Virtual Factory Modeling Using Time-Difference Progress Tracking
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Solution Overview
Problem
Current computing systems lack the capability to effectively build a virtual representation of a real factory and analyze its operational situation in real-time, limiting the ability to optimize production planning and management.
Innovation Solution
A computing system comprising a database and a virtual factory building module that uses monitoring devices to gather data on product movement and calculate time differences between signal outputs from different locations, allowing for the creation of a virtual factory model that reflects real-time operational data and enables real-time analysis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a virtual factory model is built using multiple monitoring devices and time difference calculations, then real-time analysis capability is improved, but device complexity increases
Solution Approach 1:
The system divides the factory monitoring into multiple independent monitoring devices placed at different locations, each capturing local product position data. This segmentation allows parallel data collection from multiple points simultaneously, enabling real-time analysis without requiring a single complex centralized system.
Solution Approach 2:
A computing system acts as an intermediary that receives signals from multiple monitoring devices, calculates time differences between signal outputs, and reconstructs product movement trajectories. This intermediary processing layer simplifies the overall system architecture by centralizing the complex calculations while keeping individual monitoring devices relatively simple.
2Measurement precision
If monitoring devices are placed at multiple locations outside facilities to track product movement, then work progress tracking accuracy is improved, but device complexity and installation complexity increase
Solution Approach 1:
Instead of placing monitoring devices inside facilities where space is constrained, the system positions devices at multiple locations outside facilities, utilizing the third dimension (spatial arrangement outside the production area) to achieve comprehensive tracking coverage without interfering with internal facility operations.
Solution Approach 2:
The system pre-calculates time differences between signal outputs from different locations and establishes the virtual factory model structure in advance. This preliminary preparation enables real-time work progress tracking without requiring complex real-time computations during actual product movement, simplifying the operational complexity.
Data Source
AI summary
A computing system for building a virtual factory includes database and a virtual factory building module. The database stores modeling data. The virtual factory building module builds the virtual factory in which a progress situation of a work performed from a first portion to a second portion is displayed, based on the modeling data and a time difference between an output time of a first signal and an output time of a second signal, which is calculated based on the first signal output when a product is at a first portion on one or more facilities monitored from a first location present in an outside of the one or more facilities used in a real factory and the second signal output when the product is at a second portion on the one or more facilities monitored from a second location present in the outside of the one or more facilities. The first location is spaced from the second location, and the first portion is spaced from the second portion.