DE102014204969A1 - Process for monitoring production processes and associated monitoring device - Google Patents

Abstract

The invention relates to a method for monitoring production processes, in particular in a series production of several quantities of the same goods (1, 1a), in which at least one work process to be monitored is performed manually. The invention also relates to a monitoring device (7.1, 7.2, 7.3), comprising a fastening device (9) for attaching the monitoring device (7.1, 7.2, 7.3) to a body site (8, 8a) of a human (4) on a workpiece (1, 1a) and / or on a manually guided tool (2, 2a) is formed.

Description

The invention relates to a method for monitoring production processes, in particular in a series production of several quantities of the same goods, in which at least one work process to be monitored is carried out manually. The invention also relates to a monitoring device, comprising a fastening device which is designed for fastening the monitoring device to a body part of a person, to a workpiece and / or to a manually guided tool.

The object of the invention is to provide a method and an associated device, whereby the quality of goods to be manufactured is improved, in particular by improving the manual operations to be performed better monitored and documented and / or detected erroneous operations and thereby avoided can.

• – Befestigen einer Überwachungsvorrichtung, die wenigstens einen Positionssensor, wenigstens einen Orientierungssensor und wenigstens eine Steuereinrichtung aufweist, an einer Körperstelle eines Menschen, welcher den zu überwachenden Arbeitsvorgang manuell durchführt, an einem Werkstück, das manuell bearbeitet und/oder montiert wird, und/oder an einem manuell geführten Werkzeug, mit dem der manuelle Arbeitsvorgang durchgeführt wird,
• – Erfassen von Positionswerten und/oder Orientierungswerten des wenigstens einen Positionssensors, und/oder des wenigstens einen Orientierungssensors durch die Steuereinrichtung in zeitlich aufeinander folgenden Schritten und Speichern der erfassten Positionswerte und/oder Orientierungswerte in der Überwachungsvorrichtung.

The object of the invention is achieved by a method for monitoring production processes, in particular in a series production of several quantities of the same goods, in which at least one work process to be monitored is performed manually, comprising the steps:

• Attaching a monitoring device comprising at least one position sensor, at least one orientation sensor and at least one control device to a body site of a human manually performing the work to be monitored on a workpiece which is manually processed and / or mounted, and / or on a manual tool that performs the manual operation,
• Detecting position values and / or orientation values of the at least one position sensor, and / or the at least one orientation sensor by the control device in temporally successive steps and storing the detected position values and / or orientation values in the monitoring device.

According to the methods of the invention, those position values and / or orientation values are detected and stored corresponding to those positions and / or orientations of the monitoring device at particular times that the monitoring device in space, i. within a manufacturing shop, in particular at a manual workstation of an assembly line during the manually performed work process.

In this case, the monitoring device can form a self-sufficient device, which can determine positions and / or orientations without requiring external transmitters or receivers. The monitoring device may comprise a universal fastening device, so that the monitoring device can be flexibly attached to a variety of objects, such as workpieces, tools or to the worker himself, in particular releasably secured.

By detecting the position values and / or the orientation values by the control device in temporally successive steps and storing them in the monitoring device, it is possible to create a temporal and spatial profile on which path an object to which the monitoring device is attached moves in space Has.

In a further embodiment of the method, the detected position values and / or the detected orientation values of identical operations of a plurality of items of goods in the monitoring device, in particular in the control device or in an associated memory, can be buffered and at least one data record can be generated from the temporarily stored position values and / or temporarily stored orientation values be generated in particular wirelessly to a separate from the monitoring device manufacturing control.

The at least one data record transmitted to the production control can be stored for the purpose of documenting production processes. In particular, requirements from quality management can be met in a particularly precise and secure manner.

In a supplementary embodiment of the method, the position values and / or orientation values stored in temporally successive steps can be compared with predetermined position setpoints and / or orientation setpoints.

Based on such a comparison conclusions can be drawn on the error-free or faulty execution of the manual operation. In particular, a faulty execution of the work process can be signaled directly to a worker. This is possible in particular without further external evaluation devices.

