CN109884996B - Production control system, method and production management system - Google Patents
Production control system, method and production management system Download PDFInfo
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- CN109884996B CN109884996B CN201910108383.7A CN201910108383A CN109884996B CN 109884996 B CN109884996 B CN 109884996B CN 201910108383 A CN201910108383 A CN 201910108383A CN 109884996 B CN109884996 B CN 109884996B
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
- Y02P90/60—Electric or hybrid propulsion means for production processes
Abstract
The invention provides a production control system, a method and a production management system, which relate to the technical field of intelligent production, and the production control system comprises: the system comprises a main controller, and a work station controller, an AGV controller and a warehouse controller which are connected with the main controller; the system comprises a plurality of workstations with the same configuration, each workstation is provided with a workstation controller, and the same configuration comprises the following steps: the workstations are arranged identically, the sizes of the workstations are identical and the common equipment of each workstation is identical. The production control system, the production control method and the production management system provided by the invention can be used for carrying out production line modification in time according to the state of the workstation, and the modification period is shortened to a certain extent so as to improve the production efficiency of the whole manufacturing system.
Description
Technical Field
The invention relates to the technical field of intelligent production, in particular to a production control system, a production control method and a production management system.
Background
With the development of social economy and the improvement of manufacturing level, people pursue higher and higher substance life, personalized demand is more and more prominent, and world automobiles begin to convert from mass flow production to mass customized production. In this production mode, the Customer-to-factory (Customer-to-factory) mode, in which the Customer has a direct conversation with the factory, will become the mainstream, and the C2M will enable the Customer's personalized needs to be fed back to the automobile manufacturer at the lowest cost, at the fastest speed, and more accurately. The vehicle body personalized customization production technology based on the mode can become one of the core competitive forces of various vehicle production enterprises in the world to overcome the opponents.
At present, most of automobile production lines usually produce for preset automobile types, and when the automobile types proposed by the individual demands of consumers are modified, the modification period is long, and the production efficiency of the whole manufacturing system is influenced.
Disclosure of Invention
In view of the above, the present invention provides a production control system, a production control method and a production management system, so as to alleviate the technical problem of the influence on the production efficiency caused by the long modification period.
In a first aspect, an embodiment of the present invention provides a production control system, including: the system comprises a main controller, and a work station controller, an AGV controller and a warehouse controller which are connected with the main controller; the system comprises a plurality of workstations with the same configuration, each workstation is provided with a workstation controller, and the same configuration comprises the following steps: the workstations are arranged in the same way, the sizes of the workstations are the same and the general equipment of each workstation is the same; the system comprises a working station controller, an AGV controller, a warehouse controller and a main controller, wherein the working station controller is used for feeding back a working station state to the main controller, the AGV controller is used for feeding back an AGV state to the main controller, and the warehouse controller is used for feeding back a clamp and a material state to the main controller; the main controller is in communication connection with the MES server and is used for receiving the production tasks issued by the MES server, distributing the production tasks according to the states of the workstations, the AGV states and the states of the clamps and the materials, generating an operation task table and issuing the operation task table to the work station controller, the AGV controller and the warehouse controller; the operation task table comprises a beat table and process information corresponding to production tasks; the warehouse controller is used for extracting and displaying process information so that a worker arranges corresponding clamps and materials according to the process information; the AGV controller is used for extracting the beat table and sending a scheduling task to the AGV according to time information contained in the beat table so that the AGV can carry fixtures and materials according to the scheduling task; the working station controller is used for receiving the operation task list and issuing an operation instruction to the production robot according to the operation task list so that the production robot carries out production work according to the operation task list.
With reference to the first aspect, an embodiment of the present invention provides a first possible implementation manner of the first aspect, where the general-purpose device of each workstation at least includes: the device comprises a workstation robot, a coping device, a universal rotary table, a rotary table base station, a welding clamp assembly and a control cabinet, wherein the universal rotary table is provided with a clamp; the universal equipment of each workstation is the same, including the model, the size and the equipment layout of the universal equipment are the same; the working station controller is also used for sending fault information to the main controller when the fault information of the general equipment is monitored; the main controller is also used for receiving the fault information, searching for an idle workstation in a plurality of workstations with the same configuration, and switching the clamp and the welding tongs assembly of the workstation corresponding to the fault information to the idle workstation.
