On the digital process planning interface, the product's three-dimensional display is realized, which can be scaled and rotated, and the plan dispatcher can clearly observe the state change of the product. The order in which the processes are performed, the names and implementation contents of the processes, the required time and resources are clearly expressed in the form of various tables, charts, and texts. Capacity planning, quota allocation, and station layout design can be quantified with process planning. The Pert diagram links parts, manufacturing features, and resources to operations. At the same time, it can define the material flow between processes and then develop a material plan. With the help of the Gantt chart, the line balance is adjusted and the critical path on the production line is identified by the planner. At the same time, the process plan will alert planners to the potential resource conflicts.
The preliminary process planning can also perform performance analysis of the production line by means of discrete event simulation functions, including production, material flow, load balancing, bottleneck and buffer size, etc., to achieve the verification and optimization of the plan.
Simulation analysis of discrete event systems, generally to establish a system simulation model, according to the type of workstation and operation, select the appropriate distribution function and control strategy to describe the system. When building a simulation model in a PLM environment, much of the information in the process planning can come from the PLM system, and the software automatically completes the information transfer, which is convenient to operate. After the simulation model is run for a long enough time, the system gives the performance index values ​​of the plan after continuous operation, such as production capacity, tempo, efficiency, work-in-progress, inventory, etc., and expresses them in the form of charts, reports, etc. . When the production scale is large and the system is complex, the model for simulation analysis will adopt a hierarchical structure, which indicates the factory, workshop production line, work section, team group and other levels, making the model's expression clear and clear at a glance. Production, planning personnel at different levels in factories, workshops, and sections can conduct more in-depth analysis and research on their own responsibilities, grasp the relationship between the whole and the local, and make appropriate adjustments when necessary. When simulation modeling takes into account internal and external supply chains, production resources, and business processes, you can analyze the impact of production changes on upstream and downstream, evaluate the pros and cons of different production line control strategies, and verify the synchronization of production lines and secondary production lines. .
Some production lines may have "bottlenecks" in their operation, which limits the operating efficiency of the entire system and becomes the key to increasing production capacity. For such problems, the production department will propose a variety of improvements, which are often partial revisions to the original plan. The final improvement can be given by the simulation run of the revised scheme and quantitative analysis.
In some industries, when designing and optimizing the production system, more and more logistics are taken into account, and the logistics trend, density, and transportation mode are simulated and analyzed, and the logistics is visualized. The Sankey diagram can be used to visually display the current configuration. The amount of material transferred.
There are many simulation tools that apply genetic algorithms to production system simulations to optimize system parameters based on various constraints (such as yield, inventory, resource utilization, and delivery date) to achieve the overall optimization goals.
Digital processing of parts
On the PLM platform, product designers, process personnel, CNC programmers, tooling designers, plan dispatchers, and production managers share product design data in the form of bill of materials (eBOM) and manufacturing engineering data in the form of electronic process sheets (eBOP). They can access the correct component manufacturing data at the right time when performing their respective tasks, and realize parallel collaborative work between the various components. In this way, the engineering cycle is shortened and the engineering quality of the manufacturing process is improved.
With the PLM platform, process technicians can easily obtain various information (such as digital models, drawings, technical conditions, etc.) of the parts provided by the design department, and have a comprehensive understanding of the products. According to the processing method of the designed parts, the technical procedures are compiled. The model generated by the CAD system is the basis for programming the NC machining program. The resource information provided by the PLM platform obtains the guarantee conditions required for processing, such as the structural form of the CNC machine tool, the drive shaft, the stroke, the tool measuring tool, the fixture, etc., the NC program is programmed, the post processing is performed, and other process documents are prepared. These documents will be passed to the Distributed Digital Control (DNC) system and Manufacturing Execution System (MES) on the shop floor as a basis for guiding the work instructions for the worker's operations and the production plan for the production plan.
As such, simulation techniques are also very important in digital processing. The main thing to do is CNC cutting simulation and cutting parameter simulation optimization. Before the initial verification of the NC program, there will always be some negligence or embarrassment, which needs to be verified and improved. The CNC cutting simulation tool displays the relative motion of the tool and the workpiece and the material removal process according to the tool position file to detect whether there is interference and “overcut†phenomenon. Interference checking of the cutting process not only needs to detect the interference between the tool and the workpiece, but also whether there is interference or collision between the spindle and the fixture of the machine to ensure the safety of the process. Whether it is an expensive multi-axis CNC machine or a complex shape with long machining cycles, collisions and interference are absolutely not allowed. The prediction of interference, especially for five-axis NC machining, cannot be achieved by human alone.
On the other hand, various professional simulation software as "point tools" also provide an important auxiliary role for determining the processing method and programming the NC program. Using machining simulation software to simulate the mechanism of the machining process, analyze the physical changes in the process, such as the formation process of the chip, the temperature distribution of the tool and material during the machining, the change of the cutting force, etc., to understand these will help determine the cooling conditions. The optimization of processing parameters such as the number of revolutions and the feed rate is indispensable for the preparation of a reasonable numerical control program. In addition to machining parameter simulation, this kind of tool software also has casting process simulation and welding process simulation.
Digital assembly
In the early stage of product development, designers can use the original data of the CAD system to construct a virtual prototype, analyze the positional relationship of each component of the product, the distance and coordination between each other, and the tolerance of the detection tolerance.
Digital PreAssembly (DPA) technology focuses on the dynamic process of product assembly, designing the assembly sequence of product components, and defining and adjusting assembly sequences using Gantt charts and tree diagrams. Establish a path for assembly and disassembly to simulate the spatial envelope swept by the component during assembly for interference checking. Once there is interference, give a sound or color hint. Sometimes a series of cross sections can be used to dynamically show the detailed interference process, indicating the extent of the interference.
From the perspective of production engineering, digital pre-assembly studies more about the implementation process of the assembly, placing the assembly process under the engineering environment (including plant, personnel, tooling, tools, etc.), the workshop environment and work of the product in the assembly process. The unit, logistics distribution path, product posture are simulated, analyzed and edited, which is close to the engineering reality. Digital pre-assembly studies apply not only to the assembly process, but also to the disassembly and repair process. The digital assembly technology supported by PLM has the following features:
Shorten the development cycle of new products
Identify problems early and reduce design errors
Use a virtual prototype to verify the design and reduce development risks
Guarantee to use the correct version
Fast response to engineering changes
Resolve potential problems in a virtual environment and reduce time to market for new products
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