13) is configured to provide an operator with workpiece-related information and / or information related to one or more process subsystems (17), in particular one or more paint application or drying stations of the paint shop.

30. Computer program product, such as a computer readable program carrier, including a computer program instruction, when executed by a processor, causing the processor to carry out the steps of the method according to one of Claims 1 to 26.

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