The predetermined position command values and / or orientation command values can be stored in the monitoring device in all embodiments of the invention and the comparison of the position values and / or orientation values stored in temporally successive steps with the predetermined position command values and / or Orientation setpoints are performed in the control device of the monitoring device.

The monitoring device may comprise an output device, wherein, according to a variant of the method according to the invention, the control device transmits a signal associated with the respective result as a function of the result from a comparison of the position values and / or orientation values stored in temporally successive steps with the predetermined position setpoints and / or orientation setpoints the output means outputs.

The output means may be a display on which the signal is optically output. Alternatively or additionally, the signal may be the vibration of a vibrating means which may be heard and felt by a worker. For example, the worker can wear a monitoring device on his wrist, in particular wear a smartwatch on the wrist, either the correct execution or the erroneous execution of a manual operation is confirmed by vibration.

Alternatively or additionally, the correct execution of the work process can be displayed to the worker on the display or signaled to the worker by means of the vibrating means before the execution of a work process.

To carry out one of the methods according to the invention, the monitoring device may be a portable computer, in particular a PDA, a mobile telephone, in particular a smartphone and / or a smartwatch.

The object of the invention is also achieved by a monitoring device, comprising a fastening device, which is designed for attachment of the monitoring device to a human body, a workpiece and / or a manually guided tool, and having at least one position sensor, at least one orientation sensor and at least one control device, which is designed to detect position values and / or orientation values of the at least one position sensor, and / or of the at least one orientation sensor of a manually to be performed work process, in particular in a series production of several pieces of the same goods, in temporally successive steps and save.

The monitoring device may comprise a control device that is designed and / or configured to perform one or more of the described methods.

The at least one orientation sensor may include a gyro sensor and / or the at least one position sensor may include an acceleration sensor.

In all embodiments, the monitoring device can have a memory in which position setpoint values and / or orientation setpoint values of the work process to be performed manually to be monitored, in particular in a series production of several pieces of identical goods, are stored.

The monitoring device can have an output device designed as a display and / or vibration means and a camera, wherein the control device is designed to evaluate an image of an environment detected by the camera, the data obtained from the image evaluation with acquisition data generated from the acquired position values and / or orientation values and / or to compare setpoint data generated from the stored position setpoints and / or orientation setpoints and to output a signal associated with the respective result on the display and / or the vibration means as a function of a result obtained from the comparison.

In all embodiments, the monitoring device may be a portable computer, in particular a PDA, a mobile phone, in particular a smartphone and / or a smartwatch.

For example, in the manufacture of motor vehicles, there are a plurality of jobs on the finished motor vehicle to which a process, i. perform a work that can not be monitored automatically, especially not online easily on its quality out. These are in particular manually executed by a worker, in particular with a hand tool work operations. An example is the manual placement of plugs on the vehicle body. The plugs represent so-called hole closures. The responsibility that the plugs in the process, i. are set correctly in the production of the series goods, so far lies with the employee, i. the worker.

As a result of an increasingly greater number of variants of goods to be manufactured, in particular vehicles in a production line, the plan for a particular work process frequently changes. For quality reasons, a considerable effort is sometimes operated, for example, by means of elaborate camera systems on columns and / or ceilings of the production hall of the operation is monitored optically, for example, the presence of the plug is visually checked after completed manual operation. Depending on the body condition of the vehicle at the time of the optical Often, however, not all stoppers can be inspected.

Another example of online monitoring and setting of manufacturing and / or assembly processes is the screw by means of so-called EC screwdrivers. Such electrically, hydraulically or pneumatically driven screwdrivers generally have torque and rotation angle transducers and electronic controls which automatically control the screwing sequences, in particular with regard to a tightening torque to be maintained. The screw runs can be recorded and stored, so that on the one hand the screwing operations are maintained according to target specifications and on the other hand, the actual screwing processes in particular to meet quality management can be logged and thus documented.

