JP5550514B2 - Component management system - Google Patents

Description

  The present invention relates to a component management system that manages the usage status of component parts of a product.

  Conventionally, product manufacturing information and installation location are associated with each other and recorded in a database, and when a malfunction occurs at the product installation location, a product having manufacturing information similar to that of the product is searched from the database. Thus, there is known a system that can identify an installation place where a product having a cause of failure may be installed, and can easily determine the range of influence of the defective product (see, for example, Patent Document 1). .

JP 2005-327231 A

  By the way, when a problem occurs at the installation location of a product, the product may be used continuously by replacing the defective component with a component mounted on another same-type product at the installation location. In such a case, the manufacturer that inspects this product, etc., knows which parts have been replaced when and how long the replaced parts have been used in the same product that was previously installed. Can not do it. For this reason, at the time of product inspection, there is a problem that it is not possible to accurately determine whether or not parts need to be replaced.

  Also, in general, product manufacturing history management is performed by connecting a product and a product management system that manages the product via a network, and periodically sending the usage status of the product to the product management system. , Managing product usage. Therefore, for example, for products that are used in an environment where communication with the outside is interrupted, such as underwater vehicles that move underwater, the usage status of components cannot be collected, and product management is not possible. There was a problem that it was difficult.

The present invention has been made in view of such circumstances, and even when a part is replaced at an installation site, the identification of the replaced part and the usage status of each part can be grasped, and an appropriate inspection is performed. An object of the present invention is to provide a component management system that can be used.
Another object of the present invention is to provide a component management system capable of managing parts even for products used in an environment where communication cannot be used.

In order to solve the above problems, the present invention employs the following means.
The present invention is a component management system for managing the usage status of parts constituting a product, provided in each of a plurality of parts constituting the product, and a recording medium in which identification information of the parts is recorded, A product mounting management device that is provided in a product and enables two-way communication with the recording medium provided in each of the components, the product mounting management device; When any part of the product is replaced, the operation time counted by the time measuring unit and the time of the product for each of the recording media provided in other parts excluding the replaced part Provided is a component management system comprising processing means for writing in association with identification information and restarting timekeeping after resetting the operating time of the timekeeping means.

According to the present invention, an IC tag is provided for each part of a product, and product identification information and operating time (usage time) on which each part is mounted are recorded on these IC tags. The situation can be easily managed.
In addition, since the IC tag and the product mounting management device are mounted on the product, it is possible to manage the parts by communication within the product. Therefore, even in a product that is used in an environment where communication with the outside is interrupted, such as an underwater moving body that moves in water, it is possible to reliably manage the usage status of parts.

  In the component management system, the product mounting management device acquires identification information of a component recorded in each IC tag at a predetermined timing, and the acquired identification information of the component is the identification information of the previous component. When it has been changed, it may be detected that a part has been replaced.

  The part identification information is recorded on each IC tag, the part identification information recorded on the IC tag is read at a predetermined timing, and compared with the previous part identification information, the part has been replaced. Can be easily detected.

  The component management system further includes an inspection management device that manages information related to the inspection of the product, and the inspection management device includes a previous inspection date, a current inspection date, Information obtained from the product mounting management device by acquiring the usage time of each part from shipment to the current inspection date and the usage time of each part from the previous inspection date to the current inspection date from the product mounting management device The estimated usage time of each part on the next scheduled inspection date is estimated from the next scheduled inspection date, and if the estimated usage time of each part exceeds the usage limit time for that part, the replacement instruction for that part is issued. It is good also as outputting.

  In this way, the inspection management device grasps the usage status of each component by giving information on the usage status of the component recorded on the IC tag of each component to the inspection management device via the product mounting management device. Can do. And if these usage conditions are used, the necessity of replacement | exchange of each component can be judged exactly.

  The component management system further includes an inspection management device that manages information related to the inspection of the product, and the inspection management device includes a previous inspection date, a current inspection date, Information obtained from the product mounting management device by acquiring the usage time of each part from shipment to the current inspection date and the usage time of each part from the previous inspection date to the current inspection date from the product mounting management device The next inspection date may be determined from the use limit time of each part.

  In this way, the inspection management device grasps the usage status of each component by giving information on the usage status of the component recorded on the IC tag of each component to the inspection management device via the product mounting management device. Can do. Then, by using these usage conditions, a preferable next inspection date can be determined from the usage limit time of each component.

