Exploration on the Application of Digital Planning Technology in Press Shop
In the era of global digital economy, with the rapid development of the automobile industry, the traditional automobile manufacturing production model has become increasingly unable to meet the needs of the market. The transformation and upgrading of the automobile manufacturing industry is imperative, and the road of intelligent manufacturing is traditional manufacturing. One of the choices companies can make when facing the challenge of change. Following mechanization, electrification, and automation, the global manufacturing industry is transforming and upgrading to digitization and intelligence.
Stamping is the first process in the field of automobile manufacturing. The quality of stamping products and the level of production efficiency play an important role in vehicle production. In recent years, with the continuous expansion of the auto manufacturing industry’s own production scale, the stamping shop is also moving towards intelligence. The application of 3D design and simulation software has played a key role in the digital planning of the stamping shop. In view of this How to combine new technologies to develop a fast and effective three-dimensional digital planning method to complete the process plan planning of the stamping workshop is the key to improving the intelligent level of the stamping workshop.
Establishment of virtual press shop
Modeling of 3D model of workshop equipment
Under the traditional design mode, the process planning of the stamping workshop mainly relies on the layout experience of the original similar projects. The process equipment, public pipelines, and the main body of the plant are relatively independent in the design and construction stages, resulting in equipment and public utilities during the construction process. Mutual interference between pipelines and various platforms in the plant, resulting in construction changes, rework, etc., affecting the construction progress, causing project delays and unnecessary losses.
In response to this problem, a three-dimensional model of each component of the stamping workshop needs to be established to form a virtual stamping workshop. By checking the relationship between the components in the virtual stamping workshop, the interference can be accurately analyzed.
The 3D model of workshop equipment is mainly completed by 3D design software, such as MicroStation, CATIA, SolidWorks, etc. The complexity of the modeling of the 3D model of the workshop is like the process of establishing a real workshop. The equipment unit model, area model and workshop model all need to invest a lot of manpower and material resources in the early stage, but the model is highly versatile and often has reference significance for other future projects.
The 3D model modeling steps of equipment are as follows:
⑴ Types of 3D equipment models. Commonly used equipment and station appliances in the passenger car stamping workshop, the blank storage cabinet in the blank storage area, the uncoiling shear line in the blank production area, the research and distribution press and the trial press in the mold repair area, the mold and the load bearing in the mold storage area Die sleepers, stamping production lines and automation equipment in the stamping production area, waste conveying lines in the waste processing area, sheet metal lamp gallery in the stamping parts repair area, shelves in the stamping parts storage area, cranes in the workshop, electric flat cars, AGV trolleys and Forklift etc. In the above equipment, there are multiple models, select one or several of its typical models for modeling, to lay the foundation for building a 3D model library.
⑵Establish three-dimensional equipment model. Under the current situation, it is a general trend in the industry for equipment manufacturers to use 3D software to model. Each key unit generally has a 3D model, which can be obtained directly from the equipment manufacturer. In the case where the 3D model of individual equipment cannot be obtained or the data provided by the equipment manufacturer is too different from the actual demand, the establishment of the 3D model of the equipment must be completed through the two-dimensional drawings of the equipment and the observation of the actual equipment.
The establishment of the 3D model of workshop equipment lays the foundation for the development of the overall 3D model of the workshop, and at the same time gradually enriches the 3D model library of the workshop. It should be noted that the establishment of the overall three-dimensional model of the workshop is to better and more intuitively improve the planning scheme of the workshop; to check the interference between various areas and equipment of the workshop, the main use is the outline and dimensions of the production line equipment, and the internal The mechanical mechanism is not the focus, but the outline and dimensions of each device must be accurate. The three-dimensional model of some equipment is shown in Figure 1 and Figure 2.
Modeling of the overall 3D model of the workshop
Figure 1 Three-dimensional model of five-sequence stamping line
Figure 2 Three-dimensional model of crane
The modeling tools for the overall 3D model of the workshop are software such as Revit and MicroStation. The overall process model of the press shop includes a civil engineering model, a process equipment model, and a public pipeline model. The key equipment units and civil engineering public modules can be assigned parameters in the model to solve the faults in the design phase and the construction phase.
