Industrial IoT Production Control for Dynamic Line Capacity Balancing
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Solution Overview
Problem
In intelligent manufacturing, existing IoT systems struggle to coordinate the production capacity of multiple production line equipment effectively, leading to inefficiencies and increased costs due to the inability to uniformly regulate and manage the output of all production equipment, resulting in no-load times and complex data processing challenges.
Innovation Solution
A system with a user platform, service platform, management platform, and sensor network platform that interact through centralized and sub-platform layouts, allowing for uniform data processing and transmission, enabling the creation of configuration files for real-time manufacturing capacity adjustments across production line equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the unit time manufacturing capacity of downstream equipment is increased to match upstream equipment capacity, then workpiece accumulation is prevented, but equipment complexity and coordination difficulty increase
Solution Approach 1:
The patent implements a feedback mechanism where the management platform continuously monitors the manufacturing capacity and operational status of each equipment, and dynamically adjusts the manufacturing capacity of upstream equipment based on downstream equipment's real-time status. This prevents workpiece accumulation without requiring all equipment to operate at maximum capacity simultaneously, thereby reducing coordination complexity while maintaining productivity.
Solution Approach 2:
The patent makes the manufacturing capacity of equipment dynamic rather than fixed. The management platform can adjust the manufacturing capacity of upstream equipment in real-time based on downstream equipment's operational status. This dynamic adjustment allows the system to adapt to changing conditions without requiring complex permanent coordination arrangements between all equipment.
2Productivity
If upstream equipment stops operation to wait for downstream equipment, then workpiece accumulation is avoided, but production time and energy consumption increase
Solution Approach 1:
The management platform uses feedback from downstream equipment's operational status to dynamically control upstream equipment's manufacturing capacity. Instead of complete stoppage, the system adjusts upstream equipment to operate at an optimal capacity that matches downstream processing speed, thereby avoiding both workpiece accumulation and complete idle time losses.
Solution Approach 2:
The patent changes the operational parameters of upstream equipment dynamically based on downstream status. Rather than binary stop/start control, the system adjusts manufacturing capacity parameters continuously to match downstream processing capabilities, reducing idle time while preventing accumulation.
3Ease of operation
If production lines are divided into separate sub areas for independent control, then control simplicity is improved, but overall coordination and data integration become difficult
Solution Approach 1:
The patent merges the control of multiple sub areas into a unified management platform that can see and coordinate all equipment across different workshops and processes. The management platform integrates data from all sub areas while maintaining the ability to control each area independently when needed, thus preserving both control simplicity and data integration.
Solution Approach 2:
The management platform is designed with universal functionality to handle diverse equipment types, processes, and data formats from different sub areas. It can perform multiple functions including data collection, analysis, coordination, and control across the entire production system, eliminating the need for separate control systems while maintaining simplicity through a single unified interface.
4Productivity
If the manufacturing capacity of each link is increased to meet production targets, then productivity is improved, but equipment maximum capacity limits are exceeded
Solution Approach 1:
The management platform continuously monitors the operational status and manufacturing capacity of each equipment, and uses this feedback to dynamically adjust upstream equipment's output. This ensures that no equipment exceeds its maximum capacity while maintaining optimal overall productivity through coordinated control.
Solution Approach 2:
The patent applies partial action by adjusting only the necessary equipment's manufacturing capacity to meet production targets, rather than uniformly increasing all equipment capacity. The management platform identifies which equipment needs capacity adjustment and applies changes only where necessary, maintaining reliability while achieving productivity goals.
Data Source
AI summary
The present disclosure discloses a system of an industrial internet of things for industrial production control and a method. The system of industrial internet of things includes a user platform, a service platform, a management platform, a sensor network platform, and an object platform that interact in turn. The service platform adopts a centralized layout, and the management platform and the sensor network platform adopt a front sub platform layout. The user platform generates product manufacturing parameters of a production line, and transmits them in a form of instructions through the service platform, the management platform, and the sensor network platform. The sensor network platform finally integrates the received instructions with the real-time manufacturing data of the product to form different types of configuration files, and transmits them to the object platform, so that the object platform can perform production control processing based on the received data.