With reference to the first aspect, an embodiment of the present invention provides a second possible implementation manner of the first aspect, where the production task issued by the MES server is a production task corresponding to a lower body assembly of multiple vehicle types; the process of generating the operation task list by the main controller comprises the steps of obtaining codes of a plurality of vehicle types and work sequence numbers of production processes corresponding to the codes, distributing the production tasks of the plurality of vehicle types according to a preset production sequence according to the codes and the work sequence numbers, and generating the operation task list, wherein the operation task list is a production task list produced in parallel sequence of the plurality of vehicle types, and the work sequence numbers are work sequence numbers corresponding to lower body assembly of the plurality of vehicle types.
With reference to the first aspect, an embodiment of the present invention provides a third possible implementation manner of the first aspect, where the system further includes an RFID reader connected to the station controller; the working station controller is also used for sending a reading instruction to the RFID reader-writer when the station entering information of the AGV is monitored; the RFID reader-writer is also used for receiving the reading instruction, reading the RFID tags of the clamp and the material state carried by the AGV and sending the read RFID tags to the workstation server; the workstation server is also used for judging whether the RFID label is consistent with the process information carried in the operation task list; if so, issuing a working instruction to the production robot; and if not, sending error reporting information to the AGV controller.
With reference to the first aspect, an embodiment of the present invention provides a fourth possible implementation manner of the first aspect, where the AGV controller and multiple AGVs form an AGV dispatching subsystem; each AGV is communicatively coupled to an AGV controller.
With reference to the fourth possible implementation manner of the first aspect, an embodiment of the present invention provides a fifth possible implementation manner of the first aspect, where the AGV controller is further configured to receive skid information sent by an AGV; and inquiring whether the skid information is consistent with the skid information contained in the process information, if not, sending skid updating information to the wind turbine switching station, wherein the skid updating information comprises an identification code of the AGV and the skid information contained in the process information.
With reference to the first aspect, an embodiment of the present invention provides a sixth possible implementation manner of the first aspect, where the main controller further includes an OPC module, and the station controller, the AGV controller, and the warehouse controller interact with the main controller through the OPC module.
With reference to the first aspect, an embodiment of the present invention provides a seventh possible implementation manner of the first aspect, where the system further includes a plurality of human-computer interaction interfaces; the plurality of human-computer interaction interfaces are respectively arranged on different workstations, are connected with the workstation controller and are used for displaying the configuration of the workstations and the operation task list.
In a second aspect, an embodiment of the present invention further provides a production management system, where the production management system includes a production execution system and a production control system according to the first aspect, and the production execution system communicates with the production control system through a workshop ring network; the production execution system comprises an MES server and is used for issuing a production task to the production control system so as to enable the production control system to carry out production work.
In a third aspect, an embodiment of the present invention further provides a production control method, where the production control method is used in the production control system according to the first aspect, and the production control system includes: the system comprises a main controller, and a work station controller, an AGV controller and a warehouse controller which are connected with the main controller; the system comprises a main controller, a working station controller, an AGV controller, a warehouse controller and a material state feedback controller, wherein the working station controller is used for feeding back a working station state to the main controller, the AGV controller is used for feeding back an AGV state to the main controller, and the warehouse controller is used for feeding back a clamp and a material state to the main controller; the method comprises the following steps: the main controller is in communication connection with the MES server, receives the production tasks issued by the MES server, distributes the production tasks according to the states of the workstations, the AGV states and the states of the fixtures and the materials, generates an operation task table, and issues the operation task table to the work station controller, the AGV controller and the warehouse controller; the operation task table comprises a beat table and process information corresponding to production tasks; the warehouse controller extracts and displays the process information so that the working personnel can arrange corresponding clamps and materials according to the process information; the method comprises the steps that an AGV controller extracts a tempo table and sends a scheduling task to the AGV according to time information contained in the tempo table, so that the AGV carries fixtures and materials according to the scheduling task; and the work station controller receives the work task list and issues a work instruction to the production robot according to the work task list so that the production robot carries out production work according to the work task list.
The embodiment of the invention has the following beneficial effects:
the production control system, the production control method and the production management system provided by the embodiment of the invention are provided with a plurality of workstations with the same configuration, and the states of the workstations are fed back by the workstation controller, so that the master controller can timely acquire the states of the workstations, production tasks are conveniently distributed according to the states of the workstations, the AGV states, the clamp states and the material states, and an operation task table is generated.
Additional features and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objectives and other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
In order to make the aforementioned and other objects, features and advantages of the present invention comprehensible, preferred embodiments accompanied with figures are described in detail below.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings used in the description of the embodiments or the prior art will be briefly described below, and it is obvious that the drawings in the following description are some embodiments of the present invention, and other drawings can be obtained by those skilled in the art without creative efforts.
