Production Sequence Simulation Using Real-Time Carrier Locating Data
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Solution Overview
Problem
Existing production systems in metal processing, particularly sheet-metal processing, often suffer from inefficiencies due to varying processing times of production tools and complex transport paths, leading to underutilization of tools and carriers, and requiring lengthy simulations to optimize production sequences.
Innovation Solution
The implementation of a production apparatus with autonomous or remote-controlled carriers, a locating system for precise tracking of carriers, tools, and components, and a digital model that simulates production sequences using real-time data from the locating system to optimize tool usage and transport routes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If production tools and carriers are operated without real-time tracking, then device complexity is reduced, but productivity decreases due to underutilization
Solution Approach 1:
The locating system enables carriers and production tools to self-report their positions and statuses automatically. Each carrier is equipped with locating means that continuously transmit position data to the control device, eliminating the need for manual tracking and enabling autonomous optimization of production sequences.
Solution Approach 2:
The system implements continuous feedback loops where the locating system monitors carrier positions in real-time, the control device analyzes this data to determine optimal production sequences, and the system automatically adjusts carrier routing and processing schedules. This closed-loop feedback enables dynamic optimization without manual intervention.
2Manufacturing precision
If traditional simulations are used to optimize production sequences, then manufacturing precision improves, but loss of time increases due to months-long simulation periods
Solution Approach 1:
The system performs preliminary simulations and optimizations continuously in the background using real-time data from the locating system. The control device maintains an updated optimal production sequence based on current carrier positions and predicted future states, so when decisions are needed, the optimization is already complete and ready for implementation.
Solution Approach 2:
The simulation system transitions from static, periodic simulations to dynamic, continuous simulations that adapt to real-time changes in carrier positions, processing times, and production priorities. The control device continuously recalculates optimal sequences as new data becomes available, enabling the system to respond dynamically to changing conditions without lengthy re-simulation periods.
3Productivity
If real-time locating systems are implemented, then productivity improves through optimized production sequences, but device complexity increases due to additional tracking infrastructure
Solution Approach 1:
The locating system is designed to serve multiple functions simultaneously: it tracks carrier positions for routing optimization, monitors processing times for schedule adjustment, provides data for simulation and prediction, and enables real-time production sequencing. This multi-functionality reduces the need for separate specialized systems and justifies the infrastructure investment through diverse productivity benefits.
Data Source
AI summary
The disclosure relates to digital models of a production apparatus. The digital models can generate simulations of production sequences of the production apparatus, and a controller can access the simulation to improve operations of the production apparatus. The digital model uses data of a locating system to create the simulation. The locating system monitors carriers for transporting components. The controller can compare parameters of the simulation results with corresponding parameters of earlier simulation results and/or actually obtained parameters of earlier production sequences, which can be stored in a model library. The disclosure further relates to corresponding production control methods.