  The component management system includes an inspection management apparatus that manages information related to the inspection of the product, an operator database in which identification information of an operator who performs the inspection and qualification information that the worker has are stored in association with each other When the identification information of the worker who inspects the product is input, the inspection management device acquires qualification information corresponding to the input identification information of the worker from the worker database. Then, it is possible to determine whether or not the worker has the qualification necessary for performing the work from the acquired qualification information, and to permit the work when the qualification is obtained.

  As described above, when a worker database is provided in which worker identification information and worker qualification information are associated with each other and the worker starts work, whether or not the worker has appropriate qualifications. This makes it possible to prevent work by an erroneous worker.

  According to the component management system of the present invention, even when a part is replaced at the installation site, the replacement part can be identified and the usage status of each part can be grasped, and an appropriate inspection can be performed. Moreover, according to the component management system of this invention, there exists an effect that components can be managed also regarding the product used in the environment where communication cannot be used.

It is the block diagram which showed schematic structure of the component management system which concerns on one Embodiment of this invention. It is the block diagram which showed schematic structure of the product mounting management apparatus. It is the figure which showed an example of the information recorded on an IC tag. FIG. 4 is a diagram illustrating an example of usage history information illustrated in FIG. 3. It is the figure which showed an example of the information stored in the memory | storage part of a product mounting management apparatus. It is the figure which showed an example of the components log | history shown in FIG. It is the flowchart which showed the process implemented by the product mounting management apparatus. It is explanatory drawing used in order to demonstrate operation | movement of a product mounting management apparatus. It is explanatory drawing used in order to demonstrate operation | movement of a product mounting management apparatus. It is explanatory drawing used in order to demonstrate operation | movement of a product mounting management apparatus. It is the figure which showed the periphery structure of the test | inspection management apparatus. It is the figure which showed the structure relevant to the worker's appropriate judgment performed by the test | inspection management apparatus. It is the figure which showed one example of a connection with an IC tag and a product mounting management apparatus, and is a figure which showed the example of a connection in case components themselves have a power supply. It is the figure which showed one example of a connection of an IC tag and a product mounting management apparatus, and is a figure which showed the example of a connection when components themselves do not have a power supply.

An embodiment of a component management system according to the present invention will be described below with reference to the drawings.
FIG. 1 is a block diagram showing a schematic configuration of a component management system according to an embodiment of the present invention. As shown in FIG. 1, the component management system according to the present embodiment is provided in IC tags (recording media) 1 a, 1 b, 1 c provided in each of a plurality of parts constituting the product 10, and the product 10. The product mounting management apparatus 2 (hereinafter referred to as “management apparatus 2”) that enables bidirectional communication with the IC tags 1a, 1b, and 1c provided in each component. In addition, the component management system obtains information such as part usage history from the management device 2 during periodic inspections such as overhaul of the product 10, and determines whether or not the product needs to be replaced. A management device 3 is provided.

  FIG. 13 and FIG. 14 are diagrams showing an example of connection between the IC tag and the management apparatus 2. FIG. 13 shows a connection example when the component itself has a power source, and FIG. 14 shows a connection example when the component does not have a power source.

  As shown in FIG. 2, the management device 2 mainly includes a timekeeping unit 21 that measures the operating time of the product 10, a processing unit 22, and a storage unit 23 that records information about the components that make up the product 10. I have. For example, when the processing unit 22 detects that any part of the product 10 has been replaced, the processing unit 22 applies to each of the IC tags 1a, 1b, and 1c provided in the other parts other than the replaced part. In addition to writing information associating the operation time measured by the time measuring unit 21 with the identification information of the product 10, the operation time of the time measuring unit 21 is reset to restart the time measurement.

  FIG. 3 shows an example of information recorded on the IC tags 1a, 1b, and 1c. As shown in FIG. 3, component identification information J11 and usage history information J12 of the component are recorded in the IC tags 1a, 1b, and 1c provided in the components. For example, as shown in FIG. 4, the usage history information includes a combination of identification information (mounted product information) of a product on which the part is mounted and a usage time (operation time). For example, the usage history information shown in FIG. 4 is used for 10 hours after the part is mounted on the product of the identification number A, and then used for 100 hours after being mounted on the product of the identification number C. It shows that it was mounted on the product of B and used for 50 hours.

  FIG. 5 shows an example of information recorded in the storage unit 23 of the management device 2. In the storage unit 23, product identification information J21, product operation information J22, parts history J23, and shipment / inspection related information J24 are recorded. The product operation information J22 is the cumulative operation time of the product 10. The component history J23 is, for example, a history of identification information of each component mounted on the product 10, as shown in FIG. That is, when the product 10 is shipped, the part number at the time of shipment is recorded, and when the part is replaced thereafter, the part number after the replacement is sequentially recorded. The shipment / inspection related information J24 is, for example, product shipment date, inspection date history, and the like.

