Design of Control System for Flexible Automatic Processing Line

In order to meet the requirements of automatic processing for mechanical components manufacturing enterprises, the paper describes a design method of automatic production line. Firstly, the paper made the overall design of the automatic production line, takt time is calculated according to the annual production demand, and the analysis of device configuration and position layout of the production line was carried out based on the annual production requirement. Secondly, the paper selects types of CNC machines and industrial robots, and design structural of the silo, the temporary storage platform, the conveyor belt, the fuel injection and water removal. 3D model of each component and space layout of the production line are drawn by Solidworks software. Thirdly, the process flow of automatic production line was designed, and the CNC intelligent management system was developed to meet the requirements, which can monitor the process information such as takt time. Test is carried out after establishment of automatic production line, the test run finally shows that the automatic production line works stably and can meet the requirements of enterprise.

Decomposition program for allocating interstage storage along an automatic production line

In order to make the shell production automatically and efficiently, reduce the injury to the worker’s health caused by the harmful dust, this paper describes an automatic shell production line controlled by PC and PLC. The executive body of the shell production line is robots, PLC transmits signals between robot and PC. The new automatic shell production line can not only stucco but also possess the features of smooth operation for shell making and reliable use and low noise. It has been proved that the shells automatic production line has improved production efficiency, reduce the contact with harmful environment of manipulators greatly, and make the production process are controlled well and safely.

This research was driven by the need for a more efficient production scheduling system in a consumable liquid product division of a large consumer products company. The manufacturing process under inspection consists of continuous and discrete elements, on both production and packaging lines. The production lines are split into continuous production lines and batch production lines which produce the product in fixed batch amounts. Then there are several bottling lines, some of which package a particular bottle size and others that can package multiple bottle sizes. The main objective of this research was to reduce the amount of time it takes for the client to create production and bottling schedules. An optimization model was developed to automate this process and provide the client with the best possible schedule. The objective of the model is to minimize cost by minimizing the number of switches across the production and bottling lines, as well as minimizing the amount of overproduction. Inputs into the model include model parameters, like the number of shifts to schedule, and monthly demand numbers for each stock keeping unit (SKU). The variables being solved for are the amount of each flavor to be produced across the production lines during each shift, and the number of bottles of each SKU to be bottled across the bottling lines during each shift. Due to the unique constraints and resources of the client, a custom formulation using mixed integer programming was necessary to achieve these objectives. Overall, our model fell short in some areas but succeeded in others. Our analysis showed that the model had a 13% average decrease in production switches but an 87% average increase in bottling switches compared to the current manual scheduling system. However, the ability of our system to create a good enough initial schedule reduces the time it takes expert human schedulers to develop a final schedule by up to 85%. Runtime and computational constraints barred us from creating an optimal, cost-minimized solution for our client, and future work can be directed toward solving these issues.

Li-ion battery is used widely in many industrial areas, and formation is a necessary process in battery manufacture. After formation, the performance of Li-ion power batteries can be activated. In the process of production, the key technology in the formation has been changed. The technology of formation and holding independently for each battery is turning into the formation after being clamped and then holding now. Therefore, the design of the automatic production line must base on the battery groups after being clamped. This text will introduce a new production line for the formation of Li-ion battery, mainly discuss the formation of clamped batteries, and how to realize the automation of the production line. The line uses the three-dimensional multi-layer frameworks, speed-fold chains and stoppers. The speed-fold chain is a new type of conveyor chain, and known as "flexible manufacturing unit". The battery groups can be stopped in the manufacturing line by the stoppers, and then they can be charged or discharged. The line can be connected by the lifting machine.

Promoting and thrust gear on refrigerator body in automatic production line has been designed. The existed equipment has poor adaptability and low efficiency. The key improvement on promoting and thrust gear is to use hydraulic system as driving force. Movement of independent model car on the production line track has been circulated. Reasonable movement effect is achieved after analysis on hydraulic circuit simulation by FulidSIM-H. At last, the promoting and thrust gear is put to use in production line and got good performance.

In the steel pipe manufacturing industry, the steel pipe manufacturing process is completed by multiple processes. And on the automatic production line, the transfer process between steel pipe working procedure is realized by the steel pipe transfer device. The unreasonable structural design of related parts in the steel pipe transfer device will result in the failure of the steel pipe transfer process to proceed smoothly, which will directly affect the normal operation of steel pipe production line, resulting in steel pipe productivity’s decrease and causing losses to steel pipe manufacturers. This article proposes an improved design method of the turnover mechanism of transfer device between steel pipe manufacturing processes.

The plating technology meets many difficulties due to the shape variety, frame complexity and material diversity of the ceramic packages. Nowadays much of the plating still relies on handwork, which limits both the batch production and quality stability of ceramic packages. One method to solve the problem is the automatization of plating by using advanced equipments, stable plating process and control methods. Therefore, in the paper the automatic plating for ceramic package was reported in three aspects, i.e., plating equipments, plating process and control methods. The technique of this work has been successfully applied in practical production, and supported batch production of ceramic packages. The increasing demand on the production of ceramic packages requires more advanced techniques, among which plating is one indispensable process. The automatization plating technique can benefit the batch production of ceramic packages, though it is difficult to be realized due to the variety or even non-standard requirement of ceramic packages. Especially in the batch production of mixed types of packages, the different configurations, surface materials and plating procedures have high requirements on the automatization process. Only the production line that combines with multi-processes in a range of operational parameters can take full advantage of the automatization method. Thus, in this paper, the development of automatic production lines for plating ceramic packages was reported according to the plating equipment, plating process and control method.

