CN113298348B - Intelligent manufacturing process control system and method suitable for personalized customization - Google Patents
Intelligent manufacturing process control system and method suitable for personalized customization Download PDFInfo
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Abstract
The invention provides an intelligent manufacturing process control system adaptive to personalized customization, comprising: the system comprises a product module management unit, a product analysis unit, a module association unit, a module cluster aggregation unit and a module cluster configuration interface unit. The invention also provides an intelligent manufacturing process control method suitable for individual customization. The invention is oriented to the process control of personalized customization production, improves the customizability through the product composition of the module cluster, and improves the production efficiency and the quality stability of the product. Meanwhile, based on the production process organization of the module cluster, the processing mode, the production line composition and the flow of each production procedure and equipment thereof in the flexible production line can be kept stable on the whole, and the definability and the definition efficiency of the flexible production line are improved. The transparency of production information is facilitated based on the modularized and flexible production line integration layer.
Description
Technical Field
The invention relates to the technical field of intelligent manufacturing, in particular to an intelligent manufacturing process control system and method suitable for personalized customization.
Background
Since the introduction of the industrial age, the manufacturing model of the product has moved from the first manual production (industrial 1.0), mass production (industrial 2.0), to mass-customized production (industrial 3.0), and in recent years, the development of the smart manufacturing technology has moved to personalized customized production (i.e., industrial 4.0).
The mass production is characterized in that a fixed production line is used for producing products of single variety in mass, and the raw material purchasing cost and the production cost are reduced through scale benefits. The mass production divides the production of complex products into a plurality of working procedures, each working procedure is fixed as a step, and raw materials and intermediate products are transferred from the previous working procedure to the next working procedure in a fixed sequence along a production line and are sequentially processed. The advantages of mass production are high productivity, high efficiency and low cost. The disadvantage is that a mass production line produces only a single type of product and multiple lines are required if multiple types of products are to be produced.
On the basis of technologies such as mechatronics, computer networks, production management informatization systems and the like, on a large-scale customized production, alternatives are respectively put into a plurality of procedures of a mass production assembly line, and production instructions are issued according to the customized requirements of customers to select the alternatives of the procedures; for example, if there are 4 alternatives in process 1, 2 alternatives in process 2, 2 alternatives in process 4, and 4 alternatives in process 5, then the entire line can run 4 × 2 × 4=128 types of products; the options of the product types are provided for the customer to select, and the user can select and match the options according to which of the options meets the requirements of the user, so that customization is realized. However, the customization of mass-customized production is limited customization, and consumers cannot actually participate in the design and production process of products, and only passively select the type of products in the selection, and thus it is not a personalized production that is adapted to the individual characteristics and needs of each consumer in nature.
The personalized customized production is to design and produce products according to personalized characteristics and requirements of each consumer. In the personalized customization production process, factors such as component parts, structural form, parameters, materials, manufacturing process, assembly, packaging and the like of the product are adaptively adjusted or regenerated according to the personalized customization requirements of each consumer, namely, various optional schemes are not preset by manufacturers any more, but a set of product manufacturing scheme meeting the requirements is really generated from the personalized customization requirements of the consumers instead of selection and collocation of the consumers.
The personalized customization production obviously can better meet the requirements of consumers on products, improve the user experience of product use, and is beneficial to realizing differentiated competition compared with similar products.
However, in terms of manufacturing processes, the size of each order is obviously reduced while the total number of orders is increased in geometric grade due to personalized customized production, types of products to be manufactured by the production line are rapidly diversified, each process of the production line and manufacturing equipment thereof need to be converted from focusing on single processing to being compatible with multiple processing modes, the composition and process flow of the production line need to be changed frequently, and the switching between the processing modes and the production line needs to be realized simply and rapidly. Meanwhile, the production efficiency and cost control required by large-scale production are kept, and the stability of the production process and the product quality is guaranteed. In the above changes, the generation, transmission, and analysis of the data stream and the control command stream in the production management are more complicated, and the requirements for flexibility, compatibility, and transparency of the production management information increase. All of these variations require the provision of intelligent manufacturing process control systems and methods that can accommodate individualized customization.
Problems with the prior art for process control for personalized custom production include: (1) In order to meet the individual requirements of consumers, secondary reconstruction of factors such as product components, structural forms, parameters, materials, manufacturing processes, assembly, packaging and the like must be performed, and how to ensure the stability of the process and quality of the reconstructed product. Because of the limited types of products produced by the single production and customized production of industry 2.0 and industry 3.0, the quality test of the products is facilitated, and an effective quality inspection standard process is formed. But for personalized production, the product is variable and has no foreexamples, so that sufficient product tests are difficult to develop, and the standard flow of quality inspection is not easy to be clear. (2) As described above, while satisfying the personalized production requirements, the processing mode of the production process and its equipment, the production line configuration and its flow remain dynamic, but frequent switching of mode and flow will also greatly reduce the production efficiency and reduce the stability and reliability of production, so an efficient, concise and flexibly definable control mode for switching of production mode and production line flow is required. (3) The increase of the product type and order magnitude, the improvement of the complexity and the dynamic property of the production process and the increase of the information flow and data volume lead the difficulty of analyzing, monitoring and regulating the production management information to be obviously increased, and put forward higher requirements on cycle control, task scheduling and process tracking in the production management.
