CN115599059A - Variable-station automobile production line with error-proof early warning function and automobile production method - Google Patents
Variable-station automobile production line with error-proof early warning function and automobile production method Download PDFInfo
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- G05B19/41875—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by quality surveillance of production
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Abstract
The invention relates to the field of automobile manufacturing, in particular to a variable-station automobile production line with a mistake-proofing early warning function. The manufacturing execution system dynamically plans the number, location, and length of the stations. The vehicle body identification system identifies vehicle information, the manufacturing execution system finishes the planning of stations according to the vehicle information, and issues the vehicle information to the production control system to finish the production process planning. The production control system uses flexible interfaces to connect different production modules. The production monitoring system collects data to realize closed-loop control. When the production line is abnormal, the production error prevention system sends out an alarm or stops production. The invention also comprises a method for producing the automobile by using the automobile production line with the variable station and the error-proof early warning function. According to different vehicle information, the invention not only can realize more optimized production line planning, but also can monitor the state of the production line in real time, and ensure the reliability of the production line.
Description
Technical Field
The invention relates to the field of automobile manufacturing, in particular to an automobile production line with a variable station and a method for producing automobiles, wherein the automobile production line has a mistake-proofing early warning function.
Background
As shown in fig. 1, a vehicle position obtaining method commonly used in a whole vehicle manufacturing enterprise currently locates a vehicle position through a vehicle body identification system 200 (AVI system) and an inductive switch 405. The inductive switch 405 is installed at the entrance of the conveyor line 3021 of the production line, and when a vehicle newly enters the production line and passes through the inductive switch 405, the conveyor line 3021 is driven by the roller 3022 to advance, so that the vehicle newly entering the production line and the original vehicle on the production line are driven to integrally move to the next station.
Referring to FIG. 1, a vehicle on a production line, such as vehicle A, either moves to the next station (e.g., from station 1 to station 2) or completes the production line work off the production line. Vehicle a is placed on carrier 401 into the production line, and the position of carrier 401 is fixed. Therefore, when the vehicle 401 with the vehicle a enters the production line, the inductive switch 405 is triggered to operate, so that the manufacturing execution system 100 (MES system) knows that the vehicle a enters the first station. When a subsequent carrier 401 of the carrier 401 of vehicle a passes the inductive switch 405, the manufacturing execution system 100 concludes that vehicle a enters the second station, and so on, to complete the movement of vehicle a between stations. If the vehicle leaves the production line, the vehicle body recognition system 200 and the manufacturing execution system 100 of the subsequent production line record and track the new station of the vehicle A.
When the vehicle A moves, all vehicles on a production line, including the vehicle B, the vehicle C and the vehicle D, can also move forwards and respectively enter the corresponding stations 3, the vehicle C moves to the station 2, and the vehicle D enters the station 1. The vehicle D, which is a newly entering vehicle, is first acquired by the vehicle body recognition system 200 and sent to the manufacturing execution system 100. Subsequently, as vehicle D passes inductive switch 405, manufacturing execution system 100 marks vehicle D that it is currently located at station 1. After entering the production line, the manufacturing execution system 100 performs the same logic processing as that of the vehicle a, and updates the information of the station where the vehicle D is located in the manufacturing execution system 100. The vehicle arriving at the station completes the assembly production process of the station under the control of the production control system 300.
The main defects of the prior art include:
1. the current vehicle position cannot be obtained in real time because the entire production line has no acquisition device or calculation device to feed back information to the MES system, and the MES system can only infer the vehicle position by the preset distance between the vehicles and the notification that the vehicles enter the production line. When the actual operating conditions of the conveyor line do not correspond to the preset constants, a large deviation occurs between the actual movement position of the vehicle and the position considered by the MES system, which may seriously result in production line downtime, for example, the robot at the station cannot match the position of the vehicle to be assembled.
2. The requirement of production line extension stations cannot be met. In the prior art, each station is already determined in the design stage, and then a corresponding production module (production apparatus) is installed according to each station. Because the MES system cannot accurately infer the location of the vehicle, the equipment at the workstation needs to be left with sufficient margin to account for the vehicle misalignment. After the surplus stack of a plurality of equipment of same station, can lose a lot of spaces that can install equipment originally. Particularly, when a plurality of vehicle models need to be supported for production, the difficulty of production line layout is aggravated by a large amount of equipment required by different vehicle models. When necessary production equipment cannot be arranged at an original station, a new production line needs to be rebuilt, and the cost is high.
3. In the integration of the manufacturing execution system and the production control system, a dedicated interface is realized by using dedicated logic according to different production modules, although customization can be rapidly completed for different production tools when a new production line is deployed, when the production line needs to be fine-tuned, the production line needs to be completely re-deployed, because the dedicated interface is used from the production module to the production control system to the manufacturing execution system and can be different along with different types and even models of the production modules. Therefore, once the introduction of a new production module is involved, the logic of the production control system is modified, and the logic of the manufacturing execution system is modified, so that the post-debugging maintenance is huge in engineering quantity.