Fig. 1 is a block diagram of a production control system according to an embodiment of the present invention;
FIG. 2 is a schematic layout of a workstation according to an embodiment of the present invention;
FIG. 3 is a block diagram of another production control system according to an embodiment of the present invention;
FIG. 4 is a schematic diagram of a parallel production mode for single vehicles according to an embodiment of the present invention;
FIG. 5 is a schematic diagram of another parallel production mode for single-vehicle models according to an embodiment of the present invention;
FIG. 6 is a schematic diagram of a parallel production mode for hybrid production of a plurality of vehicle models according to an embodiment of the present invention;
fig. 7 is a flowchart of a production control method according to an embodiment of the present invention.
Icon: 10-a main controller; 20-a station controller; 30-an AGV controller; 40-a warehouse controller; 50-an RFID reader; 60-human-computer interaction interface; 101-an OPC module; 201-safety grating; 202-a turntable; 203-HMI system; 204-main control cabinet; 205-welding power supply cabinet; 206-safety fence; 207-welding jaw assembly; 208 — workstation robot.
Detailed Description
To make the objects, technical solutions and advantages of the embodiments of the present invention clearer, the technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings, and it is apparent that the described embodiments are some, but not all embodiments of the present invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
At present, all automobile manufacturers around the world actively research and explore the technology of cross-platform multi-vehicle type flexible mixed line production. Some automobile companies already master the automobile body mixed line production technology of 1-2 automobile body platforms and 4-6 automobile types. However, the production line of the existing mixed line production can only produce preset vehicle models, the production line is difficult to move autonomously or copy rapidly, new vehicle models or vehicle models needing to be newly built or modified, the modification period is still long, and the production input cost is still very high.
Particularly, different production processes exist for three lower vehicle bodies (a cabin assembly, a front floor assembly and a rear floor assembly) and different vehicle types, stations of the different processes are inevitably idle in a certain period due to vehicle type mixed production in the current assembly line production mode, waste is caused, the investment cost of equipment and a site is huge, the reproducibility is extremely poor, and the marketing period of new vehicle types is influenced.
Based on this, the embodiment of the invention provides a production control system, a production control method and a production management system, so as to alleviate the technical problem that the production efficiency is influenced by the existing production technology.
To facilitate understanding of the present embodiment, a detailed description will be given of a production control system disclosed in the present embodiment.
The first embodiment is as follows:
an embodiment of the present invention provides a production control system, such as a block diagram of a structure of the production control system shown in fig. 1, where the production control system includes: a main controller 10, and a station controller 20, an AGV controller 30 and a warehouse controller 40 connected to the main controller 10; wherein, this production control system includes the workstation of a plurality of the same configurations, and every workstation all is provided with station controller 20, and above-mentioned same configuration includes: the workstations are arranged identically, the sizes of the workstations are identical and the common equipment of each workstation is identical.
During specific implementation, the main controller can be arranged in a management department of a production workshop, the work station controllers are respectively arranged at each work station, an AGV (automatic Guided Vehicle) controller can be arranged in an AGV dispatching room to monitor the state of each AGV, and the warehouse controller can be arranged in a warehouse. Specifically, the station controller is used for feeding back the state of the station to the main controller, the AGV controller is used for feeding back the state of the AGV to the main controller, and the warehouse controller is used for feeding back the state of the clamp and the material to the main controller.
The main controller is also in communication connection with an MES (Manufacturing Execution System) server (not shown in fig. 1), and is configured to receive a production task issued by the MES server, distribute the production task according to a workstation state, an AGV state, and a fixture and material state, generate an operation task table, and issue the operation task table to a workstation controller, an AGV controller, and a warehouse controller; the operation task table comprises a beat table and process information corresponding to the production tasks.
Further, the warehouse controller is used for extracting and displaying process information so that a worker arranges corresponding clamps and materials according to the process information;
the AGV controller is used for extracting the beat table and sending a scheduling task to the AGV according to time information contained in the beat table so that the AGV can carry fixtures and materials according to the scheduling task;
the working station controller is used for receiving the operation task list and issuing an operation instruction to the production robot according to the operation task list so that the production robot carries out production work according to the operation task list.
The production control system provided by the embodiment of the invention is provided with a plurality of workstations with the same configuration, and the states of the workstations are fed back through the workstation controller, so that the master controller can timely acquire the states of the workstations, production tasks are conveniently distributed according to the states of the workstations, the AGV states, the clamps and the material states, and an operation task table is generated.