Disclosure of Invention
Object of the invention
To overcome at least one of the above-mentioned deficiencies of the prior art, the present invention provides an intelligent manufacturing process control system and method that is adaptive to individual customization.
(II) technical scheme
As a first aspect of the present invention, the present invention discloses an intelligent manufacturing process control system adapted to personalization, characterized by comprising:
the product module management unit is used for defining, registering and managing the composition modules of the personalized customized product and the customizable attributes of the composition modules;
the product analysis unit is used for analyzing any personalized product into a module list according to product information in the product order;
the module association unit is used for associating the composition modules in the module list into module combinations according to the association of the product composition modules;
the module cluster aggregation unit is used for aggregating module combinations of personalized customized products in the same manufacturing time window into a module cluster according to the characteristic similarity of the module combinations;
the module cluster configuration interface unit is used for establishing a configuration list for each module cluster according to the relevant information of the module cluster;
and the flexible production line is used for converting the configuration data items into production instructions according to the configuration data items in the configuration list and producing the module assemblies in the module clusters.
Preferably, the product module management unit classifies the composition modules of the personalized customized product into a basic module, a matching module and a custom module; the basic module is a module with a general structure and necessary for each individual customized product; the matching module is a module which can be matched according to the functions, appearances and the like of each individual customized product; the custom module is a modular product component which is customized according to the individual preference and demand of the consumer.
Preferably, the product parsing unit compares the module list with the descriptive data structure of each type of module, thereby determining whether the module included in the module list belongs to the basic module, the matching module, or the custom module.
Preferably, the module association unit divides the constituent modules in the module list into a plurality of module combinations for the basic module, the matching module and the custom module in the module list based on the association of each module.
Preferably, the module cluster aggregation unit takes the custom module combination of each customized product as an independent module cluster for the custom module combination; for the module combination formed by the basic module and/or the matching module, the module combination characteristics are extracted according to the module type, the specification model of each type module, the customization parameter range and the customization alternative contained in the module combination, and the similarity between the module combinations is evaluated, so that the module combinations are clustered into module clusters.
As a second aspect of the present invention, the present invention discloses an intelligent manufacturing process control method adapted to individual customization, comprising:
defining, registering and managing the composition modules of the personalized customized products and the customizable attributes of the composition modules;
analyzing any personalized customized product into a module list according to product information in the product order;
according to the relevance of the product composition modules, correlating the composition modules in the module list into module combinations;
aggregating module combinations of personalized customized products in the same manufacturing time window into module clusters according to the characteristic similarity of the module combinations;
establishing a configuration list for each module cluster according to the relevant information of the module cluster;
and converting the configuration data items into production instructions according to the configuration data items in the configuration list, and producing the module assemblies in the module cluster.
Preferably, the composition modules of the personalized customized product are classified into a basic module, a matching module and a self-defining module; the basic module is a module with a general structure and necessary for each individual customized product; the matching module is a module which can be matched according to the functions, appearances and the like of each individual customized product; the custom module is a modular product component which is customized according to the personalized preference and demand of the consumer.
Preferably, the list of modules is compared to the descriptive data structure for each type of module to determine whether the module contained in the list of modules belongs to a base module, a match module, or a custom module.
Preferably, for the basic module, the matching module and the custom module in the module list, the constituent modules in the module list are divided into a plurality of module combinations based on the relevance of each module.
Preferably, for the custom module combination, the custom module combination of each customized product is taken as an independent module cluster; for the module combination formed by the basic module and/or the matching module, the module combination characteristics are extracted according to the module types, specification models of various types of modules, customized parameter ranges and customized alternatives contained in the module combination, and the similarity between the module combinations is evaluated, so that the module combinations are clustered into module clusters.
(III) advantageous effects
The invention is oriented to the process control of personalized customization production, improves the customizability through the product composition of the module cluster, and improves the production efficiency and the quality stability of the product. Meanwhile, the production process organization based on the module cluster ensures that all production procedures and equipment processing modes, production line composition and flows in the flexible production line are integrally kept stable, and the definability and the definition efficiency of the flexible production line are improved. The transparency of production information is facilitated based on the modularized and flexible production line integration layer.
Drawings
The embodiments described below with reference to the drawings are illustrative and intended to explain and illustrate the present invention and should not be interpreted as limiting the scope of the invention.
FIG. 1 is a block diagram of an intelligent manufacturing process control system adapted to personalization provided by the present invention;
FIG. 2 is a block diagram of a flexible production line provided by the present invention;
FIG. 3 is a flow chart of a method for intelligent manufacturing process control with personalization customization provided in accordance with the present invention.
Detailed Description
In order to make the implementation objects, technical solutions and advantages of the present invention clearer, the technical solutions in the embodiments of the present invention will be described in more detail below with reference to the accompanying drawings in the embodiments of the present invention.
