Production systems and production control methods with locating system-based simulations of production sequences
The disclosure relates to digital models of a production apparatus. The digital models can generate simulations of production sequences of the production apparatus, and a controller can access the simulation to improve operations of the production apparatus. The digital model uses data of a locating system to create the simulation. The locating system monitors carriers for transporting components. The controller can compare parameters of the simulation results with corresponding parameters of earlier simulation results and/or actually obtained parameters of earlier production sequences, which can be stored in a model library. The disclosure further relates to corresponding production control methods.
1. A production system comprising:
a production apparatus having
i) one or more production tools for manufacturing components, wherein parameters of the production tools include one or more of laser beam intensity, laser beam focus, bending tool used, throughput speed, feed speed, pulse ratio during pulsed operation, power, and energy, and
ii) one or more carriers or transport aids, or both carriers and transport aids, arranged and configured to transport the components between the production tools;
a controller arranged and configured to control the production apparatus on the basis of production data;
a locating system for localizing a mobile unit arranged or embodied on any one or more of the carriers, components, production tools, or transport aids, wherein the locating system is configured to
i) determine the position of the mobile unit,
ii) detect identification information stored on the mobile unit and to communicate the position data thus determined of the one or more of the carriers, components, production tools, and transport aids to the controller, or
iii) both i) and ii); and
a digital model of the production apparatus that provides a simulation of production sequences, wherein the simulation is based at least on the data of the locating system,
wherein the production system comprises a model library having simulated production sequences, actually implemented production sequences, or both simulated and actually implemented production sequences, wherein the controller is configured to compare the production sequence simulated in the digital model with the production sequences of the model library, and
wherein at least one production tool of the production apparatus comprises a loading zone for loading and unloading a carrier or transport aid, wherein the production system comprises an image recording unit configured to capture image information in the loading zone, and wherein the locating system comprises an image evaluation unit configured to determine a loaded or unloaded state of a carrier or transport aid using the image information.
2. The production system of claim 1 , wherein the controller is configured to control the production apparatus on the basis of results of the simulation.
3. The production system of claim 1 , wherein the production data comprise one or more of production sequences, arrangements of the production tools, characteristic parameters of the production tools, and component data.
4. The production system of claim 1 , wherein in the power is laser power, and wherein the energy is laser energy.
5. The production system of claim 1 , wherein the power is stamping power, and wherein the energy is stamping energy.
6. The production system of claim 3 , wherein the characteristic parameters of the component data include one or more of material, contour, dimensions, deformations, and thickness.
7. The production system of claim 1 , wherein the carriers or transport aids, or both the carriers and transport aids, comprise at least one sensor.
8. The production system of claim 1 , wherein the simulation, the model library, or both the simulation and the model library are embodied in a cloud-based fashion.
9. The production system of claim 1 , wherein the locating system comprises an ultra-wideband system.
10. The production system of claim 1 , wherein the locating system is configured to detect the position of the carriers with an accuracy of less than 1 meter.
11. The production system of claim 1 , wherein the locating system is configured to detect the position of the carriers with an accuracy of less than 0.3 meters.
12. The production control system of claim 1 , wherein the simulation is stored in the form of a material flow simulation.
13. The production system of claim 1 , wherein at least one production tool comprises a metal processing tool.
14. The production system of claim 1 , wherein at least one component or workpiece comprises a sheet-metal part.
15. The production system of claim 1 , wherein the digital model comprises a map of a part of the production apparatus or of the complete production apparatus.
16. A production control method, the method comprising:
(a) obtaining a production system comprising
a production apparatus having
i) one or more production tools for manufacturing components, wherein parameters of the production tools include one or more of laser beam intensity, laser beam focus, bending tool used, throughput speed, feed speed, pulse ratio during pulsed operation, power, and energy, and
ii) one or more carriers or transport aids, or both carriers and transport aids, arranged and configured to transport the components between the production tools;
a controller arranged and configured to control the production apparatus on the basis of production data;
a locating system for localizing a mobile unit arranged or embodied on any one or more of the carriers, components, production tools, or transport aids, wherein the locating system is configured to
i) determine the position of the mobile unit,
ii) detect identification information stored on the mobile unit and to communicate the position data thus determined of the one or more of the carriers, components, production tools, and transport aids to the controller, or
iii) both i) and ii); and
a digital model of the production apparatus that provides a simulation of production sequences, wherein the simulation is based at least on the data of the locating system,
wherein the production system comprises a model library having simulated production sequences, actually implemented production sequences, or both simulated and actually implemented production sequences, wherein the controller is configured to compare the production sequence simulated in the digital model with the production sequences of the model library, and
wherein at least one production tool comprises a loading zone for loading and unloading a carrier or transport aid, wherein the production system comprises an image recording unit configured to capture image information in the loading zone, and wherein the locating system comprises an image evaluation unit configured to determine a loaded or unloaded state of a carrier or transport aid using the image information;
(b) detecting position information, identification information, or both position information and identification information, of one or more of a carrier, a transport aid, a production tool, or a component by a locating system and producing locating system data;
(c) simulating a production sequence to provide simulation results, wherein the simulation is based at least on the locating system data; and
(d) controlling a production apparatus on the basis of the simulation results, wherein the simulation results comprise a digital model of the production apparatus.
17. The production control method of claim 16 , further comprising comparing the digital model with simulated production sequences or actually implemented production sequences, or both, stored in a model library.
18. The production control method of claim 16 , wherein the simulation is stored in the form of a material flow simulation.
19. The production method of claim 16 , wherein the digital model comprises a map of a part of the production apparatus or of the complete production apparatus.