In a specific implementation, the general equipment of each workstation at least comprises: the device comprises a workstation robot, a coping device, a universal rotary table, a rotary table base station, a welding clamp assembly and a control cabinet, wherein the universal rotary table is provided with a clamp; specifically, the universal equipment of each workstation is the same, including the model, the size and the equipment layout of the universal equipment are the same; for example, the brands, sizes and models of universal equipment such as the workstation robots, the sharpening devices, the rotary tables, the rotary table base stations and the like are all consistent, and meanwhile, the equipment layout of each workstation is also consistent, so that the rapid copying performance of the workstation can be ensured to the greatest extent. Furthermore, the fixture and the rotary table can be positioned by adopting a universal separable positioning mechanism, and the fixture has the advantages of high positioning precision and quick switching.
During specific implementation, the station controller is further used for sending fault information to the main controller when fault information of the general equipment is monitored; the main controller is also used for receiving the fault information, searching for an idle workstation in a plurality of workstations with the same configuration, and switching the clamp and the welding tongs assembly of the workstation corresponding to the fault information to the idle workstation.
Because the brand, the size and the model of the universal equipment such as the robot, the sharpening device, the rotary table base station, the control cabinet and the like of each workstation are consistent, and the layout of the universal equipment is also consistent, when the master controller monitors that the universal equipment of one workstation breaks down, the clamp and the welding tongs can be quickly switched to another idle workstation to continue to ensure production. And, because anchor clamps and revolving stage adopt separable positioning mechanism to fix a position, also help realizing the quick switching of workstation.
Fig. 2 shows a layout diagram of a workstation, where the layout diagram shown in fig. 2 includes a safety grating 201, a general turntable 202, an HMI (Human Machine Interface) system 203, a main control cabinet 204, a welding power supply cabinet 205, a safety fence 206, a welding clamp assembly 207, and a workstation robot 208, where the welding clamp assembly 207 includes a welding clamp and a welding clamp bracket, and the main control cabinet and the welding power supply cabinet constitute a control cabinet of the workstation.
Since the production control system includes a plurality of workstations having the same configuration, the layout of the plurality of workstations can be set to the same configuration in order to quickly switch the jig and the welding jig assembly or the like to another workstation for continuing production after the layout of one workstation is determined in order to facilitate the duplication of the production line. It should be understood that fig. 2 is only a preferred schematic diagram of the above-mentioned workstation, and the layout of the workstation may also be set according to practical situations, and it is ensured that the layout of each workstation is consistent, which is not limited by the embodiment of the present invention.
In practical use, the plurality of workstations are generally used for producing the lower vehicle body, such as a cabin assembly, a front floor assembly, a rear floor assembly and the like, different production processes exist in different vehicle types, the production control system can be used for quickly utilizing the idle independent workstations due to different production processes, and specifically, the fixture can be quickly switched to produce the lower vehicle body assembly of another vehicle type so as to realize parallel production.
Specifically, the production tasks issued by the MES server are production tasks corresponding to lower body assemblies of a plurality of vehicle types;
therefore, the process of the main controller generating the job task table includes: the method comprises the steps of obtaining codes of a plurality of vehicle types and work sequence numbers of production processes corresponding to the codes, enabling a main controller to distribute production tasks of the plurality of vehicle types according to the codes and the work sequence numbers and a preset production sequence to generate an operation task list, wherein the operation task list is a production task list produced by the plurality of vehicle types in parallel, and the work sequence numbers are work sequence numbers corresponding to lower vehicle body assemblies of the plurality of vehicle types.
In a specific implementation, the number of the plurality of workstations may also be increased or decreased according to the actual production process requirement, which is not limited in the embodiment of the present invention.
Further, the main Controller, the station Controller, the AGV Controller, and the warehouse Controller may be PLC (Programmable Logic Controller) -based controllers, and include a CPU (Central Processing Unit), an instruction and data memory, an input/output Unit, a power module, and a digital analog Unit therein, so as to achieve an automatic control requirement. For example, the main controller can be an IT-PLC which is in communication connection with an MES server and receives production tasks, and the workstation controller can be realized by the workstation PLC and feeds back the workstation state to the IT-PLC, such as whether the workstation is idle or not; the AGV controller can be set as an AGV-PLC, and is communicated with each AGV to acquire the states of the AGVs, such as whether a scheduling task is executed or not, and carrying work is carried out; the warehouse controller may be configured as a warehouse PLC, disposed at the warehouse, and in communication with the material server of the warehouse to query whether fixtures and materials are used, and the remaining quantity, etc. The specific use condition of the PLC may be set according to an actual situation, which is not limited in the embodiment of the present invention.