It should be noted that: in the drawings, the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described are some embodiments of the present invention, not all embodiments, and features in embodiments and embodiments in the present application may be combined with each other without conflict. 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.
As shown in fig. 1, the intelligent manufacturing process control system adapted to personalized customization provided by this embodiment includes: the system comprises a product module management unit, a product analysis unit, a module association unit, a module cluster aggregation unit and a module cluster configuration interface unit.
And the product module management unit is used for defining, registering and managing the composition modules of the personalized customized products and the customizable attributes of the composition modules.
In order to realize customized product production, it is necessary to modularize the components of the product, i.e. integrate several components into a standardized module, and then assemble the module into a complete product. Because the modularization can compress the inside spare part total number of product, the standardization of mutually supporting between inside spare part of reinforcing product and the spare part, the stability of reinforcing product reduces the degree of difficulty of equipment. Particularly for customized products, the modularization can reduce the mutual coupling among parts, so that the influence interference of the customization of the module on other modules is obviously reduced, the standardization is favorable for the mutual matching between the customized module and other modules, and the customized module can adopt the assembly steps and the flow similar to other modules.
The product module management unit classifies the composition modules of the personalized customized products into a basic module, an optional module and a custom module.
The basic module is a module with a general structure and necessary for each individual customized product; the matching module is a module which can be matched according to the functions, appearances and the like of each individual customized product. The basic module and the matching module are standard type modules provided by a production party after pre-design, experiment and debugging, and production processes and manufacturing equipment for the basic module and the matching module are configured in a production line. Of course, the basic module and the matching module also have customizability; for example, the base module and the matching module can be customized in a large batch, each module provides multiple options for customization, and corresponding processes and equipment on a production line can realize the processing of the base module and the matching module according to the selected options. Or, the basic module and the matching module can also have a certain customizable range in the aspects of parameters and the like, so long as the parameters specified by the customer are in the customizable range, the corresponding processes and equipment on the production line can be processed according to the parameters through conventional and expected numerical setting, and the basic module or the matching module in the customizable range can meet the product performance and quality standards through the prior design, experiment and debugging and can be matched with other modules.
For example, for producing personalized and customized children's bicycle products, the base module includes a frame, front and rear wheels, handlebars, front and rear fenders, axles, chains, pedals, a seat damper, brakes, etc.; the matching module can comprise a front basket, a rear seat, a bell, a battery car lamp, a battery horn, decorative strips of various colors on the frame, fluorescent strips and the like. Modules such as vehicle frames, front and rear wheels all have multiple alternatives of different parameter specifications or provide customizable parameter ranges.
The custom module is a modular product component customized independently according to the personalized preference and demand of a consumer, is not a module of a standard type provided by a producer, and has no preset process and equipment for the custom module on a production line. The custom module comprises at least the following cases: firstly, for a basic module and an optional module, the parameter range customized by a consumer exceeds the customizable parameter range; for example, the customer customizes a vehicle seat according to the child development condition, and the length, width and thickness of the vehicle seat exceed the range of customizable parameters of the vehicle seat serving as a base module. The second is that the self-defined module is other types of modules than the types of modules provided by the producer in advance. For another example, a consumer customizes to install a three-dimensional car logo on the front mudguard, and the 3D shape of the car logo is designed by the consumer, such as the shape of a cartoon animal or a character; in order to install the car logo, obviously, the self-defined module also comprises a fixing screw for fixing a car logo base on the front mudguard, and meanwhile, the front mudguard serving as the basic module also needs to be a specially processed front mudguard with screw holes at the front end.
Production management personnel can define, register, delete and modify the component modules of the product and the descriptive data structure thereof through the product module management unit. The product module management unit employs a descriptive data structure to express the ID identification, module type, specification model, and customizable attributes of each module. The product module management unit may register and manage the above constituent modules and their descriptive data structures through a product module database. Wherein the customizable attributes comprise options for the base module or the patch module, and/or customizable parameter ranges. For example, in the child bicycle product of the above example, the product module management unit may define, register and manage module types of the component modules, including: the bicycle comprises a frame, front and rear wheels, a handlebar, front and rear fenders, a wheel shaft, a chain, pedals, a saddle shock absorber, a brake, a front basket, a rear seat, a bell, a battery car lamp, a battery horn, decorative strips and fluorescent strips of various colors on the frame, and the like; each type of module may in turn comprise a different specification, for example one specification for each shape of the vehicle frame, and each specification is characterised by its own ID. For each specification type of vehicle frame, the length, height and other dimensions of the vehicle frame can be customized within a certain range, and the vehicle frame is defined as customizable attributes.
The product analysis unit is used for analyzing any personalized customized product into a module list according to product information in the product order.
The product analysis unit firstly decomposes the product information in the order into a module list required by the product according to the product information in the order, extracts parameters, personalized demand information and the like in the product information and corresponds to each module in the module list. When a customer places an order for a personalized customized product, the customer selects a configurable matching module on the basis of a product prototype template provided by a manufacturer, and inputs self-defined parameters or selects one of optional solutions for one or more basic modules and matching modules of the product; in addition, the customer can realize self-definition by using a mode of inputting the personalized demand description information. The product analysis unit obtains the product information in the order from the order interface, and the product information in the order can be in a form or a text form. The product analysis unit is preset with a key information extraction rule, each type of module defined in the product module management unit is provided with a relevant information extraction index, so that the modules required by the product can be determined from the product information of an order, the module list is formed, and parameters and personalized requirements in the product information correspond to each module in the module list.