Next, the writing process to the IC tag executed by the management apparatus 2 will be described with reference to FIG. Further, in order to explain the processing performed by the management apparatus 2 in an easy-to-understand manner, here, as shown in FIG. An example will be described in which a part is mounted and the part number C-2 is replaced with a part number A-1 due to a failure or the like after operating for 10 hours in this state.
The replacement of parts due to a failure or the like is performed with the product power turned off, so there is a possibility that the parts have been replaced when it is detected that the power supply has been turned off. A series of processing shown in FIG.

  First, when it is detected that the power supply is changed from the off state to the on state (“YES” in step SA1 in FIG. 7), the processing unit 22 of the management device 2 detects the component identification information written in the IC tag of each component. Are compared with the component history J23 recorded in the storage unit 23 (step SA2 in FIG. 7). Here, in the part history J23, part numbers C-1, C-2, and C-3 are recorded as part identification information at the time of shipment. Accordingly, the part numbers C-1 and C-3 match because there is no change before the power is turned off and after the power is turned on, but the part number C-2 is replaced with the part number A-1, so the part identification information Will not match ("NO" in step SA3 in FIG. 7). If the component identification information does not match, the processing unit 22 of the management apparatus 2 determines that the component with the component number C-2 has been replaced with another component, and stores the newly mounted component number A-1 in the storage unit. 23 is written in a new recording area of the part history, specifically, in the column “Replacement 1” in FIG. 6 (step SA4 in FIG. 7).

  Next, the processing unit 22 reads the operation time counted by the time counting unit 21 (step SA5 in FIG. 7), and component numbers C-1, C- other than the component of the component number A-1 in which the component replacement has been performed. The mounted product number and the operating time read from the time measuring unit 21 are written in the usage history information of the IC tag of the part 3 (step SA6 in FIG. 7). As a result, for example, as shown in FIG. 9, information on the mounted product number C and the usage time of 10 hours is written in the first line of the usage history information of the IC tags of the part numbers C-1 and C-3. Also, no information is written to the IC tag of the part number A-1 for which part replacement has been performed at this timing, but information on the product in which the part number A-1 part was previously mounted is stored. It is written in the IC tag. In the example of FIG. 9, it can be seen that the part with the part number A-1 has been used in the product with the product identification information A for 50 hours.

When the information writing process is completed in this manner, the processing unit 22 resets the time measuring unit 21 and then restarts the time measuring (step SA7 in FIG. 7).
Then, for example, after the product C has been operated for 100 hours, the power is turned off for the purpose of inspection, and then turned on (“YES” in step SA1 in FIG. 7). The unit 22 reads the component identification information written in the IC tag of each component and collates it with the component identification information recorded in the storage unit 23 (step SA2 in FIG. 7). Here, if the replacement of parts is not performed this time, the parts identification information matches ("YES" in step SA3 in FIG. 7).

The processing unit 22 reads the operating time counted by the timing unit 21 (step SA5 in FIG. 7), and the IC tag of the component number C-1, A-1, C-3 that has not undergone component replacement has been read. The installed product number and the operating time read from the timer unit 21 are written in the new writing area. As a result, for example, as shown in FIG. 10, in the second row of the IC tag usage history information of the components of the component numbers C-1, A-1, and C-3, the mounted product number C and the usage time of 100 hours are displayed. Information is written.
When the information writing process is completed in this manner, the processing unit 22 resets the time measuring unit 21 and then restarts the time measuring (step SA7 in FIG. 7).

  In addition, the processing unit 22 of the management device 2 reads the operating time by the time measuring unit 21 at a predetermined time interval and updates the usage history of each component in the IC tag when the power of the product is maintained ON. It is good to do. In addition, the usage time at this time may be updated by overwriting the previously written usage time. Regarding the writing of the usage time periodically performed, it is possible to prevent useless use of the recording area of the IC tag by overwriting and updating the usage time.

Next, the inspection management apparatus 3 used at the time of product inspection will be described.
For example, as shown in FIG. 11, the inspection management device 3 is connected to various databases in which information such as manufacturing processes before shipment of the product 10 is stored via a communication medium. As the database, for example, repair history DB, manufacturing history DB, machine tool DB, component configuration DB, inspection machine DB, inspection record DB, inspection equipment DB, processing machine DB, work instruction DB, customer DB, tool DB, work DB4 etc. are mentioned. The inspection management device 3 is connected to such a database. For example, when a defect is found during the inspection of the product 10, by acquiring various information stored in these databases, The cause of failure can be easily identified.