Further, as shown in fig. 3, another block diagram of the production control system, in addition to the structure shown in fig. 1, the production control system further includes an RFID reader 50 connected to the station controller 20; a Radio Frequency Identification (RFID) reader is usually disposed in a workstation, and the workstation controller is further configured to send a reading instruction to the RFID reader when the arrival information of the AGV is monitored;
the RFID reader-writer is also used for receiving the reading instruction, reading the RFID tags of the clamp and the material state carried by the AGV and sending the read RFID tags to the workstation server;
the workstation server is also used for judging whether the RFID label is consistent with the process information carried in the operation task list; if so, issuing a working instruction to the production robot; and if not, sending error reporting information to the AGV controller.
When the system is actually used, the AGV controller and the plurality of AGVs form an AGV dispatching subsystem; and each AGV is in communication connection with the AGV controller so as to execute a scheduling task issued by the AGV controller and carry out the handling process of the clamp and the materials.
Further, when the AGV carries a skid, the AGV controller is further used for receiving skid information sent by the AGV; and inquiring whether the skid information is consistent with the skid information contained in the process information or not, and if not, sending skid updating information to the wind turbine switching station, wherein the skid updating information comprises an identification code of the AGV and the skid information contained in the process information, so that the AGV can replace the skid in time, and the carrying efficiency of the clamp and the logistics is improved.
Generally, when the interaction process between the main controller and the station controller, the AGV controller and the warehouse controller is implemented based on a plant ring network, because different controllers are arranged at different places, for example, a work station controller is arranged at each work station, an AGV controller is arranged at an AGV dispatching room, a warehouse controller is arranged at a warehouse and the like, therefore, the communication between the controllers may be a wired communication or a wireless communication, and further, the main controller further includes an OPC (OLE for Process Control) module 101, wherein, the OPC module 101 is a communication module based on OPC technology, which is Object Linking and Embedding (OLE) oriented to process control, a standard access mechanism may be provided for multiple data sources, and thus, communication between multiple controllers may be achieved through OPC techniques. Therefore, the station controller, the AGV controller and the warehouse controller can interact with the main controller through the OPC module.
Further, in order to facilitate a plurality of workers to manage and monitor the production control system, the production control system further comprises a plurality of human-computer interaction interfaces 60; the human-computer interaction interfaces 60 are respectively arranged on different workstations, connected with the workstation controller 20, and used for displaying the configuration of the workstations and the operation task list so that the workers can check the production tasks and the production processes of the current workstations at any time.
For the sake of understanding of the production control system, A, B two vehicle models are produced in parallel, and A, B is used as a code of the two vehicle models.
Assuming that the number of the workstations is 6, and the production tasks corresponding to the lower body sub-assembly of A, B vehicle types are produced, the production process of the A vehicle type comprises the following steps: two orders of a cabin, a first order of a front floor and a first order of a rear floor; the production process of the B vehicle type comprises the following steps: the first sequence of the engine room, the two sequences of the front floor and the two sequences of the rear floor.
It should be understood that, except for the necessity of the production process, the other unnecessary work stations of the 6 independent work stations can be freely matched and combined to realize parallel production, thereby improving the productivity and the equipment utilization rate. In specific implementation, the main controller can obtain the vehicle type codes A and B, and then distributes the production tasks of a plurality of vehicle types according to the preset production sequence according to the codes and the work order number to generate an operation task list. Considering that a plurality of workstations have the same configuration, autonomous movement and duplication are facilitated, and thus, when a lower body sub-assembly of one vehicle type is separately produced, a plurality of processes of the lower body sub-assembly of the vehicle type can be produced in parallel; when the production line is used for producing the lower body sub-assembly of A, B vehicle types in a mixed mode, a plurality of procedures of the lower body sub-assembly of A, B vehicle types can be produced in a parallel mode, wherein fig. 4 shows a schematic diagram of a parallel mode production mode of a single vehicle type, specifically, a schematic diagram of a production mode for producing the lower body sub-assembly of A vehicle type alone, and further fig. 5 shows a schematic diagram of a parallel mode production mode of another single vehicle type, specifically, a schematic diagram of a production mode for producing the lower body sub-assembly of B vehicle type alone; fig. 6 shows a schematic diagram of a parallel production mode for hybrid production of a plurality of vehicle models, taking A, B two vehicle models as an example.
