WO2016189638A1

WO2016189638A1 - Electric screwdriver management system

Info

Publication number: WO2016189638A1
Application number: PCT/JP2015/064987
Authority: WO
Inventors: 錦戸憲治; 鈴木康之; 湯川浩司; 角田信広; 井谷一夫
Original assignee: 株式会社エニイワイヤ
Priority date: 2015-05-26
Filing date: 2015-05-26
Publication date: 2016-12-01
Also published as: JPWO2016189638A1; JP6038397B1

Abstract

This electric screwdriver management system has slave stations capable of exchanging data with a master station, connected to each of a plurality of electric screwdrivers. The slave stations have a detection means that can obtain electric signals that change in accordance with the output torque of the electric screwdrivers. The detection means: store, as an initial setting value, a calculated value obtained on the basis of the electric signals during any initial setting; and detect an operation error if the calculated value obtained on the basis of the electric signals is outside a range for permitted torque during normal operation, said permitted torque range having a prescribed tolerance added to or subtracted from the initial setting value.

Description

Electric driver management system

The present invention relates to an electric driver management system for managing a plurality of general-purpose electric drivers used when assembling and manufacturing automobiles, electrical appliances and the like by a flow operation by a plurality of workers.

In a product that is assembled and manufactured by a flow operation by a plurality of workers, a simple task that does not require special skills is often performed by a worker who is not skilled in the product or manufacturing method using a dedicated tool. In addition, the screw tightening operation is a simple operation as described above. An operator who is not skilled in the product or the manufacturing method uses a tool such as an impact wrench or an electric screwdriver (hereinafter sometimes referred to as a screw tightening tool). There is a lot to do.

In screw tightening operations, it is important to tighten with an appropriate torque. Therefore, various methods have been proposed for detecting torque from a screw tightening tool and controlling tightening stoppage or detecting tightening abnormality. For example, as one of such methods, Japanese Patent Application Laid-Open No. 7-308864 discloses a technique for completing a tightening force by using a change in the waveform of a torque pulse of an impact type screw tightening device.

Japanese Patent Laid-Open No. 07-308864

ネジ Since the output torque of screw tightening tools decreases due to wear of components such as bearings and lubricating oil, it was necessary to check whether the planned torque was output before use. However, with the conventional torque detection technology, it is not possible to directly check whether there is such a decrease in output torque, so it is necessary to check the torque value of the screw tightening tool one by one with a torque measuring instrument before starting work. There was a problem that it took time and effort to confirm the result.

Therefore, an object of the present invention is to provide an electric driver management system capable of easily confirming whether there is an abnormality in output torque for a plurality of screw tightening tools.

In the electric driver management system according to the present invention, a slave station capable of exchanging data with the master station is connected to each of the plurality of electric drivers.

The slave station has detection means for obtaining an electric signal that changes in accordance with the output torque of the electric driver. Then, a calculated value obtained based on the electric signal at an arbitrary initial setting is stored as an initial setting value, and the calculated value obtained based on the electric signal at a normal operation is predetermined as the initial setting value. When the torque is out of the allowable torque range, the abnormal operation is detected.

The initial setting may be instructed from the master station to the slave station.

The initial setting may be instructed by an input operation via an initial setting means provided in the slave station.

The initial set value is transmitted from the slave station to the master station, and the master station transmits the initial set value to a slave station different from the slave station that transmitted the initial set value. Also good.

According to the present invention, based on an initial setting value obtained based on an electric signal that changes in accordance with the output torque of the electric driver at an arbitrary initial setting, and an electric signal that changes in accordance with the output torque of the electric driver in a normal operation. By comparing the calculated values obtained in this manner, it is possible to easily check whether there is an abnormality in the output torque for a plurality of screw tightening tools.

In addition, since the initial output torque that is the basis for comparison judgment is measured for each electric driver at any initial setting, the output torque differs for each electric driver due to the difference in performance characteristics of various electric motors. But you can make accurate judgments individually.

Furthermore, if the instructions at the initial setting can be changed according to the situation, the applicable range can be expanded. For example, if the initial setting is performed before the newly installed system is normally used, the initial setting can be efficiently performed in a short time by instructing all the slave stations at the time of initial setting.

On the other hand, in a system that is normally used, if the initial setting is after the faulty slave station has been replaced, another normal operation can be performed by instructing the initial setting via the initial setting means provided in the slave station. The initial setting of the replaced slave station can be performed very easily while maintaining normal use of the system without affecting the operation of the slave station.

