Method for inputting a spatial layout of production devices to a computer-aided planning program and for optimizing the latter
In a factory planning method, provision is made for the models ( 15 a ) of the model layout to be placed on a substrate, with the result that the position of the models can be determined using digital image processing after the models have been placed. As a result, the real models ( 15 a ) can be used for clear factory planning, in which case collisions ( 33 ) on account of an area requirement ( 15 b ) resulting from particular specifications to be displayed by the planning program are and an optimized proposal to preferably also be output are provided for. This advantageously makes it possible to combine the intuitive factory planning method using real models with the factory planning method using planning programs, thus enabling interactive working with both planning methods.
1. A method for analyzing a spatial layout of production devices, which together form a production plant, using a computer-aided planning program, the method comprising:
arranging a plurality of physical models on a flat substrate to form a model layout of the production plant, the physical models including at least one of two-dimensional models and three-dimensional models of a plurality of production devices, which each physical model is true to scale in terms of physical area requirements of the production device represented by that physical model, and wherein at least one of the physical models includes an optically-detectable identification symbol that identifies that physical model,
capturing an image of the model layout by a sensor or an image sensor,
the planning program receiving the model layout image, and based on the model layout image:
calculating a position of each physical model included in the model layout image,
detecting at least one optically-detectable identification symbol in the model layout image,
for each detecting identification symbol, determining the physical model identified by that identification symbol and automatically accessing from storage a data record for the production device represented by that physical model,
the planning program analyzing the model layout based at least on (a) the calculated position of each physical model and (b) the data records accessed for each physical model having a detected identification symbol, wherein the analysis includes determining overlaps of the respective relevant area requirements of production devices represented by adjacent physical models, and
the planning program generating and displaying with an output device an image of the analyzed model layout, which indicates the determined overlaps.
2. The method according to claim 1 , wherein the data records of respective production devices contain specifications for the respective production devices.
3. The method according to claim 1 , wherein the data records of respective production devices contain standards and guidelines.
4. The method according to claim 1 , wherein further data records are provided in the planning program, which data records relate to relationships between the production devices.
5. The method according to claim 4 , wherein the further data records are related to material flows and transport paths.
6. The method according to claim 1 , wherein additional data records relating to structural conditions of the production plant are provided in the planning program.
7. The method according to claim 1 , wherein the planning program calculates a proposed correction for avoiding the overlaps which have been determined, and
the proposed correction is displayed using the output device.
8. The method according to claim 5 , wherein the planning program calculates a proposed correction for avoiding unused empty areas, and
the proposed correction is displayed using the output device.
9. The method according to claim 1 , wherein the planning program calculates a proposed correction to the model layout, and wherein the output device displays at least one of the overlaps and proposed corrections on the flat substrate.
10. The method according to claim 1 , further comprising the planning program calculating proposed corrections to the model layout and calculating at least one of expected costs and area requirements for at least one of the model layout and the proposed corrections.
11. The method according to claim 1 , wherein:
the planning program stores further data records relating to relationships between the production devices,
the planning program calculates proposed corrections to the model layout, and
at least one of the data records of the production devices and the further data records relating to relationships between the production devices include individual preferences which restrict a number of variations of the proposed corrections.
12. The method according to claim 1 , wherein the optically-detectable identification symbols are optically readable and are fitted to the respective physical models in such a manner that they are optically accessible from a viewing direction of the substrate from above after the respective physical models have been placed on the substrate.
13. The method according to claim 10 , wherein a temporal sequence of digital images is created from the model layout using the image sensor,
changes in the positions of the optically-detectable identification symbols are determined by comparing the digital images, and
the changed positions of the carriers are linked to data records of the production devices in the planning program using identification identifiers associated with respective identification symbols.
14. A system for inputting a spatial layout of production devices, which together form a production plant, to a computer-aided planning program, comprising:
a plurality of physical models on a flat substrate to form a model layout of the production plant, the physical models including at least one of two-dimensional models and three-dimensional models of a plurality of production devices, which each physical model is true to scale in terms of physical area requirements of the production device represented by that physical model, and wherein at least one of the physical models includes an optically-detectable identification symbol that identifies that physical model,
a sensor for capturing an image of an arrangement of the plurality of physical models defining a model layout,
a processor for executing a planning program to receive the model layout image, and based on the model layout image:
calculate a position of each physical model included in the model layout image,
detect at least one optically-detectable identification symbol in the model layout image,
for each detecting identification symbol, determine the physical model identified by that identification symbol and automatically accessing from storage a data record for the production device represented by that physical model,
analyze the model layout based at least on (a) the calculated position of each physical model and (b) the data records accessed for each physical model having a detected identification symbol, and
based on the analysis, determine overlaps of the respective relevant area requirement of adjacent production devices, and
an output device for displaying an image of the model layout analyzed by the planning program, which image indicates the determined overlaps.
15. The system as claimed in claim 14 , wherein the data records of respective production devices contain specifications for respective production devices, in particular standards and guidelines.
16. The system as claimed in claim 14 , wherein further data records are provided in the planning program, which data records relate to relationships between the production devices.
17. The system as claimed in claim 14 , wherein additional data records relating to the structural conditions of the production plant are provided in the planning program.
18. The system as claimed in claim 14 , wherein the planning program calculates a proposed correction for avoiding the overlaps which have been determined, and
the proposed correction is displayed using the output device.
19. The system as claimed in claim 18 , wherein the planning program calculates a proposed correction for avoiding unused empty areas, and
the proposed correction is displayed using the output device.
20. The system as claimed in claim 14 , wherein the output device displays at least one of the overlaps and proposed corrections on the flat substrate.