It should be understood that the schematic diagrams of the parallel production modes shown in fig. 4 to fig. 6 are not all parallel production modes, and are not listed here because the number of the collocation combinations is too large.
Based on the parallel production mode, the workflow of the production control system provided by the embodiment of the invention may include:
(1) an IT-PLC (main controller) receives a production task issued from an MES server;
(2) according to the workstation state fed back by the workstation PLC, the AGV state fed back by the AGV-PLC, the fixture and material state fed back by the warehouse PLC, production task allocation is carried out, an operation task table is generated and is issued to the AGV-PLC;
(3) the AGV-PLC sends the corresponding AGV according to the operation task, and the corresponding AGV reaches the appointed operation place;
(4) the IT-PLC issues an operation task to the warehouse, warehouse personnel arrange corresponding fixtures and materials to the AGV according to the operation task, and the AGV carries the fixtures and the materials to reach a designated workstation;
(5) an RFID reader-writer of the workstation reads RFID tags of the clamp and the material and feeds tag information back to the workstation PLC;
(6) the work tasks issued by the workstation PLC and the IT-PLC are mutually checked, if the work tasks are correctly checked, the AGV feeds back an AGV-PLC work completion signal to wait for a new work task;
(7) the workstation PLC issues a production task, the workstation robot starts working, the workstation PLC feeds back a work completion signal to the IT-PLC after the work is completed, if the work completion signal is checked, the workstation PLC feeds back error information to the IT-PLC to wait for processing, and after the error information is eliminated, the production task is continuously completed.
During specific implementation, the production control system can change the general equipment of each workstation according to corresponding production process, production requirements and the like, increase or reduce the number of workstations, and timely carry out production line transformation according to the workstation state, so that the transformation period is favorably shortened, and the production efficiency of the whole manufacturing system is favorably improved.
Example two:
on the basis of the above embodiment, an embodiment of the present invention further provides a production management system, where the production management system includes a production execution system and the production control system described in the first embodiment, and when the production management system is specifically implemented, the production execution system communicates with the production control system through a workshop ring network.
The production execution system comprises an MES server and is used for issuing a production task to the production control system so as to enable the production control system to carry out production work.
Further, an embodiment of the present invention further provides a production control method, where the production control method is used in the production control system described in the first embodiment, and the production control system includes: the system comprises a main controller, and a work station controller, an AGV controller and a warehouse controller which are connected with the main controller; the working station controller is used for feeding back the working station state to the main controller, the AGV controller is used for feeding back the AGV state to the main controller, and the warehouse controller is used for feeding back the clamp and the material state to the main controller.
A flow chart of a production control method as shown in fig. 7, the method comprising the steps of:
step S702, the main controller is in communication connection with the MES server, receives the production tasks issued by the MES server, distributes the production tasks according to the states of the workstations, the AGV states and the states of the fixtures and the materials, generates an operation task table, and issues the operation task table to the workstation controller, the AGV controller and the warehouse controller;
the operation task table comprises a beat table and process information corresponding to production tasks;
step S704, the warehouse controller extracts and displays process information so that a worker can arrange corresponding clamps and materials according to the process information;
step S706, the AGV controller extracts a tempo table and sends a scheduling task to the AGV according to time information contained in the tempo table, so that the AGV carries fixtures and materials according to the scheduling task;
step 708, the work station controller receives the job task list, and issues a job instruction to the production robot according to the job task list, so that the production robot performs production according to the job task list.
The production control method provided by the embodiment of the invention has the same technical characteristics as the production control system provided by the embodiment, so that the same technical problems can be solved, and the same technical effects can be achieved.
The production control system, the production control method, and the computer program product of the production management system according to the embodiments of the present invention include a computer-readable storage medium storing a program code, where instructions included in the program code may be used to execute the method described in the foregoing method embodiments, and specific implementation may refer to the method embodiments, and will not be described herein again.
In addition, in the description of the embodiments of the present invention, unless otherwise explicitly specified or limited, the terms "mounted," "connected," and "connected" are to be construed broadly, e.g., as meaning either a fixed connection, a removable connection, or an integral connection; can be mechanically or electrically connected; they may be connected directly or indirectly through intervening media, or they may be interconnected between two elements. The specific meaning of the above terms in the present invention can be understood in specific cases for those skilled in the art.
