Production Line Adjustment Planning for Cyber-Physical Mismatch
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Solution Overview
Problem
Existing production line adjustment methods fail to effectively match the simulated cyber environment with actual machine conditions, leading to suboptimal operational productivity due to incomplete adjustments of the actual environment based on design values.
Innovation Solution
A production line and model adjustment support system that calculates differences between cyber and actual machine data, generating candidate adjustment plans targeting either the cyber model, actual machine, or both, allowing users to select highly productive adjustment strategies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If only the movement path is adjusted to avoid interference in the actual machine environment, then interference is avoided, but the highly productive operating method obtained from cyberspace performance evaluation cannot be implemented
Solution Approach 1:
Instead of only adjusting the movement path to avoid interference, the invention inverts the approach by also adjusting the actual machine environment (robot position, peripheral structure position) to match the cyberspace model, enabling the implementation of highly productive operating methods while avoiding interference through coordinated adjustments of both software and hardware elements
Solution Approach 2:
The invention segments the adjustment process into multiple independent adjustment targets: movement path adjustment, robot position adjustment, and peripheral structure position adjustment. This segmentation allows selective application of adjustments based on specific interference scenarios, enabling productivity optimization by applying only the necessary adjustments
2Measurement precision
If the cyberspace model is adjusted to match actual machine conditions, then model accuracy is improved, but additional adjustment work is required beyond simple movement path correction
Solution Approach 1:
The invention makes the adjustment system dynamic by providing multiple adjustable parameters (movement path, robot position, peripheral structure position) that can be flexibly selected and combined based on the specific situation. This dynamic approach allows the system to adapt to different interference scenarios without requiring complex pre-programmed adjustment procedures
Solution Approach 2:
The adjustment support system automatically calculates the necessary adjustments and generates adjustment plans based on the detected differences between cyberspace and actual machine data, reducing the complexity of manual adjustment planning and enabling users to select from pre-calculated options rather than designing adjustments from scratch
Data Source
AI summary
An adjustment support system includes a controller and a storage, in which the storage holds production line model data related to a model of one or more production facilities in a cyberspace of a production line and actual machine data obtained by actually measuring one or more production facilities disposed in an actual space of the production line, the controller calculates a difference between the production line model data and the actual machine data, upon determination that the difference exists on a basis of a result of calculating the difference, the controller creates one or more adjustment plans each targeting at least one of the model of the one or more production facilities in the cyberspace or the one or more production facilities disposed in the actual space, and the controller outputs the one or more adjustment plans having been created.