4. No warning is provided when the assembly is carried out at each station, in particular when the assembly work involves human intervention. When the vehicle is about to pass through the working position but the corresponding production process is not completed, the line is stopped manually by an operator.
Disclosure of Invention
The invention aims to provide a variable-station automobile production line with a mistake-proofing early warning function and an automobile production method, and mainly solves the problems in the prior art.
In order to achieve the purpose, the technical scheme adopted by the invention is to provide a variable station automobile production line with a mistake-proofing early warning function, wherein a conveying line is used for driving a vehicle to be assembled to advance, and a plurality of stations corresponding to production procedures are arranged along the conveying line; the manufacturing execution system is connected to the vehicle body identification system, the production control system, the production monitoring system and the production error proofing system;
the manufacturing execution system stores a plurality of groups of manufacturing parameters, and selects one group to be issued to the production control system and the production error-proofing system according to the vehicle information acquired by the vehicle body identification system; the production control system configures all production processes of each station according to the manufacturing parameters; the production monitoring system collects the state information of the production line and feeds the state information back to the manufacturing execution system to realize closed-loop control on production of the production line; and the production mistake-proofing system configures an exception handling specification according to the manufacturing parameters and sends out a prompt or a warning by combining the production line state information.
Furthermore, the manufacturing execution system comprises a production line management module, a vehicle management module, an error-proofing management module, a production management module, a database module and a quick communication module;
the production line management module provides a man-machine interaction interface to receive the manually input manufacturing parameters and is also used for scheduling the vehicle management module, the error-proofing management module and the production management module to work cooperatively; the vehicle management module is connected to the vehicle body identification system and transmits the vehicle information acquired by the vehicle body identification system to the production line management module; the error-proofing management module is connected to the production monitoring system and the production error-proofing system, issues the manufacturing parameters to the production error-proofing system, and transmits the production line state information acquired by the production monitoring system to the production line management module and the production error-proofing system; the production management module is connected to the production control system, and the vehicle information and the manufacturing parameters are transmitted to the production control system; the rapid communication module provides direct communication connection among the production control system, the production monitoring system and the production error-proofing system and is used for bypassing the production management module to carry out rapid data interaction; the manufacturing parameters and the vehicle information are stored in the database module.
Further, the vehicle body identification system comprises an RFID reading module; the RFID reading module scans a radio frequency tag installed on the vehicle to be assembled and reads the vehicle information; the vehicle information at least comprises a vehicle identification code.
Further, the configuration management module comprises a file storage unit and a communication unit; the file storage unit stores the manufacturing parameters corresponding to the vehicle to be assembled; the communication unit is used for connecting the file storage unit to the manufacturing execution system and the production module.
Further, the configuration management module comprises a file storage unit and a communication unit; the file storage unit stores the manufacturing parameters corresponding to the vehicle to be assembled; the communication unit is used for connecting the file storage unit to the manufacturing execution system and the production module; the communication unit is connected with the production modules of different models by using a flexible interface, so that the communication connection mode between the manufacturing execution system and the production control system is not changed along with the models of the production modules.
Further, the production monitoring system comprises a carrier, a vehicle monitoring module, a carrier monitoring module, a travel acquisition module and an inductive switch;
the carrier is fixed on the conveying line of the production line, loads the vehicle to be assembled to advance and sequentially passes through the stations; the vehicle monitoring module collects the arrangement state information of the vehicle to be assembled on the carrier; the carrier monitoring module and the inductive switch are sequentially installed from the inlet of the production line; the carrier monitoring module acquires the in-position state information of the carrier on the conveying line; when the carrier and the vehicle to be assembled cross the inductive switch, reporting limit state information; the stroke acquisition module acquires stroke state information of the conveying line;
the production line state information reported by the production monitoring system comprises the arrangement state information, the in-position state information, the limit state information and the travel state information.
Furthermore, the travel acquisition module comprises a data acquisition unit, a data calculation unit and a data storage unit; the data acquisition unit is an encoder; the data calculation unit converts the data of the encoder into the travel state information; the data storage unit is connected to the data acquisition unit and the data calculation unit.
Furthermore, the production error-proofing system comprises an early warning configuration module, an early warning module, a production stop module and a station sensing module; the early warning configuration module generates the exception handling specification from the manufacturing information issued by the manufacturing execution system, comprises an early warning line and a production stopping line, and issues the exception handling specification to the early warning module and the production stopping module; the station sensing module is arranged on the production control system and used for acquiring production process completion information of the stations;
the early warning configuration module collects the production line state information and the production process completion information and sends the production process completion information to the early warning module and the production stopping module, when the production line state information meets the early warning line, the early warning module sends early warning, and when the production line state information meets the production stopping line, the production stopping module stops the vehicle production process and gives an alarm.
The invention also provides a method for assembling an automobile by using the variable station automobile production line with the error-proofing early warning function, which is characterized by comprising the following steps of:
firstly, a production line is deployed for the vehicle to be installed;
secondly, initializing a production line according to the vehicle information of the vehicle to be assembled, and determining the number, the position and the length of the stations;
and finally, the vehicle to be assembled enters a production line to start production.