Furthermore, the product analysis unit compares the module list with the descriptive data structures of each type of module in the product module management unit, so as to determine whether the module contained in the module list belongs to the basic module, the matching module or the self-defined module. For example, if the module type and parameters of a module in the module list conform to the type and customizable attributes of a base module or a matching module, the module in the module list is determined as the base module or the matching module; and if the module type of a certain module in the module list is not in accordance with the types of the basic module and the matching module, or the parameter of the certain module in the module list exceeds the customizable range of the basic module and the matching module, determining the module in the module list as a self-defined module.
And the module association unit is used for associating the composition modules in the module list into a module combination according to the association of the product composition modules. For the basic module, the matching module and the custom module in the module list determined by the product analysis unit, the composition modules in the module list are divided into a plurality of module combinations based on the relevance of each module, namely the assembly matching relationship or the function matching relationship among the modules. For the user-defined module, the module association unit combines the basic modules/matching modules which have an assembly matching relationship or a function matching relationship with the user-defined module into a user-defined module combination. For other basic modules and optional modules, the module association unit divides the basic modules and optional modules into module combinations according to a set module combination scheme. For example, in the above example of a child bicycle product, the seat as a custom module needs to be combined with the seat damper as a custom module according to the functional matching relationship, and the custom size of the seat inevitably causes the size of the seat damper to be simultaneously increased or the number of the shock absorbing springs to be configured to be increased. For example, a three-dimensional emblem as a custom module requires a specially-processed front fender having a screw hole at the front end to be combined together as the custom module based on the assembling and fitting relationship. For the frame of the basic module, the handlebar, the chain and the pedal which have the assembly relation with the frame can be used as the module combination according to the preset module combination scheme.
After the association forms the module combination, the module association unit also executes adaptation degree check on each module combination, so that the adaptation degrees of the customized component modules are evaluated aiming at the module combination, and an early warning is provided for the module combination with the evaluated adaptation degree lower than an allowable range. For example, for the vehicle frame with the customized size parameters, the degree of adaptation to the customized size parameters of the vehicle frame needs to be evaluated for other modules such as handlebars, chains, pedals and the like in the module combination.
And the module cluster aggregation unit is used for aggregating module combinations of personalized customized products in the same manufacturing time window into a module cluster according to the characteristic similarity of the module combinations.
Obviously, any product order will have a delivery time limit set, i.e. the order relates to the time limit for the personalized customized product to complete its manufacture, so that a manufacturing time window can be defined based on this time limit, for example every few hours, every day, every week as a manufacturing time window. And carrying out module combination formed after product analysis and module combination on all the personalized customized products with delivery time limit in the window, and carrying out characteristic similarity evaluation on the module combination.
For the custom module combinations, because the custom module combinations of different customized products are generally low in similarity, the custom module combinations of each customized product are generally used as an independent module cluster. For the module combination formed by the basic module and/or the matching module, the module combination characteristics can be extracted according to the module type contained in the module, the specification and model of each type module, the customization parameter range, the customization alternative and the like, and the similarity between the module combinations is evaluated, so that the module combinations are clustered into module clusters. The similarity of the module combination characteristics in the same module cluster is maximized, and the difference of the module combination characteristics in different module clusters is maximized. After the module combinations in the manufacturing time window are aggregated for the first time to form a plurality of module clusters, for the module combinations newly added in the manufacturing time window, the module combinations are classified into one of the module clusters based on the similarity between the module combination characteristics of the module combinations and each module cluster.
In the subsequent intelligent manufacturing link of the invention, the organization construction and the dynamic configuration of the flexible production line are carried out according to the module cluster. Based on the similarity of the module clusters, the production processes and the processing modes of the production processes and the equipment thereof, the production line structure and the flow thereof in the flexible production line can be kept stable on the whole, large and frequent switching is avoided, the change of specifications, parameters and optional schemes of module combination in the same module cluster is adapted, and the flexible production line only needs to be debugged locally and in a small amount of processes, so that the production efficiency and the stability are improved, and the definition and the control of the flexible production line are facilitated. In particular, if the manufacturing plant has a plurality of flexible lines side by side, individual clusters of modules may be assigned to different flexible lines. If there is only a single line, the modules may be clustered in time to be assigned to the flexible production line.
According to the invention, a flexible production line which can define production modes and production line flow switching efficiently and simply is set up, and production and assembly of each module are realized aiming at a module cluster by using a programming configuration mode. As shown in fig. 2, the flexible manufacturing line includes: production layer, supporting layer, integration layer.