Previous studies on stochastic-flow production networks have typically assumed either fully automatic or fully manual workstations. However, real-world production systems often integrate both machines and human workers. Additionally, rework operations are also common; in certain sectors, such as surface mount technology (SMT), these tasks remain manual due to the complexity and flexibility required for small-batch production in small and medium-sized enterprises. This study focuses on a stochastic-flow hybrid production network (SFHPN) consisting of two production lines--one automatic and one manual, where all rework operations are handled by the manual line. A reliability evaluation framework is proposed, incorporating an algorithm designed to determine the minimal capacity of each workstation and to evaluate the satisfaction probability representing the system’s reliability. The proposed model captures a fundamental yet practical hybrid production structure that reflects the cooperative interaction between automation and manual operations. This framework enables production managers to enhance decision-making, operational efficiency, and overall system stability.

Waterproof and breathable socks are the focus of hosiery development. The greater demand prompts the need for automated systems and production line planning to further reduce manpower requirements in the process of technological development. We discuss production line planning in this paper. A textile permeation operation is carried out in a circular production line. The permeation process includes three processes: soaking water-based PU resin, drying and removing moisture, and hosiery cooling. By the above production process, the development of the production line requires the integration of six modules to form a complete production line. The purpose of increasing the production capacity and reducing the floor space is achieved by the closed chain circulation production line. When the sock mold enters each process workstation, the angle is adjusted by the auxiliary guide rail, so that the sock body can enter the drying process and the cooling process after being permeated. Integrating the modular design of the above mechanisms with a variety of mold combinations, a variety of products are produced to achieve the purpose of flexible manufacturing and automated production by replacing the modules and molds.

In the case of large-scale and mass production lines often the same model of an industrial robot is used in various places of the line and is intended to various task. However, the replacement of one industrial robot to another is a long lasting and arduous process. It requires stopping all the production line and sometimes even dismantling the whole workcell. Such situations are not frequent in production lines that are not flexible. They are related the most often with the failure on an industrial robot. However, during the designing of a flexible production line the ability to replace any robot, which is unrestricted, fast and trouble-free, greatly increase the flexibility level of such line. It could be realized by modular design of the proposed production line. In this way it could be possible to change any elements of such production system. But this approach needs to apply the specialized informatics system.This paper presents the obtained design of several versions of the same production workcell. Each, succeeding version of the designed production workcell contains more and more modular elements. Thereby it would be presented the evolution of a workcell design beginning from the typical design and ending with the fully modular one. One of tools needed to realize this task is the elaboration of a base of modules and typical joint and mounting elements that could be utilised in the described designing process. It is also presented the guidance information about the designing and programming processes useful at each stage of analysed process.

Intelligent manufacturing is the theme and main direction of the “Made in China 2025” development strategy, and the application of industrial robots is an important direction of intelligent manufacturing. In the next few years, industrial robots will be widely used in various enterprises, which will inevitably require a large number of high-tech industries. Industrial robots are high-tech products of modern society and play an important role in the process of economic development, especially in the manufacturing industry. Industrial robot technology is widely used in automated production lines, so that industrial production efficiency can be greatly improved. Instead of manual labor to carry out various complex production and operations, to achieve industrial production automation. Analyze the application of industrial robots in automated production lines at this stage, and explore their future development directions, so that they can better serve the manufacturing industry. This article takes the industrial robots and PLCs in the industrial automation production line as the research object, and takes the automated production line for mass production of a product as an example. It explains the joint control scheme of the PLC controller and the industrial robot controller, and provides for the construction of joint control of similar production lines in the future.

Smart grid relay protection device is the key equipment to ensure the security and stability of power grid operation, and it is the basis to realize the secure and stable supply of energy and the sustainable, healthy development of national economy. At present, the production of relay protection device is discrete island mode which slows down the production process, the automation degree of device assembly and testing process is not high, the production process is opaque, which reduce the output of the product. This paper designs an automatic production line control system which is based on model of Cyber-Physical Systems (CPS), and meets the requirements of production process parameters, and realizes the automatic production of equipment assembly, testing, logistics etc. This system uses auto machines replacing human labor and designs logic timing control, and uses active Radio Frequency Identification (RFID) tags to track device and detect relevant status. In this line system, each process station adopts modular design idea and uses PLC for independent control and data acquisition. Furthermore, the system has been integrated and tested in conjunction with Manufacturing Execution System (MES), the dispatching system of Automated Guided Vehicle (AGV), device product testing system. The production line based on CPS model is of great significance for improving shop floor’s environment, saving labor costs, and improving the quality and production efficiency of relay protection products.

Development of Automated Flexible Manufacturing System for Medium Variation and Medium Volume Production

PurposeThe purpose of this paper is to adopt the total productive maintenance (TPM) in the food industry and especially in bakery products. The paper aims to develop a methodology for increasing production rate, improving the quality of the products and providing a healthier and safer work environment.Design/methodology/approachThe methodology is based on analysing the reliability data of an automatic production line. It is divided into four steps, whose aims are to bring forth improved maintenance policies of the mechanical equipment. Also, the continuous and thorough inspection of the production process is achieved through measurements of the overall equipment effectiveness (OEE).FindingsThe goal of development methodology is to bring competitive advantages, such as: increasing the productivity; improving the quality of the products; and reducing the cost production of the line.Practical implicationsThe development methodology in the food industry increases the production rate, improving the quality of the products and providing a healthier and safer work environment. It can be useful to guide food product machinery manufacturers and bread and bakery products manufacturers to improve the design and operation of the production lines that they manufacture and operate.Originality/valueThis paper presents the implementation of TPM in a pizza production line and, using certain assumptions, the generalization of the results in bakery production lines.