The functions, if implemented in the form of software functional units and sold or used as a stand-alone product, may be stored in a computer readable storage medium. Based on such understanding, the technical solution of the present invention may be embodied in the form of a software product, which is stored in a storage medium and includes instructions for causing a computer device (which may be a personal computer, a server, or a network device) to execute all or part of the steps of the method according to the embodiments of the present invention. And the aforementioned storage medium includes: a U-disk, a removable hard disk, a Read-Only Memory (ROM), a Random Access Memory (RAM), a magnetic disk or an optical disk, and other various media capable of storing program codes.
Finally, it should be noted that: although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art will understand that the following embodiments are merely illustrative of the present invention, and not restrictive, and the scope of the present invention is not limited thereto: any person skilled in the art can modify or easily conceive the technical solutions described in the foregoing embodiments or equivalent substitutes for some technical features within the technical scope of the present disclosure; such modifications, changes or substitutions do not depart from the spirit and scope of the embodiments of the present invention, and they should be construed as being included therein. Therefore, the protection scope of the present invention shall be subject to the protection scope of the claims.
Claims (9)
1. A production control system, comprising: the system comprises a main controller, and a work station controller, an AGV controller and a warehouse controller which are connected with the main controller; the system comprises a plurality of workstations with the same configuration, each workstation is provided with the workstation controller, and the same configuration comprises the following steps: the workstations are arranged in the same way, the sizes of the workstations are the same, and the general equipment of each workstation is the same;
the working station controller is used for feeding back a working station state to the main controller, the AGV controller is used for feeding back an AGV state to the main controller, and the warehouse controller is used for feeding back a clamp and a material state to the main controller;
the main controller is in communication connection with the MES server and is used for receiving a production task issued by the MES server, distributing the production task according to the workstation state, the AGV state and the clamp and material state, generating an operation task table and issuing the operation task table to the workstation controller, the AGV controller and the warehouse controller; the operation task table comprises a beat table and process information corresponding to the production task;
the warehouse controller is used for extracting and displaying the process information so that a worker arranges corresponding clamps and materials according to the process information;
the AGV controller is used for extracting the beat table and sending a scheduling task to the AGV according to time information contained in the beat table so that the AGV can carry the clamp and the material according to the scheduling task;
the working station controller is used for receiving the operation task list and issuing an operation instruction to the production robot according to the operation task list so that the production robot carries out production work according to the operation task list;
the working station controller is also used for sending fault information to the main controller when the fault information of the general equipment is monitored; the main controller is also used for receiving fault information sent by the working station controller, searching for an idle working station in a plurality of working stations with the same configuration, and switching a clamp and a welding clamp assembly of the working station corresponding to the fault information to the idle working station;
the production tasks issued by the MES server are the production tasks corresponding to the lower body assemblies of a plurality of vehicle types;
the process of the main controller for generating the job task table comprises the following steps: the method comprises the steps of obtaining codes of a plurality of vehicle types and work sequence numbers of production processes corresponding to the codes, distributing production tasks of the plurality of vehicle types according to a preset production sequence according to the codes and the work sequence numbers, and generating an operation task list, wherein the operation task list is a production task list produced by the plurality of vehicle types in parallel, and the work sequence numbers are work sequence numbers corresponding to lower body assemblies of the plurality of vehicle types.
2. The system according to claim 1, characterized in that the generic equipment of each of said workstations comprises at least: the device comprises a workstation robot, a coping device, a universal rotary table, a rotary table base station, a welding clamp assembly and a control cabinet, wherein the universal rotary table is provided with a clamp;
the universal equipment of each workstation is the same, including the model, the size and the equipment layout of the universal equipment are the same;
the working station controller is also used for sending the fault information to the main controller when the fault information of the general equipment is monitored;
the main controller is further configured to receive the fault information, search for an idle workstation among a plurality of workstations with the same configuration, and switch the clamp and the welding tongs assembly of the workstation corresponding to the fault information to the idle workstation.
3. The system of claim 1, further comprising an RFID reader coupled to the station controller;
the working station controller is further used for sending a reading instruction to the RFID reader-writer when the arrival information of the AGV is monitored;
the RFID reader-writer is further used for receiving the reading instruction, reading the RFID tags of the clamp and the material state carried by the AGV, and sending the read RFID tags to the workstation server;
the workstation server is also used for judging whether the RFID label is consistent with the process information carried in the operation task list or not; if yes, issuing a working instruction to the production robot; and if not, sending error reporting information to the AGV controller.
4. The system of claim 1 wherein said AGV controller, and a plurality of said AGVs comprise an AGV dispatch subsystem;
each the AGV all with AGV controller communication connection.