In addition, if the initial setting value is transmitted from the slave station to the master station, and the master station transmits the initial setting value to a slave station different from the slave station that transmitted the initial setting value, the same specification is used. When there are many electric drivers, the initial setting value is transmitted from the master station to each of the slave stations, so that the time and effort required for setting work can be reduced compared to the case where the initial setting value is set for each electric driver. Can be reduced.

1 is a system configuration diagram showing a schematic configuration of an electric driver management system according to the present invention. It is a system configuration | structure figure of a master station. It is a functional block diagram of the slave station connected to the electric driver. It is a functional block diagram of an electric driver I / F means. It is a graph which shows the time-dependent change of the motor current in the case of tightening a screw accompanying the operation of the electric driver. It is a graph which shows the time-dependent change of the motor electric current in the case of making it idle | slow accompanying the action | operation of an electric driver. It is a schematic diagram of an IDX table. It is a table which shows the data output from a slave station. It is a time chart figure of a transmission signal. It is a schematic diagram of the transmission procedure between a master station and a slave station.

An embodiment of an electric driver management system according to the present invention will be described with reference to FIGS.
The electric driver management system according to the present embodiment manages a plurality of electric drivers 9 used for tightening screws taken out from the screw storage shelves to the attachment target member 71.

The screw storage shelf is provided with a plurality of screw storage portions, and each of the screw storage portions is provided with a lid 6. The lid 6 has an open state in which the screw can be taken out and a closed state in which the screw cannot be taken out. The open state and the closed state are the slave stations provided in each of the screw accommodating portions. 5 can be switched through.

Each slave station 5 has an instruction lamp 62 through which the operator is instructed to remove screws. Each of the slave stations 5 also has an input operation lever 61. When an operator who has completed the take-out operation operates the input operation lever 61, information indicating the completion of the operation is used as a monitoring signal, and the common data signal It is output to the lines DP and DN.

A slave station 4 is connected to each electric driver 9. The slave station 4 controls the electric driver 9 based on the value of the motor current of the electric driver 9, and the details of the structure and function will be described later. Each slave station 4 is also connected to a common data signal line DP, DN.

A master station 2 is also connected to the common data signal lines DP and DN, and the master station 2 is further connected to the control unit 1.

A plurality of screw holes 73, in which the tightening order is determined, are provided in the attachment target member 71 of the screw to be tightened. A serial number is assigned to the attachment target member 71 itself. A bar code 72 indicating the serial number is attached to the attachment target member 71, and the serial number read by the bar code reader 7 is input to the slave station 4.

The control unit 1 is, for example, a programmable controller, a computer, and the like, and the monitoring parallel obtained based on the output unit 11 that transmits the control parallel data 13 and the monitoring data extracted from the monitoring signals transmitted from the

slave stations

4 and 5. It has an input unit 12 that receives data 14. These output unit 11 and input unit 12 are connected to the master station 2.

As shown in FIG. 2, the master station 2 includes an output data unit 21, a management data unit 22, a timing generation unit 23, a master station output unit 24, a master station input unit 25, and an input data unit 26. The control signal, which is connected to the common data signal lines DP and DN, is sent to the common data signal lines DP and DN, and is extracted from the monitoring signals sent from the

slave stations

4 and 5. The monitoring parallel data 14 is sent to the input unit 12 of the control unit 1.

The output data unit 21 delivers the control parallel data 13 from the output unit 11 of the control unit 1 to the master station output unit 24.

The management data unit 22 includes a storage unit 29 that stores an IDX table in which data necessary for controlling the electric driver 9 in the slave station 4 is collected. Then, based on the control parallel data 13 from the output unit 11 of the control unit 1 and the IDX table, data to be delivered to the slave station 4 is delivered to the master station output unit 24.

As shown in FIG. 7, the IDX table includes IDX address data ad, T / U set value IS, T / U time set value TS, normal operation set value YS, life set value MS, starting current set value SS, I / It consists of a T conversion coefficient K and a screw hole number setting value NS. The IDX address data is data for specifying any one of the plurality of slave stations 4. In this embodiment, the head address number that is the address data of the slave station 4 is used.

The T / U set value IS is a torque value when the screw fastened to the attachment target member 71 by the electric driver 9 is seated in the screw hole 73. The value varies depending on the performance characteristics of the electric motor used in the electric driver 9, and a plurality of types of electric motors are obtained in advance by a test or the like.

The T / U time set value TS is a time required for the screw fastened to the attachment target member 71 by the electric driver 9 to be seated in the screw hole 73 from the start of the screw tightening. This is the elapsed time from the start-up (in this embodiment, the fall of the start signal described later), and differs depending on the performance characteristics of the electric motor used in the electric driver 9. Similar to the T / U set value IS, a plurality of types of electric motors are obtained in advance by a test or the like.