The production layer consists of a flexible production unit and a flexible transmission unit; the flexible production unit is used for realizing the manufacture and assembly of the module combination of the personalized customized product, corresponds to equipment in each production process for producing and assembling the module combination, and can realize the optional adjustment or parameter adjustment of any component module of the product as the requirement of flexible production; the flexible transmission unit is a transportation system for autonomous conduction between the flexible production units, is responsible for flexible material transmission between the flexible production units, and can be realized by means of multidirectional conveying belts or tray robots and the like, so that the switching of production line processes and the collocation of different module combinations are realized.
For the module combination formed by the basic module and/or the matching module, because the basic module and the matching module are both standard type modules, and the flexible production modules aiming at the basic module and the matching module are configured in the flexible production line, the flexible production module can be configured by performing corresponding production parameter configuration only according to the module type, specification type, parameters, alternatives and the like of each module in the module combination.
For the custom module combination, if the custom module is judged to belong to the same type of module as the basic module or the matching module, but the parameter exceeds the customizable range of the basic module or the matching module, the related flexible production module needs to be called to configure the overproduction parameter. If the custom module belongs to a type other than the basic module and the matching module, the supporting layer needs to be called and configured based on the personalized requirements of the custom module.
The supporting layer is composed of supporting production units and is used for calling corresponding supporting production units to produce according to the individual requirements of the module types which do not belong to the custom modules of the basic module and the matching module. For example, for the stereo emblem in the above children bicycle product, the 3D printer device as the support layer production unit needs to be called for production.
The integrated layer is used as a middle layer of the flexible production line, is downwards connected with the flexible production unit, the flexible transmission unit and the supporting production unit based on various industrial Internet of things protocols, upwards provides configuration and calling interfaces for the flexible production unit, the flexible transmission unit and the supporting production unit, and realizes information feedback on the flexible production line. The specific functions of the integration layer include: firstly, the standardization of the data format of the flexible production line is realized, and the protocol standardization of different industrial control protocol data in the heterogeneous production unit and the transmission unit is realized. And secondly, a production safety firewall is defined to perform safety protection on the flexible production unit, the flexible transmission unit and the supporting production unit, so that the operation safety is guaranteed. The integrated layer controls the authority of all commands for configuring the flexible production unit, the flexible transmission unit and the support production unit through a security strategy. And thirdly, providing a message mechanism of the flexible production line to the upper layer, so that the data of the flexible production line can be provided to the upper layer after being collected, thereby realizing transparent management of the production process, receiving a production instruction of an upper information system such as MES (manufacturing execution system) through the message mechanism, and forwarding the production instruction to the production unit and the transmission unit for execution.
Specifically, as shown in FIGS. 1-2, the integration layer includes a module cluster configuration interface unit. For the module clusters formed by the module cluster aggregation unit, the module cluster configuration interface unit obtains the relevant information of the module clusters from the module cluster aggregation unit, and establishes a configuration list for each module cluster. The configuration sheet has configuration data items defined for adapting the module types of the module clusters, the specification models of the respective types of modules, the customization parameter ranges, the customization alternatives, etc., and the configuration data items describe production configuration information of the flexible production unit, the flexible transmission unit and the support production unit of the flexible production line for producing each module combination in the module cluster. The integrated layer is issued to the flexible production unit, the flexible transmission unit and the supporting production unit of the flexible production line in a mode of reading the configuration data items in the configuration list and converting the configuration data items into production instructions, and therefore production of the module assembly of the module cluster is achieved.
Based on the above system, the present invention provides an intelligent manufacturing process control method that accommodates personalization, as shown in fig. 3. The specific steps of the method are described below.
First, the constituent modules of the personalized custom product and the customizable attributes of the constituent modules are defined. In this step, the composition modules of the personalized customized product are defined as a base module, an optional module and a custom module. In this step, a descriptive data structure is used to express the ID, module type, specification, and customizable attributes of each module. Also, the above constituent modules and their descriptive data structures may be registered and managed by a product module database. The customizable attributes include alternatives for the base module or the patch module, and/or customizable parameter ranges.
And analyzing any personalized customized product into a module list according to the product information in the product order. According to the product information in the order, the product information is decomposed into a module list required by the product, and parameters, personalized demand information and the like in the product information are extracted and correspond to each module in the module list. When a customer places an order for a personalized customized product, a configurable matching module is selected on the basis of a product prototype template provided by a manufacturer, and customized parameters are input or one of optional solutions is selected for one or more basic modules and matching modules of the product; in addition, the customer can realize self-definition by using a mode of inputting the personalized demand description information. The product analysis unit obtains the product information in the order from the order interface, and the product information in the order can be in a form or a text form. The product analysis unit presets a key information extraction rule, each type of module defined in the product module management unit has a relevant information extraction index, so that which modules are needed by the product can be determined from the product information of the order, the module list is formed, and parameters and personalized requirements in the product information correspond to each module in the module list.
And comparing the module list with the descriptive data structures of each type of module, thereby determining whether the modules contained in the module list belong to the basic module, the matching module or the self-defined module. For example, if the module type and parameters of a module in the module list conform to the type and customizable attributes of a base module or a matching module, the module in the module list is determined as the base module or the matching module; and if the module type of a certain module in the module list is not in accordance with the types of the basic module and the matching module, or the parameter of the certain module in the module list exceeds the customizable range of the basic module and the matching module, determining the module in the module list as a self-defined module.