Further, when the vehicle to be installed is deployed on the production line,
firstly, adjusting the production control system, the production monitoring system and the production error-proofing system; in the production control system, adjusting a production module and connecting the newly added production module to a configuration management module by using the flexible interface without modifying a communication interface between the production control system and the manufacturing execution system; adjusting a station sensing module in the production mistake proofing system;
then, configuring the work station, the production control system, the production monitoring system and a production error-proofing system in the manufacturing execution system; in the manufacturing execution system, adjusting the manufacturing parameters corresponding to the vehicle to be installed, so as to specify the number, position and length of the stations included in a production line, specify the production process corresponding to each station, and configure the exception handling specifications in the production error-proofing system;
finally, optionally, redundant equipment which is no longer used after configuration is removed from the production control system, the production monitoring system and the production error-proofing system, and included in the production control system, and redundant production modules are removed.
Further, when initializing the process of the production line:
firstly, starting the production monitoring system to start to collect the production line state information;
secondly, checking the state of the vehicle to be assembled by using the production error-proofing system;
thirdly, the vehicle body identification system reads the vehicle information;
then, the manufacturing execution system selects one group from a plurality of groups of manufacturing parameters stored by the manufacturing execution system based on the vehicle information reported by the vehicle body identification system, configures the number, the position and the length of the stations on a production line, and issues the selected manufacturing parameters to the production control system and the production error-proofing system;
finally, the production control system configures the production process of each station according to the received manufacturing parameters; and the production error-proofing system configures exception handling specifications according to the received manufacturing parameters.
Further, the production process of the vehicle to be assembled comprises the steps of:
step S1, the production monitoring system collects the production line state information and reports the production line state information to the manufacturing execution system;
s2, the manufacturing execution system determines the current station of the vehicle to be assembled by combining the position and the length of the station of the current production line and the position information of the vehicle to be assembled on the conveying line, which is contained in the state information of the production line, and sends the current station of the vehicle to be assembled to the production control system;
s3, the production control system executes the production process corresponding to the current station; meanwhile, the production error-proofing system combines the production line state information, the production procedure completion information and the exception handling specification, and when the current station is abnormal, a prompt or a warning is sent out;
and S4, after the production process of the current station is completed, the manufacturing execution system drives the vehicle to be assembled to advance along the conveying line and returns to the step S1.
In view of the technical characteristics, the variable-station automobile production line with the error-proofing early warning function and the automobile production method automatically adapt to different types of vehicles for production by utilizing preset manufacturing parameters without reinstalling a new production line, so that the cost of enterprises is greatly reduced. Compared with the prior art, the method has the following advantages: ,
1. in the invention, the position of the vehicle to be assembled on the production line is accurately sensed by the manufacturing execution system and can be adjusted through manufacturing parameters, so that the number, size and length of the stations can be flexibly adjusted.
2. In the present invention, the manufacturing process can be adjusted by adjusting the manufacturing parameters without reprogramming the logic in the manufacturing execution system.
3. In the invention, by the flexible interface, when a production module is newly added or modified, the interfaces of a manufacturing execution system and a production control system do not need to be reprogrammed, and the debugging process is simplified.
4. In the invention, in the same station, the manufacturing execution system can correctly and orderly initiate a processing command to the production control system according to the accurate position of the vehicle to be assembled, thereby simplifying the layout of the production line and enabling the arrangement of the production modules along the production line to be more compact.
5. In the invention, the manufacturing execution system can use the production monitoring system to supervise in the process of carrying out the production process of each station based on the accurate position of the vehicle to be assembled, and use the production error prevention system to early warn and prompt production line workers to carry out timely remediation, thereby avoiding the operation of stopping the production line and improving the production efficiency.
6. In the invention, the production line state is monitored in real time by using the production monitoring system and the production error-proofing system, and the problem can be timely treated when the problem occurs. For example, the vehicle position shifts, can automatic stop produce the operation of line, avoids because the vehicle position is incorrect to lead to the installation dislocation, the condemned problem of vehicle, has promoted the reliability of producing the line.
Drawings
FIG. 1 is a schematic structural diagram of a variable-station automobile production line with a mistake-proofing early warning function in the prior art;
FIG. 2 is a schematic structural diagram of a variable station automobile production line with a mistake-proofing warning function according to a preferred embodiment of the present invention;
FIG. 3 is a detailed structural diagram of a manufacturing execution system and a body recognition system in a preferred embodiment of the variable-station automotive production line with error-proofing pre-warning function according to the present invention;
FIG. 4 is a schematic diagram of a production control system in a preferred embodiment of the variable station automobile production line with error-proofing warning function according to the present invention;
FIG. 5 is a schematic structural diagram of a flexible interface used by a light installation module in a production control system in a preferred embodiment of the variable station automobile production line with an error-proofing early warning function according to the present invention;
FIG. 6 is a schematic diagram of a production monitoring system in a preferred embodiment of the variable station automobile production line with error-proofing warning function according to the present invention;
FIG. 7 is a flowchart of a method for manufacturing a vehicle using a variable station vehicle line with an error-proofing warning function according to a preferred embodiment of the present invention;
FIG. 8 is a detailed method flowchart of the line deployment of FIG. 7;
FIG. 9 is a flowchart of a detailed method of line initialization in FIG. 7;
fig. 10 is a flowchart of a detailed method of the in-line production of fig. 7.
