Digital Unmanned Workshop Example of Intelligent Manufacturing
Digital unmanned workshop is a typical example of intelligent manufacturing, which mainly solves issues of plant, workshop, production line and the conversion from design to manufacture to reduce uncertainty between designing and manufacturing. It compresses, advances and checks the manufacturing process in digital space, so as to improve success rate and reliability of the system, shorten the conversion time from design to production and realize functions in different phases (e.g. manufacturing, assembly, quality control and inspection) of product life cycle.
Procedures: Product design → Process design → Manufacture
Technical Effects of Digital Unmanned Workshop:
1. Shorten 30% of time for the product to go public;
2. Reduce 65% of design modification;
3. Shorten 40% of process planning;
4. Reduce 13% of production cost.
Hardware Support of Digital Unmanned Workshop:
A. Model Components: intelligent equipment, AGV, automatic control, CNC, automatic identification, video monitoring, audio broadcasting, management and control system, information center, data collection, interface, intelligent analysis, control center, data platform;
B. Related Hardware Support: industrial robots, AGV, AGC, RGV, profibus, PLC, control modules, CNC, automatic handling, transmission device, bar coding identification, RFID, video collecting and playing device, voive recognition and playing device, server, control terminal, message send-receive device, automatic collecting device, interface module, terminal, server, information transmissing and publishing device, information display device.
Levels of Digital Unmanned Workshop:
Level A: Digital workshop
Level B: Digital production line
Level C: Digital processing unit
Level D: Digital operation
System Composition of Intelligent Manufacturing:
1. Management layer: MIS ERP CRM
2. System layer: SCARA MES
3. Network layer: Profinet DP Control Bus
4. Control layer: PLC SCM Digital Camera
5. Execution layer: Robots and Intelligent Manufacturing Equipment
Robots and Intelligent Manufacturing Equipment:
Industrial robot, AGV, Clean robot, Automatic assembly and testing line, Automated logistics system, etc.
Industrial robots: Clean room panel handling, Robotic arc welding system, Spot welding robot in auto plant;
Industrial Robot Complete Equipment: Robot spot welding system, Robot arc welding station, Robot gelatinizing station, Automobile welding line, Robot welding station;
Cleanroom Robots: Semiconductor chip manufacturing, FPD panel handling, SCARA vacuum manipulator, Dual-arm atmospheric manipulator;
Logistics & Warehousing Automation System: Logistics system, Logistics system for electric power measurement center, Automated logistics system, Antomated logistics system for tobacco factory, Converter station for new energy cars.
Case Study of Digital Workshop
A digital workshop project:
This assembly workshop is composed of automatic warehouse, AGV, assembly and testing system, master control system, MES system, etc. Assembly line is arranged at first floor, while subassembly and tesing lines are at third and fourth floors. High-rack warehouse start from first floor until fourth floor, which stores components and also conveys materials between floors automatically. Subassembly lines in the same floor are connected by RGV to realize automatic conveying. AGVs are used to automatically convey from warehouse to assembly line.
The whole workshop is controlled by master control management system, which connects MES system. MES system connects ERP of main workshop. ERP transmits production plan and task to master control management system through MES, then master control management system breaks the information to every production line. As there is no data input, data output or ANDON system in any working procesure in assembly and testing lines, the operator operates as per the procedure content displayed on the work station. Assembly and testing data on each station and ID numbers of assembled products will be transmitted to the higher management system to realize traceability of products. The operator can also send demand information to master control management system through ANDON system. The whole system can realize the real-time update of management data.