With such screwdrivers, torques and angles of rotation can be monitored and documented for quality reasons. The tightening program configured on the screwdrivers and the associated monitoring of the process variables ensure that the respective screw is correctly screwed in with regard to torque and angle of rotation. It is not ensured, however, that the screw is in the right place, for example if the screw can be joined at several points on the vehicle to be manufactured.

In order to ensure that all screws are tightened in a workstation with the correct torque and angle of rotation, so-called bit change systems are also used, whereby the screwdriver sets the bit-dependent correct screwdriving program. Alternatively, several nutrunners are placed in a station so that the employee, i. the worker uses the appropriate screwdriver depending on the screw.

By contrast, with the aid of the method according to the invention or with the aid of a monitoring device according to the invention, it is possible to track tools or generally bodies and / or objects in their position and / or orientation in space. This information can be obtained at what points in the space an object, such as a screwdriver, or even a completely manual tool, such as a wrench, a screwdriver or a lever is guided along, lingers and / or moves, in particular reoriented becomes. Such monitoring according to the invention of positions and / or orientations of body parts of a person who manually performs the work to be monitored, and / or a workpiece that is manually processed and / or mounted, and / or a manually guided tool with which the manual Operation allows conclusions about the completeness of manufacturing tasks and / or assembly tasks based on this position information and the associated time information.

For example, an automatic selection of screwing programs based on the position information and / or orientation information can be done. Thus, an independent process control and quality control is possible. It is thus possible, for example, to use the same screwdriver for different Schraubaufgaben. For example, the same screwdriver provided with a particular bit or nut may use similar screws, i. Screws are tightened with the same head, at different points of the finished good, in particular the finished vehicle with different torques and / or angles of rotation. Depending on the local position and / or orientation of the screw point, a respective torque and / or rotational angle tightening instruction assigned to the respective screw point can be used for this purpose. On the other hand, a worker can not guarantee the quality on his own, and in particular can not document it accurately, if he has to manually select the right tightening program for each bolting point.

With the method according to the invention and the monitoring devices according to the invention, a process control is possible, whether the operation of setting, for example, a screw or a plug has a specific acceleration characteristic, which can be inferred to the process quality.

In addition, the methods of the invention and the monitoring devices of the invention can be used by the employee, i. the worker in performing processes, i. For example, operations may assist in setting a screw or plug by displaying the next set point optically, acoustically, or by vibration.

Overall, the accuracy of the position determination can thereby be improved or even realized in the first place.

A concrete embodiment of the invention is described in the following description with reference to the attached 1 to 3d explained in more detail. Concrete features of this exemplary embodiment, regardless of which concrete context they are mentioned, may also be used individually or as appropriate considered in combination, represent general features of the invention.

Show it:

1 a schematic representation of an exemplary assembly workstation on a line of a series production of vehicles,

2 a schematic representation of the distance / time monitoring of two different manually performed operations by means of a monitoring device according to the invention using the example of a hand-held screwing tool,

3a a schematic representation of a monitoring device according to the invention,

3b a PDA as a first example of a monitoring device according to 3a .

3c a smartphone as a second example of a monitoring device according to 3a , and

3d a smartwatch configured as a wristwatch as a third example of a monitoring device according to FIG 3a ,

The 1 shows an exemplary assembly workstation on a line of mass production of vehicles. The body shell shown 1a represents a good to be produced in several quantities 1 In the course of such a series production are at the exemplary body shop 1a perform various operations manually. Such a manual operation can, as shown, a tightening a screw on the body 1a by means of a screwing tool 2a be that from one hand 3 a worker 4 is guided and operated. The worker 4 holds the screwing tool 2a in his hand 3 and does it by moving, especially his arm 5 to a planned bolting point 6a at the body shell 1a ,

A first monitoring device according to the invention 7.1 is on the manually guided tool 2 ie on the screwing tool 2a attached, with which the manual operation is performed. An alternative or supplementary second monitoring device 7.2 can at a body site 8th on a wrist, for example 8a of the worker 4 be fixed, which performs the monitored operation manually. An alternative or supplementary third monitoring device 7.3 can on a workpiece, ie in the present embodiment of the body shell 1a be attached, which is manually edited and / or mounted.