In the figure: 100-manufacturing execution system, 200-vehicle body identification system, 300-production control system, 400-production monitoring system, 500-production error-proofing system;
101-a production line management module, 102-a vehicle management module, 103-an error-proofing management module, 104-a production management module, 105-a database module and 106-a quick communication module;
201-an RFID reading module;
301-configuration management module, 302-production module; 303-an lamp module;
3011-file storage unit, 3012-communication unit; 3021-conveying line, 3022-roller, 3023-tightening gun, 3024-filling device, and 3025-gluing device; 3031-first standard interface; 3032-second standard interface;
401-vehicle, 402-vehicle monitoring module, 403-vehicle monitoring module, 404-travel collection module, 405-inductive switch; 4031-data acquisition unit, 4032-data calculation unit, 4033-data storage unit;
501-an early warning configuration module, 502-an early warning module, 503-a production stop module and 504-a station sensing module.
Detailed Description
The present invention will be further described with reference to the following embodiments. It should be understood that these examples are for illustrative purposes only and are not intended to limit the scope of the present invention. Further, it should be understood that various changes or modifications of the present invention may be made by those skilled in the art after reading the teaching of the present invention, and such equivalents may fall within the scope of the present invention as defined in the appended claims.
Referring to fig. 2 to 6, the invention discloses a station-variable automobile production line with a mistake-proofing early warning function. As shown, a preferred embodiment thereof is comprised of a manufacturing execution system 100 (MES), a vehicle body identification system 200 (AVI), a production control system 300, a production monitoring system 400, and a production error proofing system 500.
The automobile production line comprises a plurality of stations which can be dynamically planned, each station corresponds to a group of production processes, and the production processes comprise production actions and sequences required to be completed by each production module 302 on the station. The production process of each station generally corresponds to the vehicle type to be produced, and the production process is dynamically planned according to vehicle information during initialization of a production line. Before the automobile to be assembled enters the production line, the automobile information is identified by the automobile body identification system 200 (AVI), and then the manufacturing execution system 100 (MES) finishes the planning of the work station and the production process. Then, the conveyor line 3021 drives the vehicle to be equipped to pass through each station in sequence. After the automobile enters a station, a static assembly mode and a dynamic assembly mode are adopted according to the configuration of different production lines. In the static assembly mode, the conveyor line 3021 stops moving, the automobile is in a static state at a station, the production process at the station is completed by the production modules 302 (various robots, tightening guns 3022, and the like) installed around the station, and then the conveyor line 3021 is restarted to drive the automobile to the next station. In the dynamic assembly mode, the conveying line 3021 keeps moving forward at a constant speed, and the production modules 302 installed around the station follow the automobile moving forward at a constant speed to complete the production process of the station.
The manufacturing execution system 100 is a control core of the whole automobile production line, and is used for configuring the positions and the sequences of the stations on the automobile production line, configuring the production process corresponding to each station through the production control system 300, guiding the production control system 300 to complete the automobile assembly work according to the production process, and configuring the production monitoring system 300 and the production error prevention system 500. Meanwhile, it is responsible for connecting the car body identification system 200, the production control system 300, the production monitoring system 400 and the production error-proofing system 500, and providing a communication channel therebetween.
The vehicle body identification system 200 obtains vehicle information, such as a vehicle identification code, by including an RFID reading module 201 to read a radio frequency tag mounted on a vehicle to be assembled. The vehicle information may also include additional information, such as vehicle type information, etc., to speed up the data retrieval, but the vehicle integrity information is retrieved from database module 105 of manufacturing execution system 100 by using the vehicle identification code as a key.
The production control system 300 itself also has the capability of storing manufacturing parameters, but it only stores the manufacturing parameters for the current production issued by the manufacturing execution system 100, and does not store the manufacturing parameters for all vehicles supported by the production line. Specifically, the production control system 300 is constituted by a configuration management module 301 and a production module 302. According to different automobile production lines, each configuration management module 301 corresponds to one or more production modules 302. The configuration management module 301 includes a file storage unit 3011 and a communication unit 3012. The file storage unit 3011 stores manufacturing parameters for instructing current production, and the configuration management module 301 extracts information from the manufacturing parameters to instruct and control the production module 302 to complete the production process of the corresponding station. The communication unit 3012 connects the configuration management module 301 to the manufacturing execution system 100 and the production module 302. The communication unit 3012 provides a flexible interface between the manufacturing execution system 100 and the production module 302. The flexible interface functions as: when the external interface type of the production module 302 itself changes, the communication unit 3012 maintains the communication capability with the changed production module 302 by expanding its flexible interface, and at the same time, ensures that the communication interface between the communication unit 3012 and the manufacturing execution system 100 is unchanged. Thus, when the production line adjustment involves addition and modification of the production module 302, only the corresponding communication unit 3012 needs to be upgraded, thereby avoiding modification of other systems in the production line.
