With the adoption of flexible production lines, enterprises can use automated equipment such as programmable logic controllers (PLCs), computers, and sensors to effectively improve production efficiency, reduce production costs, and enhance product quality. A flexible production line is a systematic engineering endeavor involving equipment management, process design, and human–machine engineering. Its flexibility is reflected in: a small number of devices on the line yet full functionality, and a wide variety of products yet compact, reasonably configured structures.
I.Overview
In general, a flexible production line is one capable of flexibly controlling multiple process parameters throughout production. It connects traditional standalone production equipment (e.g., robotic arms and manipulators) through automation integration to process parts using multiple automated machine tools, forming a new flexible production line with independent machining functions and production capacity. While achieving full compatibility with the enterprise's existing production system in terms of process flow, equipment layout, and staffing, it can also meet the enterprise's future needs for larger scale or higher production efficiency. During implementation, a flexible production line does not suffer faults such as downtime or stoppage, nor does it require building a production-line control center; personnel can be dispatched from the on-site dispatching center at any time to adjust, optimize, manage, and coordinate the line on site. At the same time, by using automated integration technology and advanced computer network technology, the line can monitor and control various parameters in real time, improving equipment operation rates, controlling product quality, and achieving automation. Various sensors can be used in the flexible production process, such as pressure sensors and temperature sensors. Advanced control technology enables real-time monitoring of the production site and optimization of process flows. When product quality requirements are high, automatic tracking equipment can adjust process parameters to ensure product quality meets standard requirements.
II.Composition of a Flexible Production Line
A flexible production line mainly consists of flexible equipment, flexible workstations, and flexible conveyor lines.
· Flexible equipment: devices used to realize a series of functions on the production line to meet various process requirements.
· Flexible workstation: composed of a human–machine interface, communication interface, and signal acquisition and processing system, together with corresponding sensors and actuators.
· Flexible conveyor line: uses various control signals to enable automated equipment to fulfill different process requirements.
· Connection between the production line and the control system: the control system determines process requirements by detecting signals output by various sensors or actuators, and transmits information to the automated equipment via the control system to execute operations, thereby realizing automated control of production equipment and process-parameter adjustment. In practical applications, PLC program control is mostly used for automated production lines.
III.Application Case of Flexible Production Lines
Taking a domestic enterprise as an example, it operates a flexible production line comprising six production lines: an automated assembly line, an automated sub-assembly line, an electronic-product assembly line, and a second electronic-product assembly line, each with an annual production capacity of 5 million units. Among them: the automated assembly line mainly consists of a robot body system, an automatic fixture system, a conveyor belt system, and auxiliary motion mechanisms; the automated sub-assembly line mainly consists of a robot body system and control and actuator mechanisms; the electronic-product assembly line mainly consists of electronic-product fixturing equipment, an automatic assembly line, and inspection equipment; the second automated sub-assembly line mainly consists of conveyor machines and manipulators; and the intelligent control and software platform's auxiliary motion mechanisms consist of PLCs (programmable logic controllers), servo drive components, and servo motors.
Characteristics of the flexible production line:
1.A high degree of automation, with production efficiency more than double that of ordinary lines;
2.The ability to select suitable robot types and quantities according to process requirements, and to realize multiple production modes (including mixed-model production);
3.A quick-changeover function that can switch the part being operated at any time, realizing a convenient and fast "part swap";
4.Strong connectivity with other processes—either as a multi-variety line (e.g., an assembly line) or with data-exchange capability between lines;
5.After adopting a flexible production line, it reduces labor costs (currently only 2–3 workers are needed domestically) and the defects in the product-quality assurance system and the impact on market-response speed, thereby ensuring the enterprise's production.
