IIoT Production Line Feedback Control for Defect Self-Correction
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Solution Overview
Problem
The manufacturing industry lacks self-inspection and self-correction measures for production lines when defective products are produced, leading to inefficient regulation of production costs and progress.
Innovation Solution
An Industrial Internet of Things system with a perception module and processing module that perceives device information on the production line, compares quality testing data with set thresholds, and generates instructions for configuration adjustments to address configuration issues causing defective products.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual detection and subjective determination by staff are used to identify defective products, then the system is simple to operate, but production costs increase and production progress cannot be effectively controlled
Solution Approach 1:
The production line system performs self-inspection through automated detection devices that automatically identify defective products without human intervention. The system self-corrects by automatically adjusting production parameters based on detected defects, eliminating the need for manual determination by staff while maintaining operational simplicity
Solution Approach 2:
The system implements a closed-loop feedback mechanism where detection devices continuously monitor product quality, compare results against standards, and automatically adjust production parameters. This feedback loop enables effective control of production progress while reducing costs by eliminating manual inspection
2Device complexity
If manual inspection and subjective correction decisions are used, then device complexity is low, but production costs cannot be effectively controlled
Solution Approach 1:
The system automatically performs both inspection and correction functions. Detection devices identify defects and the control system automatically adjusts production parameters, enabling the system to serve itself without complex manual intervention while effectively controlling production costs through automated optimization
Solution Approach 2:
The production line is equipped with multi-functional devices that can both detect defects and automatically adjust production parameters. This universal approach consolidates multiple functions into integrated systems, managing complexity while improving cost control through automated multi-functional operations
3Productivity
If automated self-inspection and self-correction measures are implemented, then production costs are reduced and production progress is controlled, but device complexity increases
Solution Approach 1:
The system uses feedback mechanisms where detection devices continuously monitor product quality and automatically feed this information back to control systems. The control systems then automatically adjust production parameters to prevent defects, achieving cost control and production progress management through automated closed-loop control
Solution Approach 2:
The patent replaces manual mechanical inspection and correction processes with automated detection devices and electronic control systems. This substitution uses optical, electronic, and computational technologies to perform functions that were previously done manually, reducing production costs while managing complexity through automation
Data Source
AI summary
Embodiments of the present disclosure provide an Industrial Internet of Things system for a production line when a defective product is produced, a regulation method, and a storage medium. The regulation method includes: a management platform sending quality testing information in the perception information sent by an object platform to a service platform; the service platform comparing a count of defective products with a first count threshold of defective products preset by each process and generating an instruction for retrieving process information when the count exceeds the first count threshold; the management platform receiving the instruction and sending object platform configuration information and latest-stored operation information to the service platform; the service platform performing a parameter comparison with a same parameter name and generating a parameter configuration instruction; the object platform receiving the instruction and performing configuration, performing the parameter comparison again, and feeding a comparison result back.