The production module 302 contains not only the assembly devices at each station, such as the tightening guns 3023, the filling devices 3024 and the gluing devices 3025, but also the devices associated with the entire production line, such as the delivery line 3021 and the rollers 3022 of the application delivery line 3021. The roller 3022 drives the conveyor line 3021 forward, transferring the vehicle to be assembled between the different stations. The assembling equipment is arranged on the station and used for finishing the processing and assembling work of the vehicle to be assembled. The sequence of actions of all the assembly equipment at a station constitutes the production process of the station.
Referring to FIG. 5, in addition, the production module 302 includes a device for human intervention control of the operation of the production line, such as a light module 303. The safety lamp calling is one of main functions of a safety lamp module, and the principle is that an operator calls corresponding responsible persons (team leader, security, quality, logistics and the like) under abnormal conditions by operating a calling terminal at the production line, so that the equipment outage rate is reduced, and the working efficiency is improved. On the same production line, different Ann lamp calling areas are generally divided according to the characteristics of different assembling devices. Unlike prior designs where different amp call regions use different interface standards, in this embodiment all of the amp modules 303 (a, B and C) communicate with the configuration management unit 301 using a first standard interface 3031, while the configuration management unit 301 communicates with the manufacturing execution system 100 using a second standard interface 3032, such that when:
1. adjustment of the calling area, requiring replacement of different types of Ann light modules 303
2. Adjustment of the number or type of Ann light modules 303
The automatic adaptation (flexibility) of the Ann light calling system can be realized only by adjusting configuration in manufacturing parameters and then processing the configuration by the configuration management module 301 without performing secondary development of a program and stopping production on site for joint debugging.
The production monitoring system 400 is used to continuously collect production line status information, such as vehicle status and vehicle location, during normal operation, and then transmit to the manufacturing execution system 100 and the production error proofing system 500. The production monitoring system 400 is composed of a carrier 401, a vehicle monitoring module 402, a carrier monitoring module 403, a travel acquisition module 404, and an inductive switch 405. The production line state information reported by the production monitoring system comprises arrangement state information, in-position state information, limit state information, travel state information and processing state information. The carrier 401 is fixed on a conveyor line 3021, and the vehicle to be assembled should be placed on the carrier 401, then brought into the production line by the conveyor line 3021, and then pass through each processing station in turn. The vehicle monitoring module 402 is configured to identify whether the vehicle to be assembled is properly mounted on the vehicle 401, and provide mounting status information. From the entrance of the production line, a carrier monitoring module 403 (ohm dragon E3JK-TR 12-C) and an inductive switch 405 (ohm dragon WLG 2-LD) are sequentially installed. The carrier monitoring module 403 is used to identify whether the carrier 401 itself is properly mounted on the conveyor line 3021, and provide in-position status information. The vehicle monitoring module 402 and the vehicle monitoring module 403, in combination, can determine that the vehicle 401 itself and the vehicle to be assembled on the vehicle 401 are properly positioned. Mounted behind the vehicle monitoring module 403 is a sensor switch 405 that provides restraint status information, which in combination with the travel acquisition module 404, is used to determine the precise location of the vehicle to be assembled on the production line. Specifically, when the vehicle to be assembled passes over the inductive switch 405, the limit state information is reported and notified to the manufacturing execution system 100 to determine the zero point corresponding to the vehicle to be assembled. The stroke acquisition module 404 includes a data acquisition unit 4031, a data calculation unit 4032 and a data storage unit 4033, and is configured to acquire and calculate stroke data of the delivery line 3021. The data acquisition unit 4031 is an encoder, such as an ohm dragon E6C3-AG5C 256P/R2M. The encoder data is converted by the data calculation unit 4032 to obtain the travel distance of the conveyor line 3021, which is reported as the travel state information. The data storage unit 4033 is connected to the data acquisition unit 4031 and the data calculation unit 4032 and provides storage support for calculations, such as saving input parameters, intermediate results, and final results. Knowing the zero point and the distance traveled by the conveyor line 3021, the distance the vehicle has traveled along the conveyor line 3021 can be calculated, and in combination with the location and length information of the stations in the manufacturing execution system 100, it can be determined whether the vehicle has reached a particular station and a particular location in that station (e.g., 30% of the location of that station). The station sensing module 504 connected to the production module 302 of each station is responsible for collecting the status information (production process completion information) of the vehicle to be assembled at each station that has completed all processes, such as the number of bolts that have been currently tightened, the number of refills that have been currently completed, and the like.
