Virtual Cycle Time Calculation for Parallel Machining Cells
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Solution Overview
Problem
In machining cells, accurately calculating cycle time is challenging due to dynamic operation timing and parallel execution of processes, leading to inefficiencies and waste when actual machining is required for calculation.
Innovation Solution
A cycle time calculation apparatus comprising processors and memory, with resource process units that virtually judge process progress based on elapsed time, a process control unit that dynamically determines operation timings, and a cycle time calculation unit that measures and calculates the required cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If actual machining is performed to calculate cycle time, then accurate cycle time can be obtained, but workpiece waste increases and productivity decreases
Solution Approach 1:
The patent creates a virtual copy of the machining cell that replicates the operational characteristics and process times of actual work resources. This virtual model allows cycle time calculation without consuming physical workpieces, resolving the contradiction between measurement accuracy and material waste by substituting physical experimentation with virtual simulation.
Solution Approach 2:
The system performs preliminary virtual calculations of cycle time before actual machining operations. By determining the cycle time in advance through virtual execution of the sequence program, operators can plan and optimize processes without needing to consume workpieces during the calculation phase, thus eliminating waste while maintaining accuracy.
2Measurement precision
If actual machining is performed repeatedly for sequence program correction, then accurate cycle time can be obtained, but time consumption and productivity are significantly reduced
Solution Approach 1:
The virtual machining cell serves as a reusable copy that can be executed multiple times for different sequence program variations without time consumption associated with physical setup and machining. This allows rapid iteration and correction of sequence programs while maintaining accurate cycle time measurements, significantly reducing the time loss associated with repeated actual machining operations.
Solution Approach 2:
The system performs preliminary virtual testing and correction of sequence programs before committing to actual machining operations. This preliminary action allows operators to identify and correct issues in the virtual environment, reducing the need for repeated actual machining corrections and thereby minimizing time consumption.
3Ease of operation
If simple addition of process times is used to calculate cycle time, then calculation is easy, but accuracy is insufficient due to parallel execution and dynamic timing
Solution Approach 1:
The virtual machining cell replicates the complex dynamic behavior of the actual machining cell, including parallel execution of processes and dynamic start timing determination. This virtual copy automatically handles the complexity of accurate cycle time calculation through simulated resource state monitoring and elapsed time measurement, providing accurate results without requiring manual complex calculations from the operator.
Solution Approach 2:
The virtual machining cell autonomously calculates cycle time by automatically monitoring resource states, measuring elapsed times, and determining when all processes are complete. This self-service capability eliminates the need for operators to manually track parallel processes and dynamic timing, maintaining calculation simplicity while achieving high accuracy through automated virtual execution.
Data Source
AI summary
A cycle time calculation apparatus includes: a plurality of resource process units, each provided in correspondence to one of a plurality of work resources, wherein each of the plurality of resource process units virtually judges progress of a process in a corresponding work resource; a process control unit which dynamically determines timings to start operations of the plurality of work resources, and sends a command to start a process to the resource process unit in accordance with a result of the determination; a cumulative management unit which measures a time in which a resource state of at least one of the resource process units is in-operation; and a cycle time calculation unit which calculates a cycle time, which is a time required for actually executing machining in accordance with the sequence program, based on a result of the measurement by the cumulative management unit.