And associating the composition modules in the module list into a module combination according to the relevance of the product composition modules. For the basic module, the matching module and the custom module in the module list, the composition modules in the module list are divided into a plurality of module combinations based on the relevance of each module, namely the assembly matching relationship or the function matching relationship among the modules. And for the custom module, the basic module/the matching module which has an assembly matching relationship or a function matching relationship with the custom module are jointly combined into a custom module combination. And for other basic modules and optional modules, dividing the basic modules and the optional modules into module combinations according to a set module combination scheme.
After the module combinations are formed in an associated mode, adaptation degree inspection is carried out on each module combination, therefore, the adaptation degree of the customized component modules is evaluated according to the module combinations, and early warning is provided for the module combinations with the evaluated adaptation degree lower than an allowable range.
And aiming at the module combinations of the personalized customized products in the same manufacturing time window, aggregating the module combinations into a module cluster according to the characteristic similarity of the module combinations. Any product order will have a delivery time limit set, from which a manufacturing time window is defined, for example every few hours, every day, every week. And carrying out module combination formed after product analysis and module combination on all the personalized customized products with delivery time limit in the window, and carrying out characteristic similarity evaluation on the module combination. For the custom module combinations, because the custom module combinations of different customized products are generally low in similarity, the custom module combination of each customized product is generally used as an independent module cluster. For the module combination formed by the basic module and/or the matching module, the module combination characteristics can be extracted according to the module type contained by the module, the specification and model of each type module, the customization parameter range, the customization alternative scheme and the like, and the similarity between the module combinations is evaluated, so that the module combinations are clustered into module clusters. The similarity of the module combination characteristics in the same module cluster is maximized, and the difference of the module combination characteristics in different module clusters is maximized. After the module combinations in the manufacturing time window are aggregated for the first time to form a plurality of module clusters, for the module combinations newly added in the manufacturing time window, the module combinations are classified into one of the module clusters based on the similarity between the module combination characteristics of the module combinations and each module cluster.
And carrying out organization construction and dynamic configuration of the flexible production line according to the module cluster. Based on the similarity of the module clusters, the production processes and the processing modes of the equipment, the production line constitution and the flow thereof in the flexible production line can be kept stable on the whole, the large and frequent switching is avoided, the change of the specification, the parameter and the optional scheme of the module combination in the same module cluster is adapted, and only the local debugging of a small number of processes is needed to be carried out on the flexible production line, so that the production efficiency and the stability are improved, and the definition and the control of the flexible production line are facilitated. In particular, if the manufacturing plant has a plurality of flexible lines side by side, individual clusters of modules may be assigned to different flexible lines. If there is only a single line, the modules may be clustered in time to be assigned to the flexible production line.
For the module combination formed by the basic module and/or the matching module, because the basic module and the matching module are both standard type modules, and the flexible production modules aiming at the basic module and the matching module are configured in the flexible production line, the flexible production module can be configured by performing corresponding production parameter configuration only according to the module type, specification type, parameters, alternatives and the like of each module in the module combination.
For the custom module combination, if the custom module is judged to belong to the same type of module as the basic module or the matching module, but the parameter exceeds the customizable range of the basic module or the matching module, the related flexible production module needs to be called to configure the overproduction parameter. If the custom module belongs to a type other than the basic module and the matching module, the supporting layer needs to be called and configured based on the personalized requirements of the custom module.
For the module clusters, the related information of the module clusters is obtained, and a configuration list is established for each module cluster. The configuration sheet has configuration data items defined for adapting the module types of the module clusters, the specification models of the respective types of modules, the customization parameter ranges, the customization alternatives, etc., the configuration data items describing production configuration information of the flexible production unit, the flexible transmission unit and the support production unit of the flexible production line for producing each module combination in the module cluster. The configuration data items in the configuration list are read and converted into the production instructions, and the production instructions are issued to the flexible production unit, the flexible transmission unit and the supporting production unit of the flexible production line, so that the production of the module assembly of the module cluster is realized.
Therefore, the invention aims at the process control of personalized customization production, improves the customizability through the product composition of the module cluster, and improves the production efficiency and the quality stability of the product. Meanwhile, the production process organization based on the module cluster ensures that all production procedures and equipment processing modes, production line composition and flows in the flexible production line are integrally kept stable, and the definability and the definition efficiency of the flexible production line are improved. The transparency of production information is facilitated based on the modularized and flexible production line integration layer.
The above description is only for the specific embodiments of the present invention, but the scope of the present invention is not limited thereto, and any changes or substitutions that can be easily conceived by those skilled in the art within the technical scope of the present invention are also within the scope of the present invention. Therefore, the protection scope of the present invention shall be subject to the protection scope of the appended claims.
