Embedded Workpiece Control for Machine Selection and Dynamic Routing
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Solution Overview
Problem
Conventional manufacturing systems with centralized intelligence are ill-suited for diverse production environments where individual products may vary in delivery time, materials, quality, or cost, as they focus on optimizing the entire production line rather than enabling individualized optimization at the workpiece level.
Innovation Solution
An intelligent workpiece system with an embedded computing system that communicates with machines and automated guided vehicles to select optimal assembly machines and routes, facilitating customized production by broadcasting product requirements and receiving service availability information, thereby enabling individualized optimization of manufacturing cost, delivery time, and quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If centralized intelligence (MES or PLC) is used to control production, then production line optimization is achieved, but individualized optimization at workpiece level cannot be achieved
Solution Approach 1:
The patent divides the centralized control system into distributed intelligent agents embedded in each workpiece. Each workpiece contains an RFID tag and processor that can independently make decisions, segmenting the monolithic centralized intelligence into multiple autonomous units that operate individually while contributing to overall production line efficiency.
Solution Approach 2:
Workpieces are equipped with embedded intelligence enabling them to autonomously select machines, determine routing paths, and make production decisions without centralized control. The workpiece's processor evaluates machine status information and autonomously selects optimal assembly machines, allowing the workpiece to serve itself rather than being passively controlled.
2Loss of information
If RFID tags are added to workpieces for decentralized intelligence, then workpiece-level information tracking is enabled, but decision-making capability remains limited
Solution Approach 1:
The embedded processor in each workpiece is pre-programmed with decision-making algorithms and evaluation criteria. Before the workpiece enters production, it is configured with the capability to evaluate machine status information, compare options, and autonomously select optimal routing and assembly machines, preparing it in advance for independent decision-making.
Solution Approach 2:
The workpiece's embedded processor continuously receives feedback from machine status information broadcast by controllers at each assembling area. This real-time feedback enables the workpiece to dynamically adjust its routing decisions and machine selections based on current production conditions, maintaining adaptability while operating autonomously.
3Productivity
If production automation systems focus on overall line optimization, then total production efficiency is improved, but individual workpiece customization is compromised
Solution Approach 1:
The patent implements dynamic routing where each workpiece can change its production path in real-time based on individual requirements and current machine availability. The embedded processor continuously evaluates machine status information and dynamically selects optimal assembly machines, allowing the system to adapt to both individual workpiece needs and overall production efficiency requirements simultaneously.
Data Source
AI summary
An intelligent workpiece system includes a workpiece comprising a portion of a product; and an embedded computing system attached to the workpiece. The embedded computing system is configured to communicate with machines in a manufacturing environment to facilitate assembly of the workpiece into the product at a plurality of assembling areas.