The monitoring device 7.1 . 7.2 . 7.3 points as in 3a schematically shown, a fastening device 9 on, used to attach the monitoring device 7.1 . 7.2 . 7.3 at a body site 8th of the worker 4 , on a workpiece (body shell 1a ) and / or on a manually guided tool 2 (Wrench 2a ) is trained. The monitoring device 7.1 . 7.2 . 7.3 also has at least one position sensor 10 , at least one orientation sensor 11 and at least one controller 12 formed, position values and / or orientation values of the at least one position sensor 10 , and / or the at least one orientation sensor 11 a to be performed manual operation to be performed, in particular in a series production of several quantities of the same goods 1 to capture and store in temporal successive steps.

To the position values and / or orientation values in the monitoring device 7.1 . 7.2 . 7.3 to store, has the monitoring device 7.1 . 7.2 . 7.3 a sensor data memory 13 on, in which the detected position values and / or orientation values of the work process to be performed manually to be monitored are stored in chronological order.

In order to be able to compare the position values and / or orientation values recorded and stored in temporally successive steps with the predetermined position setpoints and / or orientation setpoints, the monitoring device has 7.1 . 7.2 . 7.3 a nominal data memory 14 in which the predetermined position setpoints and / or orientation setpoints are pre-stored.

The control device 12 is designed and set up in the memory 13 stored position setpoints and / or orientation setpoints acquired in chronological order with those in the memory 14 predetermined position setpoints and / or orientation setpoints.

The monitoring device 7.1 . 7.2 . 7.3 in the illustrated embodiment also has a display 15a and as a vibrating agent 15b trained output means 15 and a camera 16 on. The control device 12 is trained, one from the camera 16 evaluated environment as an image, wherein obtained from the image evaluation data generated from the detected position values and / or orientation values detection data and / or from the stored position setpoints and / or orientation setpoints generated target data by the control device 12 be compared and depending on a result obtained from the comparison, a signal associated with the respective result on the display 15a and / or the vibrating means 15b is issued.

The monitoring device 7.1 . 7.2 . 7.3 may be a special device designed according to the invention, or, as in 3b exemplifies a PDA 18 be, alternatively, as in 3c exemplifies a mobile phone, especially a smartphone 19 and a smartwatch 20 be.

In a smartphone 19 as an exemplary monitoring device 7.1 . 7.2 . 7.3 , but also in a general monitoring device according to the invention 7.1 . 7.2 . 7.3 There may be a variety of sensors, including acceleration sensors and gyroscopes. Thus, a motion detection in the three directions and in the three orientations in the Cartesian space is possible. Thus, by the monitoring device, a translational and a rotational movement of that part, so for example, the manually guided tool 2 , the screwing tool 2a , the body part 8th like the wrist 8a of the worker 4 or the workpiece, ie in the present embodiment, the body shell 1a be recorded. For example, it can be a particularly industrial-grade smartphone 19 or a corresponding special sensor for the six-dimensional motion detection are used.

The control device 12 the monitoring device 7.1 . 7.2 . 7.3 may be formed, from the detected values of the acceleration and orientation sensors, to calculate the actual movement of that part in space at which the monitoring device 7.1 . 7.2 . 7.3 is attached.

As in 2 shown schematically, starting from a defined starting position S, which may for example be a tray for the screwdriver or for a plug setting tool, the monitoring device 7.1 . 7.2 . 7.3 by means of the integrated acceleration and orientation sensors the movement of the monitoring device 7.1 . 7.2 . 7.3 capture in space and therefore the movement of the part to which the monitoring device 7.1 . 7.2 . 7.3 is fixed, continuously capture. Since the calculation of the movement from acceleration and orientation values is an integration method, a drift of the position is to be expected over the course of time. However, this drift is manageable through various measures, sometimes on the skilled person as such known measures.