The production error-proofing system 500 comprises an early warning configuration module 501, an early warning module 502, a production stop module 503 and a station sensing module 504. The early warning configuration module 501 is the core of the production error proofing system 500 and is connected to the early warning module 502, the production stop module 503 and the station sensing module 504. The early warning configuration module 501 generates an exception handling specification from the manufacturing information sent from the manufacturing execution system 100, where the exception handling specification includes an early warning line and a production stop line, and then sends the exception handling specification to the early warning module 502 and the production stop module 503. The production error proofing system 500 will receive two types of information: the line status information from the production monitoring system 400, transmitted via the rapid communication module 106, and the manufacturing process completion information from the workstation sensor module 504 of the production module 302 installed on the workstation. The production error-proofing system 500 transmits the two types of information to the early warning module 502 and the production stopping module 503, and the early warning module 502 and the production stopping module 503 respectively compare the information with the early warning line and the production stopping line in real time, for example, whether the vehicle to be assembled is correctly placed on the carrier 401, whether the vehicle to be assembled travels to a correct station, whether a corresponding production process is completed at a current station, the completion condition of the current production process, and the like. When the production line state information meets an early warning line, for example, the completion condition of the current production process does not meet expectations, the early warning module 502 sends an early warning to remind the staff of intervention. When the production line status information satisfies the production line shutdown, for example, a serious error occurs, the production shutdown module 503 stops the vehicle production process and gives an alarm. The early warning module 502 is connected to the MES 100, and the downtime module 503 communicates directly with the production control system 300 through the fast communication module 106 in the MES 100.
Referring to fig. 7, the present invention further discloses a method for assembling an automobile by using a variable station automobile production line with a mistake-proofing early warning function, which is characterized by comprising the following steps:
step S100, a production line is deployed for the vehicle to be installed.
And step S200, initializing a production line.
The vehicle body identification system reads vehicle information of a vehicle to be assembled, then the manufacturing execution system determines the number, the position and the length of the stations according to the vehicle information, and issues manufacturing parameters to complete the configuration of the stations and the production process.
And step S300, the vehicle to be assembled enters a production line and starts to be produced.
Referring to fig. 8, step S100 further includes the steps of:
and S101, adjusting equipment of a production control system, a production monitoring system and a production error-proofing system.
In a production control system, a newly added production module is connected to a configuration management module using a flexible interface without modifying a communication interface between the production control system and a manufacturing execution system. And adjusting the station sensing module in the production mistake-proofing system. And adjusting the early warning module or the production stopping module in the production mistake-proofing system, and connecting the newly added early warning module or the production stopping module to the early warning configuration module.
And S102, configuring a station, a production control system, a production monitoring system and a production error-proofing system in the manufacturing execution system.
In the manufacturing execution system, adjusting the manufacturing parameters corresponding to the vehicle to be installed includes:
1. the configuration of the workstations of the production line, i.e. the number, position and length of the included workstations, is specified.
2. And (3) specifying the production process corresponding to each station, namely how many production modules participate in each station, and the operation and the sequence of the operation which are required to be executed by each production module.
3. And (4) specifying configuration exception handling specifications, namely configuring an early warning line (namely various error conditions needing early warning) and a production stopping line (namely various error conditions needing stopping).
Each station can be provided with a plurality of early warning lines and stop production lines.
And step S103, removing redundant equipment which is not used any more after the configuration is finished in the production control system, the production monitoring system and the production error-proofing system.
In the production control system, redundant production modules are removed.
This step is optional, and as long as the production line plan is met, each module can also be kept unchanged and is just not referenced in the manufacturing parameters for subsequent reuse.
Referring to fig. 9, step S200 further includes the steps of:
step S201, a production monitoring system is started to start collecting production line state information.
Step S202, the production error-proofing system checks the state of the vehicle to be assembled.
And checking the vehicle to be assembled which newly enters the production line. The production error-proofing system utilizes a sensor (such as ohm dragon E3JK-TR 12-C) of a vehicle monitoring module to identify that a vehicle arrives at the inlet of a production line, then utilizes a sensor (ohm dragon WLG 2-LD) of a vehicle monitoring module to detect whether the vehicle to be assembled is correctly arranged on the vehicle, and the vehicle to be assembled is allowed to enter the production line by carrying the vehicle to be assembled through verification.
In step S203, the vehicle body recognition system reads vehicle information of the vehicle to be assembled.
After the vehicle to be assembled enters the production line, the vehicle body identification system identifies the vehicle information through an RFID reading module (such as SIMATIC RF 360T) and transmits the vehicle information to the manufacturing execution system.
And step S204, the manufacturing execution system finishes the production line planning.
The manufacturing execution system selects one group from a plurality of groups of manufacturing parameters stored by the manufacturing execution system by using the vehicle identification code in the vehicle information to complete the planning of the number, the position and the length of the variable stations, and issues the manufacturing parameters to the production control system and the production error-proofing system.
And step S205, the production control system and the production error-proofing system finish planning.
The production control system configures the production process for each station based on the received manufacturing parameters. And the production mistake-proofing system configures an exception handling standard according to the received manufacturing parameters, namely, a specific alarm line and a production stop line part are set.
Referring to fig. 10, step S300 further includes the following steps:
step S301, the production monitoring system collects production line state information and reports the production line state information to the manufacturing execution system.
When the vehicle to be assembled passes through the position of the inductive switch, the production monitoring system sends information to the manufacturing execution system, and the manufacturing execution system sets the zero point of the stroke for the vehicle to be assembled. And then, the production monitoring system periodically reports the travel state information of the conveying line and the execution condition of the production process on each station to the manufacturing execution system.