The normal operation set value YS is obtained when the electric motor is operating normally when the elapsed time from the start reaches a predetermined value (a predetermined value based on the T / U time set value TS in this embodiment). Torque value. The value varies depending on the performance characteristics of the electric motor used in the electric driver 9, and, as with the T / U set value IS, a plurality of types of electric motors are obtained in advance by a test or the like.

The life set value MS is a torque value when the electric driver 9 is operated with no load (idling operation) without performing a screw tightening operation. The value varies depending on the performance characteristics of the electric motor used in the electric driver 9, and, as with the T / U set value IS, a plurality of types of electric motors are obtained in advance by a test or the like.

The activation current set value SS is a current value defined for detecting activation. As will be described later, when the electric driver 9 is activated, the motor current I is a defined value for detecting that the electric driver 9 is activated by utilizing the fact that the motor current I is rapidly increased by the activation current. Since the starting current differs depending on the performance characteristics of the electric motor used in the electric driver 9, similar to the T / U set value IS, a plurality of types of electric motors are obtained in advance by a test or the like.

The I / T conversion coefficient K is a coefficient for calculating a torque value based on the motor current I. The value varies depending on the performance characteristics of the electric motor used in the electric driver 9, and, as with the T / U set value IS, a plurality of types of electric motors are obtained in advance by a test or the like.

The screw hole number setting value NS is the number of screws to be fastened to the work target product (the mounting target member 71 in the present embodiment).

The timing generation unit 23 includes an oscillation circuit (OSC) 31 and a timing generation unit 32. The timing generation unit 32 generates a timing clock of the system based on the oscillation circuit (OSC) 31, and generates a master station output unit 24, Delivered to the station input unit 25.

The master station output unit 24 includes control data generation means 33 and a line driver 34. Based on the data received from the output data section 21 and the timing clock received from the timing generation section 23, the control data generation means 33 sends a transmission signal to the common data signal lines DP and DN via the line driver 34.

The transmission procedure is one frame cycle between the start signal ST of the transmission signal and the next start signal ST, and as shown in FIG. 10, a plurality of control / monitoring data and management data are configured. The start signal ST is longer than the time width of one cycle of the transmission signal and has a potential level higher than the transmission signal threshold value Vst (18 V in this embodiment).

As shown in FIG. 9, the transmission signal includes a potential level area (+24 V in this embodiment) higher than the threshold Vst and a potential level area lower than the threshold Vst. In this embodiment, the potential level area higher than the threshold value Vst is the latter half of one cycle and the potential level area lower than the threshold value Vst is the first half of one cycle. May be reversed.

The pulse width of the potential level area lower than the threshold value Vst represents the control signal data. In this embodiment, when one cycle of the transmission data signal is t0, the pulse width (3/4) t0 represents the logical data “0”, and the pulse width (1/4) t0 represents the logical data “1”. ing. However, as long as it corresponds to the value of the control data input from the control unit 1, the length is not limited and may be determined appropriately.

Also, the monitoring signal data is represented by whether the current superimposed in the potential level area lower than the threshold value Vst is larger or smaller than a predetermined value. In this embodiment, a current signal smaller than 10 mA represents logical data “0”, and a current signal greater than 10 mA represents logical data “1”.

Since the transmission signal is a power supply voltage, each of the slave stations 4 generates an internal circuit power supply from the transmission signal. On the other hand, the power source of the electric motor of the electric driver 9 is obtained from the AC power source 10 via a power supply line different from the common data signal lines DP and DN, as shown in FIG. The power source for the motor that opens and closes the lid 6 is also obtained from a power supply line (not shown) different from the common data signal lines DP and DN.

9, the pulse width of the potential level area lower than the threshold value Vst constitutes a control data area as control data, and the control data area corresponds to the upper stage of the control / monitoring data area in FIG. Further, the current value superimposed in the potential level area lower than the threshold value Vst constitutes a monitoring data area as monitoring data, and the monitoring data area corresponds to the lower part of the control / monitoring data area in FIG. Yes.

At the end of the transmission procedure, a management data area is provided as shown in FIG. In FIG. 10, the upper part is an area where data is output from the master station (hereinafter referred to as management control data area), and the lower part is an area where data is input to the master station (hereinafter referred to as management monitoring data area). It is to show.

In the management control data area, data of the IDX table shown in FIG. 7 is superimposed from the master station 2 and transmitted to the slave station 4 at the start of system operation. Further, during the system operation, the first management control data ISTo for instructing to request information and the second management control data IDXo for designating the slave station address are superimposed from the master station 2.