On the one hand, with each line tact, which can be about 40 to 120 seconds, the tool 2 (Wrench 2a ) are placed at the beginning or at the end of the clock in a defined recording, whereby the tool 2 receives a new start position S, in particular the position of the recording as a new start position S can be referenced again. Thereafter, the process monitoring then refers to this new reference position.

On the other hand, any known already in position and / or orientation screwing 6a . 6b , Stopfenstelle, and / or storage are used as a reference position to continuously minimize the drift error. This means that the drift only has to be mastered between two particularly closely spaced process points, so that a reliable statement is possible from which to which process point the movement took place and whether this is plausible with regard to a correctly executed work process. For each reached and due to the low drift between the points known process point, the drift can be eliminated in particular by re-referencing, whereby the position in space can be followed exactly over a longer period of time.

Depending on the process, getting screws, plugging or removing parts from boxes requires a single teach-in of the process points. The plugging process or any other screwing or joining process is taught in by inserting all plugs, screws, parts one after the other, if necessary with one intermediate stop each at the reference position. Thus, all parts are related to the reference position or relative to each other, i. behind each other as a chain, each with a relative reference to each other, known. From this point on, each process point can be edited in any order, as the relative position of the points relative to the reference position is known.

The monitoring device 7.1 . 7.2 . 7.3 gets on the screwdriver 2a or attached to the plug setting tool. The movement patterns 21 . 22 From process to process site are recorded and documented the quality or recorded the process variables and the stored target movement pattern 23 . 24 which may have tolerance bands compared.

The employee, ie the worker 4 can, for example, as in 1 shown a smartwatch 20 at the wrist 8a carry, reducing the position of the hand or the tool 2 (Wrench 2a ) of the worker 4s which in turn allows conclusions to be drawn as to whether it has carried out the work process at each process station and / or at the correct process location.

In addition, the worker can 4 assistance in the process, ie given during the execution of the work process, for example by the on the screwing 2a attached smartphone 19 using the built-in camera 16 ( 3a ) captures the component to be processed, in particular photographs or films as a video. On a likewise integrated display means 15 like the display 15a , then, for example, a virtual mark on the displayed image, for example, the next editable place to be displayed. Alternatively or additionally, on the display means 15 for example, the direction in which the tool is displayed 2 , the screwing tool 2a or move the plug setting tool to get to the next process location.

Successfully or not successfully recorded and / or carried out process steps can also immediately on the display means 15 are displayed, in particular on a display means 15 those monitoring device are displayed, which at the body site 8th of the worker 4 is attached, for example in the form of a trained as a wristwatch smartphone 19 (Smart Watch 20 ) on the wrist 8a of the worker by means of a tape 25 as a fastening device 9 is attached. Alternatively or additionally, at the monitoring device, in particular on the smartphone 19 related information about a successful or unsuccessful execution of the operation by vibrating the vibrating means 15b be signaled.

Signals indicating a successful or unsuccessful detection and / or execution of the process steps on the smartwatch 20 of the worker 4 can be viewed by another monitoring device 7.1 . 7.2 . 7.3 which, for example, on the tool 2 , the screwing tool 2a or the estate 1 ie the body 1a is attached via a particular wireless interface 17 such as a Bluetooth interface, a wireless LAN interface, or a cellular network to the smartwatch 20 of the worker 4 be transmitted.