Step S302, the manufacturing execution system determines the current station of the vehicle to be assembled by combining the position and the length of the station of the current production line and the position information of the vehicle to be assembled on the conveying line, which is contained in the state information of the production line, and sends the current station of the vehicle to be assembled to the production control system.
And the manufacturing execution system compares the position of the vehicle to be assembled on the conveying line, and judges that the vehicle to be assembled enters a certain station when the position of the vehicle to be assembled is within the position and length interval of the station. The production error-proofing system monitors the position of the vehicle to be assembled on the conveying line, and if the vehicle cannot reach the correct station position for a long time or stops at an off-station position, the stop line action is triggered.
And step S303, the production control system executes the production process corresponding to the current station. Meanwhile, the production error prevention system combines the state information of the production line and the exception handling standard, and sends out a prompt or a warning when the current station is abnormal.
The production error-proofing system triggers an early warning line when finding that the progress does not accord with expectation according to the production process required to be completed by the current station and the condition of the completed production process. When the vehicle to be assembled has passed the work station but the production process is not yet completed, the production line is triggered.
And step S304, after the production process of the current station is completed, the manufacturing execution system drives the vehicle to be assembled to move forward along the conveying line, and the step S301 is returned.
When the production process triggers a preset condition in an early warning line, the production error-proofing system alarms workers by sound or screen flashing (for example, through a software program which is installed on a computer or a handheld terminal as a carrier). When the production process triggers the preset condition when the production line is stopped, the production error-proofing system reports the condition to the manufacturing execution system, and the manufacturing execution system executes the stop operation or directly sends a stop instruction to the production control system.
The above description is only a preferred embodiment of the present invention, and is not intended to limit the scope of the present invention, and all equivalent structures or equivalent processes performed by the present invention or directly or indirectly applied to other related technical fields will be covered by the scope of the present invention.
Claims (12)
1. A variable station automobile production line with a mistake-proofing early warning function uses a conveying line to drive a vehicle to be assembled to advance, and a plurality of stations corresponding to production procedures are arranged along the conveying line, and is characterized by comprising a manufacturing execution system, a vehicle body recognition system, a production control system, a production monitoring system and a production mistake-proofing system; the manufacturing execution system is connected to the vehicle body identification system, the production control system, the production monitoring system, and the production error prevention system;
the manufacturing execution system stores a plurality of groups of manufacturing parameters, and selects one group to be issued to the production control system and the production error-proofing system according to the vehicle information acquired by the vehicle body identification system; the production control system configures all production processes of each station according to the manufacturing parameters; the production monitoring system collects production line state information and feeds the production line state information back to the manufacturing execution system to realize closed-loop control on production of a production line; and the production mistake-proofing system configures an exception handling specification according to the manufacturing parameters and sends out a prompt or a warning by combining the production line state information.
2. The variable-station automobile production line with the error-proofing early warning function according to claim 1, wherein the manufacturing execution system comprises a production line management module, a vehicle management module, an error-proofing management module, a production management module, a database module and a quick communication module;
the production line management module provides a man-machine interaction interface to receive the manually input manufacturing parameters and is also used for scheduling the vehicle management module, the error-proofing management module and the production management module to work cooperatively; the vehicle management module is connected to the vehicle body identification system and transmits the vehicle information acquired by the vehicle body identification system to the production line management module; the error-proofing management module is connected to the production monitoring system and the production error-proofing system, issues the manufacturing parameters to the production error-proofing system, and transmits the production line state information acquired by the production monitoring system to the production line management module and the production error-proofing system; the production management module is connected to the production control system, and the vehicle information and the manufacturing parameters are transmitted to the production control system; the rapid communication module provides direct communication connection among the production control system, the production monitoring system and the production error-proofing system and is used for bypassing the production management module to carry out rapid data interaction; the manufacturing parameters and the vehicle information are stored in the database module.
3. The variable-station automobile production line with the error-proofing early warning function as claimed in claim 1, wherein the automobile body recognition system comprises an RFID reading module; the RFID reading module scans a radio frequency tag installed on the vehicle to be assembled and reads the vehicle information; the vehicle information at least comprises a vehicle identification code.
4. The variable-station automobile production line with the error-proofing early-warning function as claimed in claim 1, wherein the configuration management module comprises a file storage unit and a communication unit; the file storage unit stores the manufacturing parameters corresponding to the vehicle to be assembled; the communication unit is used for connecting the file storage unit to the manufacturing execution system and the production module.
5. The variable-station automobile production line with the error-proofing early-warning function as claimed in claim 4, wherein the configuration management module comprises a file storage unit and a communication unit; the file storage unit stores the manufacturing parameters corresponding to the vehicle to be assembled; the communication unit is used for connecting the file storage unit to the manufacturing execution system and the production module; the communication unit is connected with the production modules of different models by using a flexible interface, so that the communication connection mode between the manufacturing execution system and the production control system is not changed along with the models of the production modules.