Claims (2)
1. An intelligent manufacturing process control system adapted to personalization, comprising:
the product module management unit is used for defining, registering and managing the composition modules of the personalized customized products and the customizable attributes of the composition modules, and the product module management unit classifies the composition modules of the personalized customized products into a basic module, a matching module and a custom-defined module; the basic module is a module with a general structure and necessary for each individual customized product; the matching module is a module for selecting and matching each individual customized product according to the function and the appearance of the product; the user-defined module is a modular product component which is customized independently according to the personalized preference and the demand of a consumer, wherein the basic module and the matching module also have customizability; the product module management unit adopts a descriptive data structure to express the ID identification, the module type, the specification model and the customizable attributes of each component module, and registers and manages the component modules and the descriptive data structure thereof through a product module database, wherein the customizable attributes comprise the optional schemes of a basic module or a matching module and/or the customizable parameter range;
the product analysis unit is used for analyzing any personalized customized product into a module list according to product information in the product order; the product analysis unit is preset with a key information extraction rule, each type of module defined in the product module management unit is provided with a relevant information extraction index, so that which modules are needed by the product can be determined from the product information of an order to form the module list, parameters and personalized requirements in the product information are corresponded to each module in the module list, and the product analysis unit compares the module list with a descriptive data structure of each type of module in the product module management unit to determine whether the module contained in the module list belongs to a basic module, a matching module or a self-defined module;
the module association unit is used for associating the composition modules in the module list into module combinations according to the association of the product composition modules, and the module association unit also executes adaptation degree inspection and evaluation on each module combination; for the self-defined module, the module association unit combines the basic modules or the matching modules which have an assembly matching relationship or a function matching relationship with the self-defined module into a self-defined module combination; for other basic modules and matching modules, the module association unit divides the basic modules and the matching modules into module combinations according to a set module combination scheme;
the module cluster aggregation unit is used for aggregating module combinations of personalized customized products in the same manufacturing time window into a module cluster according to the characteristic similarity of the module combinations, wherein the delivery time limit can be set according to a product order, the manufacturing time window is defined, and the module combinations formed by analyzing and combining all the personalized customized products with the delivery time limit in the manufacturing time window are subjected to characteristic similarity evaluation of the module combinations; after the module combinations in the manufacturing time window are polymerized for the first time to form a plurality of module clusters, classifying the module combinations newly added in the manufacturing time window into one of the module clusters based on the similarity between the module combination characteristics of the module combinations and each module cluster;
the module cluster aggregation unit takes the custom module combination of each customized product as an independent module cluster for the custom module combination; for the module combination formed by the basic module and/or the matching module, extracting the module combination characteristics according to the module type, the specification model of each type module, the customized parameter range and the customized alternative contained in the module combination, and evaluating the similarity between the module combinations, thereby clustering the module combinations into module clusters; the similarity of the module combination characteristics in the same module cluster is maximized, and the difference of the module combination characteristics in different module clusters is maximized; after the module combinations in the manufacturing time window are aggregated for the first time to form a plurality of module clusters, classifying the module combinations newly added in the manufacturing time window into one of the module clusters based on the similarity between the module combination characteristics of the module combinations and each module cluster;
the flexible production line is used for converting the configuration data items into production instructions according to the configuration data items in the configuration list and producing the module assemblies in the module clusters;
the flexible production line comprises a production layer, a supporting layer and an integration layer, wherein the production layer is composed of a flexible production unit and a flexible transmission unit, the flexible production unit is used for manufacturing and assembling a module combination of a personalized customized product and correspondingly takes charge of equipment of each production process of the module combination, and the flexible transmission unit is a transportation system for autonomous conduction between the flexible production units and takes charge of flexible material transmission between the flexible production units;
the supporting layer is composed of supporting production units and is used for calling corresponding supporting production units to produce according to the individualized requirements of the module types which do not belong to the custom modules of the basic module and the matching module;
the integration layer is used as a middle layer of a flexible production line, the flexible production unit, the flexible transmission unit and the support production unit based on various industrial Internet of things protocols are connected downwards, configuration and calling interfaces for the flexible production unit, the flexible transmission unit and the support production unit are provided upwards, and upward information feedback of the flexible production line is realized; the specific functions of the integration layer include: the standardization of the data format of the flexible production line is realized, and the protocol standardization of different industrial control protocol data in heterogeneous production units and transmission units is realized; defining a production safety firewall, carrying out safety protection on the flexible production unit, the flexible transmission unit and the support production unit, and carrying out authority control on all commands configuring the flexible production unit, the flexible transmission unit and the support production unit through a safety strategy; providing a message mechanism of the flexible production line to the upper layer, so that the data of the flexible production line is provided to the upper layer after being collected, and transparent management of the production process is realized;
the integration layer comprises a module cluster configuration interface unit, for the module clusters formed by the module cluster aggregation unit, the module cluster configuration interface unit obtains relevant information of the module clusters from the module cluster aggregation unit, and establishes a configuration list for each module cluster, the configuration list is provided with configuration data items defined for adapting the module types of the module clusters, the specification models of the various types of modules, the customization parameter ranges and the customization options, and the configuration data items describe the production configuration information of a flexible production unit, a flexible transmission unit and a support production unit of the flexible production line for producing each module combination in the module cluster.