5. The system of claim 4 wherein the AGV controller is further configured to receive a skid message from the AGV;
and inquiring whether the skid information is consistent with the skid information contained in the process information or not, and if not, sending skid updating information to a wind turbine switching station, wherein the skid updating information comprises the identification code of the AGV and the skid information contained in the process information.
6. The system of claim 1 wherein said master controller further comprises an OPC module by which said station controller, said AGV controller and said warehouse controller interact with said master controller.
7. The system of claim 1, further comprising a plurality of human-machine interface interfaces;
the plurality of human-computer interaction interfaces are respectively arranged on different workstations, are connected with the workstation controller and are used for displaying the configuration of the workstations and the operation task list.
8. A production management system, characterized in that the production management system comprises a production execution system and a production control system according to any one of claims 1 to 7, wherein the production execution system and the production control system communicate through a workshop ring network;
the production execution system comprises an MES server and is used for issuing a production task to the production control system so as to enable the production control system to carry out production work.
9. A production control method for use in the production control system according to any one of claims 1 to 7, the production control system comprising: the system comprises a main controller, and a work station controller, an AGV controller and a warehouse controller which are connected with the main controller; the system comprises a main controller, a working station controller, an AGV controller and a warehouse controller, wherein the working station controller is used for feeding back a working station state to the main controller, the AGV controller is used for feeding back an AGV state to the main controller, and the warehouse controller is used for feeding back a clamp and a material state to the main controller; the method comprises the following steps:
the main controller is in communication connection with the MES server, receives a production task issued by the MES server, distributes the production task according to the workstation state, the AGV state and the clamp and material state, generates an operation task table, and issues the operation task table to the workstation controller, the AGV controller and the warehouse controller; the operation task table comprises a beat table and process information corresponding to the production task;
the warehouse controller extracts and displays the process information so that a worker arranges corresponding clamps and materials according to the process information;
the AGV controller extracts the beat table and sends a scheduling task to the AGV according to time information contained in the beat table so that the AGV can carry the clamp and the materials according to the scheduling task;
the working station controller receives the operation task list and issues an operation instruction to the production robot according to the operation task list so that the production robot carries out production work according to the operation task list;
when monitoring the fault information of the general equipment, the working station controller sends the fault information to the main controller; the main controller receives fault information sent by the working station controller, searches for an idle working station in a plurality of working stations with the same configuration, and switches a clamp and a welding clamp assembly of the working station corresponding to the fault information to the idle working station;
the production tasks issued by the MES server are the production tasks corresponding to the lower body assemblies of a plurality of vehicle types;
the process of the main controller for generating the job task table comprises the following steps: the method comprises the steps of obtaining codes of a plurality of vehicle types and work sequence numbers of production processes corresponding to the codes, distributing production tasks of the plurality of vehicle types according to a preset production sequence according to the codes and the work sequence numbers, and generating an operation task list, wherein the operation task list is a production task list produced by the plurality of vehicle types in parallel, and the work sequence numbers are work sequence numbers corresponding to lower body assemblies of the plurality of vehicle types.
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| WO2021042292A1 (en) * | 2019-09-04 | 2021-03-11 | 北京图森智途科技有限公司 | Hub service area demand resolution system and method |
| CN110968065A (en) * | 2019-12-18 | 2020-04-07 | 北京云杉世界信息技术有限公司 | Fresh food processing control method and device |
| CN111123929A (en) * | 2019-12-23 | 2020-05-08 | 天行智控(成都)科技有限公司 | Rail transport partition scheduling system |
| CN111633324B (en) * | 2020-06-08 | 2022-07-22 | 松山湖材料实验室 | Turbine blade manufacturing method and device based on monitoring system and monitoring system |
| WO2022111450A1 (en) * | 2020-11-26 | 2022-06-02 | 广东博智林机器人有限公司 | Brick making system, production control method and apparatus, system, production device, and medium |
| CN113435808B (en) * | 2021-03-15 | 2023-04-18 | 中国第一汽车股份有限公司 | AGV comprehensive scheduling method and system based on RFID technology |
| CN113414513B (en) * | 2021-06-12 | 2023-04-18 | 中国第一汽车股份有限公司 | AGV traction clamp front wall flexible welding line scheduling method and system |
| CN114237175B (en) * | 2021-12-01 | 2023-11-17 | 北京福田戴姆勒汽车有限公司 | Monitoring system and monitoring method for vehicle manufacturing assembly workshop equipment |
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