Research on Work-in-Progress Control System of Integrating PI and SPC

Wei Li, Cai-hong Guo
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Abstract

Taking unfinished parts, that is, parts' work-in-progress (WIP), as the background, the PI control algorithm is proposed to apply for WIP control in discrete production systems and the cascade control of PI controllers is suggested. Designing of PI controllers is transformed into an optimization problem on the frequency domain, so as to guarantee the stability and robustness of PI controllers' parameters. Effective measures are taken to resolve the situations where WIP is beyond control limits, that is, two kinds of controllers, the backlog controller and the input rate controller, are devised to stabilize WIP, which correspond with the "I controller" and the "P controller" in the PI algorithm respectively. By such doing, the engineering implementation of PI controllers is well performed. For the permanent performance improvement, the SPC&PI integration control scheme is being used for WIP control. An integrating WIP control system (I-WipCS) is set up. Based on the above research, the implementation of the I-WipCS system is carried out in the production line of certain motorcycle engines' crankcases. Subjects such as its components, the principle of integrated controllers, and the dynamic scheduling strategies are analyzed. Then the control effect of I-WipCS system is assessed through simulation under dynamic environments.
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PI与SPC集成的在制品控制系统研究
以未完成件即在制品为背景,提出了PI控制算法应用于离散生产系统的在制品控制,并提出了PI控制器的串级控制。将PI控制器的设计转化为频域上的优化问题,以保证PI控制器参数的稳定性和鲁棒性。针对在制品超出控制范围的情况,采取了有效措施,即设计了两种控制器来稳定在制品,即积压控制器和输入速率控制器,分别对应PI算法中的“I控制器”和“P控制器”。通过这样做,可以很好地实现PI控制器的工程实现。为了持续的性能改进,在制品控制采用了SPC&PI集成控制方案。建立了一个完整的在制品控制系统。在以上研究的基础上,在某摩托车发动机曲轴箱生产线上进行了I-WipCS系统的实现。对其组成、集成控制器原理、动态调度策略等进行了分析。然后,通过仿真对I-WipCS系统在动态环境下的控制效果进行了评价。
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