2. An intelligent manufacturing process control method adapted to personalization, comprising:
defining, registering and managing the composition modules of the personalized customized product and the customizable attributes of the composition modules, wherein the composition modules of the personalized customized product are classified into a basic module, an option module and a custom module; the basic module is a module with a general structure and necessary for each individual customized product; the matching module is a module for selecting and matching each individual customized product according to the function and the appearance of the product; the user-defined module is a modular product component which is customized independently according to the personalized preference and the demand of a consumer, wherein the basic module and the matching module also have customizability; expressing the ID identification, module type, specification model and customizable attributes of each component module by a descriptive data structure, and registering and managing the component modules and their descriptive data structures by a product module database, wherein the customizable attributes comprise alternatives of the base module or the optional module, and/or customizable parameter ranges;
analyzing any personalized customized product into a module list according to product information in the product order; presetting a key information extraction rule, wherein each defined type module has a relevant information extraction index, so that which modules are needed by the product can be determined from the product information of an order to form the module list, parameters and personalized requirements in the product information correspond to each module in the module list, and the module list is compared with a descriptive data structure of each type module, so that whether the module contained in the module list belongs to a basic module, a matching module or a self-defined module is determined;
according to the relevance of the product composition modules, the composition modules in the module list are correlated into module combinations, and the suitability degree inspection and evaluation are performed on each module combination; for the self-defined module, the module association unit combines the basic modules or the matching modules which have an assembly matching relationship or a function matching relationship with the self-defined module into a self-defined module combination; for other basic modules and matching modules, the module association unit divides the basic modules and the matching modules into module combinations according to a set module combination scheme;
the method comprises the steps that module combinations of personalized customized products in the same manufacturing time window are aggregated into a module cluster according to the characteristic similarity of the module combinations, wherein delivery time limit can be set according to a product order, the manufacturing time window is defined, and the module combinations formed after all personalized customized products with the delivery time limit in the manufacturing time window are subjected to product analysis and module combination are subjected to characteristic similarity evaluation of the module combinations; after the module combinations in the manufacturing time window are polymerized for the first time to form a plurality of module clusters, classifying the module combinations newly added in the manufacturing time window into one of the module clusters based on the similarity between the module combination characteristics of the module combinations and each module cluster; and regarding the custom module combination, taking the custom module combination of each customized product as an independent module cluster; for the module combination formed by the basic module and/or the matching module, extracting the module combination characteristics according to the module type, the specification model of each type module, the customized parameter range and the customized alternative contained in the module combination, and evaluating the similarity between the module combinations, thereby clustering the module combinations into module clusters;
regarding the custom module combination, the custom module combination of each customized product is used as an independent module cluster; for the module combination formed by the basic module and/or the matching module, extracting the module combination characteristics according to the module type, the specification model of each type module, the customized parameter range and the customized alternative contained in the module combination, and evaluating the similarity between the module combinations, thereby clustering the module combinations into module clusters; the similarity of the module combination features in the same module cluster is maximized, and the difference of the module combination features in different module clusters is maximized; after the module combinations in the manufacturing time window are polymerized for the first time to form a plurality of module clusters, classifying the module combinations newly added in the manufacturing time window into one of the module clusters based on the similarity between the module combination characteristics of the module combinations and each module cluster;
according to the relevant information of the module clusters, establishing a configuration list for each module cluster, wherein the configuration list is provided with configuration data items defined for adapting the module types of the module clusters, the specification models of the various types of modules, the customized parameter range and the customized optional schemes, and the configuration data items describe the production configuration information of a flexible production unit, a flexible transmission unit and a supporting production unit of the flexible production line for producing each module combination in the module cluster;
the flexible production line comprises a production layer, a supporting layer and an integration layer, wherein the production layer consists of a flexible production unit and a flexible transmission unit, the flexible production unit realizes the manufacturing and assembly of module combinations of personalized customized products and corresponds to equipment responsible for each production process of the module combinations for production and assembly, and the flexible transmission unit is a transportation system for autonomous conduction among the flexible production units and is responsible for flexible material transmission among the flexible production units;
the supporting layer is composed of supporting production units and is used for calling corresponding supporting production units to produce according to the individual requirements of the module types which do not belong to the custom modules of the basic module and the matching module;
the integration layer is used as a middle layer of a flexible production line, the flexible production unit, the flexible transmission unit and the support production unit based on various industrial Internet of things protocols are connected downwards, configuration and calling interfaces for the flexible production unit, the flexible transmission unit and the support production unit are provided upwards, and upward information feedback of the flexible production line is realized; the specific functions of the integration layer include: the standardization of the data format of the flexible production line is realized, and the protocol standardization of different industrial control protocol data in the heterogeneous production unit and the transmission unit is realized; defining a production safety firewall, carrying out safety protection on the flexible production unit, the flexible transmission unit and the support production unit, and carrying out authority control on all commands configuring the flexible production unit, the flexible transmission unit and the support production unit through a safety strategy; and a message mechanism of the flexible production line is provided to the upper layer, so that the data of the flexible production line is provided to the upper layer after being collected, and transparent management of the production process is realized.
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