Exploration and Practice of Digital Factory of Complex Electronic Equipment

Hu Changming, Cao Yaqi, Zhu Zhaoyu
2020 IOP Conference Series: Materials Science and Engineering  
For the characteristics of many varieties, small batch, short delivery cycle and high quality requirements of complex electronic equipment manufacturing, combined with a new generation of information and communication technologies and the research of advanced manufacturing technology, This paper puts forward the implementation framework of digital factory of complex electronic equipment, analyzes the connotation of digital factory, explores the application of digital twin in the manufacturing
more » ... age, discusses the process of data perception, fusion and analysis of digital factory, and establishes the factory production operation control platform. This paper verifies the feasibility of complex electronic equipment digital factory floor by the example of radar assembly digital factory, and provides theoretical basis and method reference for the comprehensive application of digital factory in complex electronic equipment field in the future. Introduction Complex electronic equipment is widely used in the fields of machinery, electric power, ships and aircraft, and is an important pillar of the national people's livelihood and national defense security. Complex electronic equipment involves many subjects, ranging from information science and technology such as electronics, communication, computer and control, to advanced manufacturing technologies such as additive manufacturing, micro-assembly and automation. It covers a wide range of knowledge and many fields, which means higher requirements for complex electronic equipment enterprises [3] . Its typical characteristics is strict manufacturing process standards, fast switching of mixed production line, strict production task planning, high product quality requirements. The traditional "equipment + artificial management" model has been difficult to meet the requirements of fine control in factory. Therefore, we must be with the aid of new technology and production mode to adapt to the intense competition of product performance, quality, cost and delivery of complex electronic equipment factory. Generalized digital factory is geared to the needs of whole life cycle of products, based on the simulation technology and virtual reality technology, and that a physical entity of the whole production process is digital simulated, evaluated and optimized in virtual environment is a new production organization way. Digital information and the data flow as the main characteristics, its purpose is to achieve rapid, low cost and high quality manufacturing [7] . In the narrow sense, digital factory is oriented to the production and manufacturing process of products, and design, management, simulation, optimization and visualization of the production resources and production process of people, machine, material, method, environment and measurement, etc., which is also aimed at reducing cost, improving quality and increasing efficiency[6] [23] . This article discusses the complex digital electronic equipment factory in digital information and the data flow as the main characteristics, 2 by means of digital, networked, intelligent, improving the production organization and management to realize workshop sophisticated controls, to satisfy flexible, efficient, high quality, transparent manufacturing needs of complex electronic equipment [5] . The world's most prestigious digital factory is the Siemens Amberg plant in Bavaria, Germany. The factory was founded in 1989. During 30 years of development, it experienced from the introduction of workshop management system, to RFID, to data optimization management, and then to the process line management system, to achieve a high degree of automation of the production process, 75% of the process work by the production equipment and computer processing. In recent years, the product information and physical entities in the virtual environment of Digital Twin system are mapped to each other to optimize and control the manufacturing process in real time. At present, the factory can produce one control device per second on average, and the product qualification rate is as high as 99.9988% [8] . GE aviation engine manufacturing center, located in Ohio, is a typical representative of another model of digital factory: "sensor + big data" industrial Internet model. Predix is GE's first cloud service platform developed specifically for industrial data analysis, enabling engine data acquisition and status monitoring through seamless integration with various applications and services deployed in the cloud [24] . At the same time, for the complex discrete manufacturing process of engines, GE has established a powerful production management and manufacturing execution system, which combines lean concepts with automation and digital methods to achieve comprehensive improvement of manufacturing performance [9, 10] Qingdao Haier mold co., LTD. (hereinafter referred to as Haier mold) is the largest mold and fixture manufacturer in China, and is one of nine interconnected factory demonstration units. Aiming at the digital factory featuring automation and fewer people, Haier mold has built the leading CPS collaborative production management system in China since 2013, realizing the free flow of data through equipment interconnection. Through system integration, information sharing and collaborative manufacturing can be realized; Through data collection, analysis and display, to achieve scientific management; Through real-time monitoring of equipment status, predictive maintenance is realized. The successful implementation of the CPS system has improved the production efficiency and enterprise competitiveness of Haier mold, and achieves good economic and social benefits. Ningxia sharing group, located in western China, which belongs to traditional manufacturing industry, is one of the first batch of 46 intelligent manufacturing pilot and demonstration projects of the ministry of industry and information technology. Through the information integration of ERP, PLM, MES, DNC and other systems, it realizes the digitalization and transparency of workshop production process. The free and orderly flow of data in the workshop can be realized through the integration between information systems, production equipment, physical world and virtual world. Digital factory is the foundation of intelligent manufacturing and the only way for industry 4.0. Many domestic and foreign manufacturers have built or started to build their own digital factories [2] . In the face of rapid emerging technologies and increasingly fierce market competition, digital factories will integrate various new technologies such as artificial intelligence and data mining, so that factories can learn, think and make decisions just like people, and finally realize intelligent factories. Compared with Siemens, GE and other international leading enterprises, the domestic digital factory started relatively late. At present, that is mainly used in casting, machining and other traditional industries. It is not yet mature for electronics industry whose characteristics are many varieties, small batch. And the construction of standard system, data fusion analysis, digital twin, control operating platform construction of research remains to be strengthened. This paper, firstly, introduces the concept and implementation method of digital factory for complex electronic equipment, and then analyzes its connotation and frame, and discusses the key technology of digital factory practice. Finally, based on theoretical exploration, the paper combined digital factory with complex electronic equipment production and manufacturing, introduces the application cases of complex electronic equipment in digital factory, and provided a method reference for the implementation of digital factory in many-varieties and small-batch manufacturing enterprises. 3 Connotation of complex electronic equipment digital factory Complex electronic equipment is the product of the integration of multiple subsystems through complex coupling relation. In addition to meeting the individual functions in their respective fields, it is also required to meet the overall functions of the system after coupling integration. Therefore, the manufacturing process of complex electronic equipment emphasizes more on reliability and integrity [4] . Digital factory of complex electronic equipment is the mutual mapping between physical entity operation and information flow in the assembly process of complex electronic equipment from parts to complete machine, which can truly reflect the integration process and meshing relationship of each part from single to whole. On the basis of operation control platform, it is targeted at refined production factors such as human, machine, material, method and environment, and combined with advanced scheduling, data collection and analysis, digital twining and other application functions to digitize physical entities and visualize plant operation, so as to realize the research and application of complex electronic equipment digital factory. Digital factory, factors of production, operation process and product as the core, on the basis of whole life cycle of product data, applies simulation technology, virtual reality technology, data fusion and analysis technology, etc., digitize all the physical activities of products in the factory, and analyze these activities, optimization and feedback mode of an integrated organization [8] . Digital factory emphasizes the digitization of production factors, processes and products, which is the digitization record of each step in the real factory (such as process planning, manufacturing, quality inspection, process management, fault maintenance, etc.). Compared with traditional factories, what is more important is that digital factories can optimize and control the production process, through the perception, integration and analysis of data, real-time monitoring and adjustment of product quality, equipment status and worker operation, so as to keep the factory on a stable and reliable running track.
doi:10.1088/1757-899x/739/1/012048 fatcat:ihriwp6pbvg2hk7ylonbxxjeuq