The specific steps to establish a three-dimensional model of the workshop are as follows:
⑴ Obtain and model the modeling data of the workshop process equipment (the detailed description has been given above). Store all three-dimensional models of equipment related to the workshop in the form of a database for later recall.
(2) Establish a civil engineering model of the workshop. Using the architectural grid as a benchmark, gradually build models of building walls, columns, roofs, beams, and ground, and improve the details of doors, windows, and overhead crane tracks to provide real-time information for project planning, formal production and use, and later operation and maintenance. Information data support is especially effective for interference problems and hidden project management and control problems involved in the civil construction stage.
⑶ Establish a three-dimensional pipeline summary model of the workshop. Three-dimensional pipeline summary is a detailed record of the elevation, pipe diameter, and location of public pipelines, and intuitively observes the interference problems between pipelines, equipment and civil construction from space, providing users with convenient conditions for early construction and saving engineering costs; The summary model can be updated in real time according to the changes of pipelines in the workshop, and the changes of public pipelines in the workshop can be recorded to facilitate future transformation and maintenance.
⑷Summarize the three-dimensional models of each part to complete the overall modeling of the three-dimensional workshop. First, determine the two-dimensional layout plan of the workshop, which includes the civil construction and process equipment positioning of each area of the workshop; secondly, import the two-dimensional layout plan into the three-dimensional model to provide a reference for the positioning of the three-dimensional model; finally, Position the three-dimensional model that has been established in the foregoing steps on the corresponding workshop positioning point.
The three-dimensional digital workshop covers the whole process from workshop design, construction to production and operation. The traditional planning methods only rely on the traditional working environment, with the help of the layout of two-dimensional drawings, use personal experience to judge and analyze, and finally complete the planning plan. It has more experience, uncertainty and inaccuracy, and the 3D digital planning method relies on 3D software and its corresponding functions to efficiently obtain an accurate and reasonable workshop process layout, which greatly reduces manual analysis Judge the time and improve the accuracy of plan planning. The overall three-dimensional digital model of the workshop is shown in Figure 3.
Workshop production information management and control system
Workshop production information management and control system is divided into two aspects. One is the management of workshop production information. Data collection is the basis of the management system. Through data collection, product production data, equipment status data, and work-in-process status can be collected. Through the analysis and processing of this information, it is convenient to react in time to the on-site situation. The data collection and control of the underlying smart device can be accessed through the interface provided by the device. More and more smart devices’ built-in software interfaces also provide convenience for data collection and management. There are many modules in the manufacturing execution system. In order to reduce the risks and costs of project implementation, companies will also adopt a step-by-step implementation strategy. As more and more application modules are introduced by the factory, the load on the manufacturing execution system is increasing, and its later computing capabilities The expansion is also a factor that must be considered.
Figure 3 The overall three-dimensional digital model of the workshop
On the other hand is the monitoring of the production process in the workshop. The monitoring system can directly display the status of each work unit in the workshop, such as the operation of each equipment in the stamping line, the automation system between the stamping lines, and the waste conveyor line. The fault information, the saturation rate of the blank storage area, mold storage area and stamping storage area. Through the analysis of this system, predictive maintenance is formed for each equipment in the workshop, so that the problems arising in the production process are eliminated in the bud.
Before the introduction of the control system, abnormal production conditions often occurred and telephone communication was frequent. After the introduction of the system, the current production status can be clearly understood through system analysis. As an information hub connecting the upper-level planning management system and the lower-level production control system of the enterprise, the system is mainly responsible for production management and scheduling execution to ensure that production is executed as planned. Collect and process production data in real time from the production site, monitor production status and abnormal production, analyze and feed back production performance, and cover the basic functions of upstream and downstream production such as inventory and logistics, thereby effectively making up for the manufacturing planning layer and control layer. Management gaps between.
There are two main lines for the digital planning of the press shop. One main line is to model the overall situation of the workshop through 3D technology and present the overall plan of the workshop in a three-dimensional manner. This is the basis for realizing the digital transformation of the workshop. The other main line is the workshop information management and control system, which realizes the refined control of all links and elements of the production process such as planning and scheduling, production logistics, process execution, process quality, and equipment management. The intersection of the two main lines realizes the interconnection between production equipment and the information system, and solves the faults between the design phase, the construction phase and the production operation phase. This will become a necessary condition for building a digital stamping workshop.