6. The variable-station automobile production line with the error-proofing early warning function according to claim 1, wherein the production monitoring system comprises a carrier, a vehicle monitoring module, a carrier monitoring module, a stroke acquisition module and an inductive switch;
the carrier is fixed on the conveying line of a production line, loads the vehicle to be assembled to move forward and sequentially passes through the stations; the vehicle monitoring module collects the arrangement state information of the vehicle to be assembled on the carrier; the carrier monitoring module and the inductive switch are sequentially installed from the inlet of the production line; the carrier monitoring module acquires the in-position state information of the carrier on the conveying line; when the carrier and the vehicle to be assembled cross the inductive switch, reporting limit state information; the stroke acquisition module acquires stroke state information of the conveying line;
the production line state information reported by the production monitoring system comprises the arrangement state information, the in-position state information, the limit state information and the travel state information.
7. The variable-station automobile production line with the error-proofing early warning function according to claim 6, wherein the stroke acquisition module comprises a data acquisition unit, a data calculation unit and a data storage unit; the data acquisition unit is an encoder; the data calculation unit converts the data of the encoder into the travel state information; the data storage unit is connected to the data acquisition unit and the data calculation unit.
8. The variable-station automobile production line with the error-proofing early warning function according to claim 1, wherein the production error-proofing system comprises an early warning configuration module, an early warning module, a production stop module and a station sensing module; the early warning configuration module generates the exception handling specification from the manufacturing information issued by the manufacturing execution system, comprises an early warning line and a production stopping line, and issues the exception handling specification to the early warning module and the production stopping module; the station sensing module is arranged on the production control system and used for acquiring production process completion information of the stations;
the early warning configuration module collects the production line state information and the production process completion information and sends the production line state information and the production process completion information to the early warning module and the production stopping module, when the production line state information meets the early warning line, the early warning module sends early warning, and when the production line state information meets the production stopping line, the production stopping module stops the vehicle production process and gives an alarm.
9. The method for assembling the automobile by using the variable station automobile production line with the mistake proofing and early warning function as claimed in claim 1, which is characterized by comprising the following steps:
firstly, a production line is deployed for the vehicle to be installed;
secondly, initializing a production line according to the vehicle information of the vehicle to be assembled, and determining the number, the position and the length of the stations;
and finally, the vehicle to be assembled enters a production line to start production.
10. The method of automobile assembly of claim 9, wherein, upon in-line deployment of the vehicle to be installed,
firstly, adjusting the production control system, the production monitoring system and the production error-proofing system; in the production control system, adjusting a production module, and connecting the newly added production module to a configuration management module by using the flexible interface without modifying a communication interface between the production control system and the manufacturing execution system; adjusting a station sensing module in the production mistake proofing system;
then, configuring the work station, the production control system, the production monitoring system and the production error-proofing system in the manufacturing execution system; in the manufacturing execution system, adjusting the manufacturing parameters corresponding to the vehicle to be installed, so as to specify the number, position and length of the work stations included in a production line, specify the production process corresponding to each work station, and configure the exception handling specification in the production error-proofing system;
finally, the redundant devices which are no longer used after the configuration is completed are optionally removed from the production control system, the production monitoring system and the production error-proofing system, and are included in the production control system, and the redundant production modules are removed.
11. The method of automobile assembly according to claim 9, wherein, upon initializing the process of the production line:
firstly, starting the production monitoring system to start collecting the production line state information;
secondly, checking the state of the vehicle to be assembled by using the production error-proofing system;
thirdly, the vehicle body identification system reads the vehicle information;
then, the manufacturing execution system selects one group from a plurality of groups of manufacturing parameters stored by the manufacturing execution system based on the vehicle information reported by the vehicle body identification system, configures the number, the position and the length of the stations on a production line, and issues the selected manufacturing parameters to the production control system and the production error-proofing system;
finally, the production control system configures the production process of each station according to the received manufacturing parameters; and the production error-proofing system configures an exception handling specification according to the received manufacturing parameters.
12. The method for assembling a motor vehicle according to claim 9, wherein the production process of the vehicle to be assembled comprises the steps of:
step S1, the production monitoring system collects the production line state information and reports the production line state information to the manufacturing execution system;
s2, the manufacturing execution system determines the current station of the vehicle to be assembled by combining the position and the length of the station of the current production line and the position information of the vehicle to be assembled on the conveying line, which is contained in the state information of the production line, and sends the current station of the vehicle to be assembled to the production control system;
s3, the production control system executes the production process corresponding to the current station; meanwhile, the production error-proofing system combines the production line state information, the production procedure completion information and the exception handling specification, and when the current station is abnormal, a prompt or a warning is sent out;
and S4, after the production process of the current station is completed, the manufacturing execution system drives the vehicle to be assembled to advance along the conveying line and returns to the step S1.
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| CN202211285616.9A CN115599059B (en) | 2022-10-20 | 2022-10-20 | Automobile production line with error-proofing early warning function and variable stations and automobile production method |
| PCT/CN2022/140210 WO2024082425A1 (en) | 2022-10-20 | 2022-12-20 | Automobile production line having error-prevention early-warning function and variable stations, and automobile production method |
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