Claims (12)

Method for monitoring production processes, in particular in a series production of several pieces of identical goods ( 1 ), in which at least one operation to be monitored is performed manually, comprising the steps of: - attaching a monitoring device ( 7.1 . 7.2 . 7.3 ) having at least one position sensor ( 10 ), at least one orientation sensor ( 11 ) and at least one control device ( 12 ), at a body site ( 8th . 8a ) of a human ( 4 ), which manually performs the work to be monitored, on a workpiece ( 1 . 1a ), which is manually machined and / or mounted, and / or on a manually guided tool ( 2 . 2a ), with which the manual operation is performed, - detecting position values and / or orientation values of the at least one position sensor ( 10 ), and / or the at least one orientation sensor ( 11 ) by the control device ( 12 ) in temporally successive steps and storing the detected position values and / or orientation values in the monitoring device ( 7.1 . 7.2 . 7.3 ). Method according to Claim 1, in which the detected position values and / or the detected orientation values of identical operations of a plurality of items of goods ( 1 . 1a ) in the monitoring device ( 7.1 . 7.2 . 7.3 ) and at least one data record is generated from the temporarily stored position values and / or intermediately stored orientation values, which in particular is transmitted wirelessly to one of the monitoring device ( 7.1 . 7.2 . 7.3 ) is transmitted separate production control. Method according to Claim 2, in which the at least one data record transmitted to the production control is stored for the purpose of documenting production processes. Method according to one of Claims 1 to 3, in which the position values and / or orientation values stored in temporally successive steps are compared with predetermined position setpoints and / or orientation setpoints. Method according to Claim 4, in which the predetermined position setpoints and / or orientation setpoints in the monitoring device ( 7.1 . 7.2 . 7.3 ) and comparing the position values and / or orientation values stored in temporally successive steps with the predetermined position setpoints and / or orientation setpoints in the control device of the monitoring device ( 7.1 . 7.2 . 7.3 ) is carried out. Method according to Claim 5, in which the monitoring device ( 7.1 . 7.2 . 7.3 ) an output means ( 15 . 15a . 15b ) and, depending on the result from the comparison of the position values and / or orientation values stored in temporally successive steps with the predetermined position setpoints and / or orientation setpoints, the control device receives a signal associated with the respective result via the output means (FIG. 15 . 15a . 15b ) is output. Method according to one of Claims 1 to 6, in which the monitoring device ( 7.1 . 7.2 . 7.3 ) a portable computer, in particular a PDA ( 18 ), a mobile phone, in particular a smartphone ( 19 ) and / or a smartwatch ( 20 ). Monitoring device comprising a fastening device ( 9 ) used to attach the monitoring device ( 7.1 . 7.2 . 7.3 ) at a body site ( 8th . 8a ) of a human ( 4 ), on a workpiece ( 1 . 1a ) and / or on a manually guided tool ( 2 . 2a ), and comprising at least one position sensor ( 10 ), at least one orientation sensor ( 11 ) and at least one control device ( 12 ), which is formed, position values and / or orientation values of the at least one position sensor ( 10 ), and / or the at least one orientation sensor ( 11 ) to be monitored manually to be performed operation, in particular in a series production of several quantities of the same goods ( 1 . 1a ) to capture and store in temporal successive steps. Monitoring device according to claim 8, wherein the at least one orientation sensor ( 11 ) a gyrosensor and / or the at least one position sensor ( 10 ) has an acceleration sensor. Monitoring device according to claim 8 or 9, characterized by a memory ( 13 . 14 ), in which position setpoints and / or orientation setpoints of the work process to be carried out manually, in particular in a series production of several pieces of identical goods ( 1 . 1a ) are stored. Monitoring device according to one of claims 8 to 10, characterized by a display ( 15a ) and / or vibration means ( 15b ) trained output means ( 15 ) and a camera ( 16 ), wherein the control device ( 12 ), one of the camera ( 16 To evaluate the captured image of an environment, comparing the data obtained from the image analysis with generated from the detected position values and / or orientation values acquisition data and / or from the stored position setpoint and / or orientation setpoint desired data and in response to a result obtained from the comparison a the corresponding signal on the display ( 15a ) and / or the vibration agent ( 15b ). Monitoring device according to one of claims 8 to 11, characterized in that the monitoring device ( 7.1 . 7.2 . 7.3 ) a portable computer, in particular a PDA ( 18 ), a mobile phone, in particular a smartphone ( 19 ) and / or a smartwatch ( 20 ).

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