Production Line Changeover Using Flexible Module Parameter Switching
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Solution Overview
Problem
The existing production line changeover process for cell module production lines is inefficient, requiring 24 hours or more due to the need to stop the line for device program modifications, CCD template re-teaching, and servo recalibration, leading to low productivity.
Innovation Solution
A product changeover method and system that determines the size information of the product to be produced, calculates the target control parameter values for flexible modules based on this information, and sends these values to the module controllers to process incoming materials efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the production line stops to modify device programs, re-teach CCD templates, and recalibrate servo sites during product changeover, then the manufacturing precision and reliability are maintained, but the productivity deteriorates due to changeover time exceeding 24 hours
Solution Approach 1:
The patent applies preliminary action by pre-storing control parameters for different product specifications in a database. When a product changeover is needed, the system directly retrieves the pre-configured parameters instead of performing time-consuming program modifications, CCD template re-teaching, and servo recalibration. This eliminates the need for lengthy setup procedures while maintaining manufacturing precision.
Solution Approach 2:
The patent uses copying by storing replicated control parameter sets in the database for various product specifications. Instead of recreating control programs during changeover, the system copies the appropriate parameter set from storage to the controller, dramatically reducing changeover time while preserving the precision required for each product type.
2Reliability
If the production line stops for extensive recalibration and re-teaching during changeover, then the reliability of product quality is improved, but the loss of time increases to 24 hours or more
Solution Approach 1:
The system performs preliminary action by pre-configuring and storing control parameters for multiple product specifications before changeover occurs. During actual product changeover, the system simply retrieves the appropriate pre-configured parameters, eliminating the need for time-consuming recalibration and re-teaching processes while ensuring reliable product quality.
Solution Approach 2:
The patent implements self-service by enabling the control system to automatically retrieve and apply the correct control parameters from the database based on the product specification. This automated parameter selection eliminates manual recalibration and re-teaching operations, significantly reducing changeover time while maintaining reliability through consistent parameter application.
3Manufacturing precision
If traditional changeover procedures including program modification and recalibration are followed, then the manufacturing precision is maintained, but the changeover efficiency deteriorates to 24 hours or more
Solution Approach 1:
The patent applies copying by retrieving pre-stored control parameter sets from the database during product changeover. Instead of performing time-consuming program modifications and recalibrations, the system copies the appropriate parameter set corresponding to the new product specification, maintaining manufacturing precision while dramatically improving changeover efficiency.
Solution Approach 2:
The patent implements parameter changes by switching between pre-configured control parameter sets in the database rather than modifying parameters during changeover. The system changes the active parameter set based on product specification, maintaining manufacturing precision through consistent parameter application while improving changeover efficiency by eliminating iterative adjustment processes.
Data Source
AI summary
A product changeover method for production line includes: determining, in response to a product changeover instruction, size information of a product to be produced; determining correspondingly, based on the size information of the product to be produced, a target value of a control parameter for at least one flexible module in a production device; and sending the target value corresponding to the control parameter of the at least one flexible module to a controller of a corresponding flexible module so as to process an incoming material of the product to be produced.