  The inspection management device 3 according to the present embodiment acquires information on the usage status of each component from the management device 2 at the time of inspection of the product 10, determines whether or not parts replacement is necessary from the acquired information, By referring to the operator DB 4, it is characterized in that it is determined whether or not an operator who performs various operations related to the inspection of the product 10 has an appropriate qualification for performing the operation.

  Hereinafter, the necessity determination of parts replacement performed by the inspection management apparatus 3 and the appropriateness determination of the worker will be described in order.

First, determination of necessity of component replacement will be described.
At the time of product inspection, the inspection management device 3 uses the previous inspection date K1, the current inspection date K2, the usage time U _all of each part from the shipment to the current inspection date, and the current inspection date from the previous inspection date. The usage time ΔU of each part up to the inspection date is acquired from the management device 2.
Next, the inspection management device 3 estimates the usage time of each part on the next scheduled inspection date from the information acquired from the management device 2 and the next scheduled inspection date. The usage time is estimated using, for example, the following equation (1).

Estimated usage time U3 = K3 * ΔU / (K2−K1) + U _all (1)

In the above equation (1), K3 is the next scheduled inspection date, ΔU is the usage time of the part from the previous inspection date to the current inspection date, K2 is the current inspection date, K1 is the previous inspection date, U _all This is the usage time of the part from the shipment to the current inspection date.
Subsequently, the inspection management device 3 determines whether or not the calculated estimated use time exceeds the use limit time of the part, and if it exceeds, outputs an instruction to replace the part.
The inspection management device 3 determines whether or not replacement is necessary for each component by performing the above-described component replacement necessity determination for all components. In addition, when a part is replaced, after the product is turned on, the management apparatus 2 executes the process shown in FIG. 7, so that information regarding the replaced part is stored in the storage unit 23 of the management apparatus 2. It is written as a history that the parts of the product have been replaced.

Next, the appropriate determination of the worker who performs each work related to the inspection will be described with reference to FIG.
FIG. 12 is a diagram showing components related to the worker's suitability determination. As shown in FIG. 12, the worker DB 4 and the inspection management apparatus 3 are connected via a communication medium. The worker DB 4 stores worker identification information given to the worker and qualification information possessed by the worker in association with each other. In addition, the worker is supposed to perform work based on the work instruction, and by reading the barcode printed on the work instruction with the barcode reader 5, the worker required for the work to be performed from now on. The qualification information is read and sent to the inspection management device 3. In addition, the worker wears a barcode in which identification information given to the worker is recorded. When starting the work, the worker inputs the worker identification information to the inspection management apparatus 3 by reading the barcode that the worker has with the barcode reader 5.

  When the qualification information and worker identification information required for the work are input via the barcode reader 5, the inspection management device 3 acquires the qualification information corresponding to the input worker identification information from the worker DB 4. To do. Subsequently, it is determined whether or not the acquired qualification information matches the qualification information required for the work. As a result, if the qualification information matches, the work by this worker is permitted. If the qualification information does not match, for example, an alarm attached to the bar code 5 is issued to call an operator to stop inappropriate work. In addition, for example, when using a machine tool or the like for work, by sending information that the operation is not permitted to the machine tool operation permission system attached to the machine tool, the machine tool is prevented from operating. Also good.

As described above, according to the component management system according to the present embodiment, an IC tag is provided for each product part, and the product identification information on which each part is mounted and the usage time are provided on these IC tags. Since it is recorded, it is possible to easily grasp the usage status of the part so far. Further, the IC tag provided in each part and the management apparatus 2 are configured to be capable of bidirectional communication, and when the part constituting the product is replaced, the identification information of the replaced part is recorded in the management apparatus 2. Therefore, for example, even when a part is replaced at the installation location of the product, it is possible to reliably grasp the replacement history and usage status of each part.
In addition, since the IC tag and the management device 2 are mounted on the product, it is possible to manage components by communication within the product. Therefore, even in a product that is used in an environment where communication with the outside is interrupted, such as an underwater moving body that moves in water, it is possible to reliably manage the usage status of parts.
In addition, according to the component management system according to the present embodiment, when a product is inspected, the component usage history written in the IC tag of each component and the component history recorded in the management device 2 are inspected and managed. Since it is given to the device 3, it is possible to appropriately determine whether or not each part needs to be replaced.

In the component management system according to the present embodiment, the inspection management apparatus 3 determines whether or not each part needs to be replaced. Instead, the next suitable inspection is performed from the use limit time of each part. The scheduled date may be determined.
Hereinafter, a method for determining the scheduled inspection date performed by the inspection management device 3 will be described.
First, the inspection management device 3 uses the previous inspection date K1, the current inspection date K2, the usage time U _all of each part from shipment to the current inspection date, and the current inspection date from the previous inspection date. The usage time ΔU of each part up to the inspection date is acquired.
Next, the inspection management device 3 determines the next inspection candidate date from the information acquired from the management device 2 and the usage limit time of each component. The next inspection candidate date is determined using, for example, the following equation (2).

K3 = (Usage limit time−U _all ) * (K2−K1) / ΔU + K2 (2)

In the above equation (2), K3 is the next inspection candidate date, U _all is the usage time of the part from shipment to the current inspection date, K2 is the current inspection date, K1 is the previous inspection date, and ΔU is the previous inspection date. This is the usage time of the part from the inspection date to the current inspection date.
Subsequently, the inspection management device 3 selects the shortest period from the current inspection date to the next inspection candidate date among the next inspection candidate dates obtained for each component. Then, it is determined whether or not the selected period is longer than the period from the previous inspection date to the current inspection date. As a result, if it is not long, the selected next inspection candidate date is determined as the next inspection date. On the other hand, if it is longer, the day (= K2 + (K2−K1)) obtained by adding the period from the previous inspection date K1 to the current inspection date K2 to the current inspection date K2 is determined as the next inspection date.

  By determining the next inspection date in this way, the part can be used effectively until the part reaches the end of its life, and the part can be used without waste. In addition, since the next inspection date comes before the end of the life of the part, it is possible to prevent the product from being damaged due to the failure of the part due to the life.

1a, 1b, 1c IC tag 2 Product mounting management device 3 Inspection management device 4 Worker DB
21 Timekeeping unit 22 Processing unit 23 Storage unit

Claims (6)

A component management system for managing the usage status of parts constituting a product,
Provided in each of a plurality of parts constituting the product, a recording medium on which part identification information is recorded;
A product mounting management device that is provided in the product and enables two-way communication with the recording medium provided in each of the components;
The product mounting management device is:
A time measuring means for measuring the operation time of the product;
When any part of the product is replaced, the operation time counted by the timing unit and the identification of the product for each of the recording media provided in other parts other than the replaced part A component management system comprising: processing means for writing information in association with each other and resetting the operation time after resetting the operation time of the time measurement means. The product mounting management device acquires the identification information of the components recorded in each recording medium at a predetermined timing, and when the acquired identification information of the components has been changed from the identification information of the previous component, The component management system according to claim 1, wherein the component management system detects that a part has been replaced. An inspection management device for managing information relating to the inspection of the product;
The inspection management device comprises:
At the time of inspection of the product, the previous inspection date, the current inspection date, the usage time of each part from the shipment to the current inspection date, and the time of each part from the previous inspection date to the current inspection date Obtain the usage time from the product mounting management device,
From the information acquired from the product mounting management device and the next scheduled inspection date, the usage time of each part on the next scheduled inspection date is estimated,
The component management system according to claim 1 or 2, wherein when the estimated usage time of each part exceeds the usage limit time of the part, an instruction to replace the part is output. An inspection management device for managing information relating to the inspection of the product;
The inspection management device comprises:
At the time of inspection of the product, the previous inspection date, the current inspection date, the usage time of each part from the shipment to the current inspection date, and the time of each part from the previous inspection date to the current inspection date Obtain the usage time from the product mounting management device,
The component management system according to claim 1 or 2, wherein a next inspection date is determined from information acquired from the product mounting management device and a use limit time of each component. An inspection management device for managing information relating to the inspection of the product;
A worker database in which identification information of a worker who performs an inspection and qualification information of the worker are stored in association with each other;
The inspection management device comprises:
When the identification information of the worker who inspects the product is input, qualification information corresponding to the input identification information of the worker is acquired from the worker database,
From the acquired qualification information, determine whether or not the worker has the qualification necessary to perform work,
The component management system according to claim 1 or 2, wherein the work is permitted when it is qualified.   The processing means reads the operating time measured by the time measuring means at a predetermined time interval when the power of the product is kept on, and the latest recorded in the recording medium of each part 6. The component management system according to claim 1, wherein the operating time is overwritten and updated.

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