In the management monitoring data area, the first management monitoring data STi and the second management monitoring corresponding to the first management control data ISTo are transmitted as status data of the electric driver 9 from the slave station 4 specified by the second management control data IDXo. Data IDXi is superimposed. In addition, data read by a bar code reader 7 described later is superimposed.

The master station input unit 25 includes monitoring signal detection means 35 and monitoring data extraction means 36. The monitoring signal detection means 35 detects the monitoring signal transmitted from the

slave stations

4 and 5 via the common data signal lines DP and DN.

As described above, the monitoring signal data is represented by the presence / absence of a current superimposed on the low potential level area as logic data, and from each of the plurality of

slave stations

4 and 5 after the start signal ST is transmitted. The monitor signal is received. Then, the monitoring signal detected by the monitoring signal detection unit 35 is delivered to the monitoring data extraction unit 36.

The monitoring data extracting means 36 extracts monitoring data and management monitoring data in synchronization with the timing from the timing generating means 32, and sends it to the input data section as serial input data.

The input data unit 26 converts the serial input data received from the monitoring data extracting means 36 into parallel (parallel) data, and sends it to the input unit 12 of the control unit 1 as the monitoring parallel data 14.

As shown in FIG. 3, the slave station 4 includes a transmission receiving means 41, a management control data extracting means 42, an address extracting means 43, a local station address setting means 44, a management monitoring data transmitting means 45, a reference station address setting means 46, Slave station input having own station control data extraction means 47, reference station control data extraction means 48, input means 50, monitoring data transmission means 51, bar code reader means 52, initial setting instruction means 63 and electric driver I / F means 80 An output unit 40 is provided.

The slave station 4 of this embodiment includes an MCU that is a microcomputer control unit as an internal circuit, and this MCU functions as the slave station input / output unit 40.

Calculations and storages necessary for the processing are executed using the CPU, RAM, and ROM included in the MCU. The CPU, RAM, and ROM in the processing of each of the above-described units constituting the slave station input / output unit 40 For the sake of convenience of explanation, the relationship between and is assumed to be omitted.

In addition to the slave station input / output unit 40, the slave station 4 further includes a numeric indicator lamp 49, a slave station line receiver 53, a slave station line driver 54, an AC / DC converter 55, an amplifier 56, and an A / D converter 57. Current / torque conversion means 58 and contactless power switch 59.

The transmission receiving means 41 receives the transmission signal transmitted to the common data signal lines DP and DN via the slave station line receiver 53, and receives this via the management control data extraction means 42, the address extraction means 43, and the management monitoring data transmission. Delivered to means 45.

Management control data extraction means 42 extracts management control signal data from the management data area of the transmission data signal, and delivers these to the electric driver I / F means 80.

As shown in FIG. 10, the address extracting means 43 counts pulses starting from a start signal ST indicating the start of the transmission data signal. Then, at the timing when the count value coincides with the local station address data set by the local station address setting unit 44, the transmission transmission signal is delivered to the local station control data extraction unit 47 and the monitoring data transmission unit 51 is validated. . Further, the transmission transmission signal is delivered to the reference station control data extraction unit 48 at a timing that matches the reference station address data set by the reference station address setting unit 46.

The management monitoring data transmission means 45 counts pulses starting from the start signal ST of the transmission signal, and obtains the timing of the management data area. Then, the management monitoring data transmission means 45 outputs monitoring signals to the common data signal lines DP and DN via the slave station line driver 54 based on the data delivered from the barcode reader means 52.

The local station control data extraction unit 47 extracts the control data value transmitted to the local station address set in the local station address setting unit 44 from the transmission transmission signal delivered from the address extraction unit 43, and uses this to extract the control data value. Delivered to the I / F means 80.

The reference station control data extracting means 48 extracts the control data value transmitted to the

slave stations

4 and 5 set by the reference station address setting means 46 from the transmission transmission signal delivered from the address extracting means 43, and this is extracted. Delivered to the electric driver I / F means 80.

The number indicator lamp 49 indicates the remaining number of tightening screws to the operator who operates the electric driver 9 according to the input signal from the electric driver I / F means 80, and the electric driver 9 uses the flashing number. Display that it is a target.

The input unit 50 delivers the monitoring data to the monitoring data transmission unit 51 based on the input data from the electric driver I / F unit 80.

The monitoring data transmission means 51 outputs a monitoring signal to the common data signal lines DP and DN via the slave station line driver 54 when it is validated by the address extraction means 43.

The bar code reader means 52 receives the data of the bar code 72 attached to the attachment target member 71 and the data of the electric driver bar code 74 attached to the electric driver 9 from the bar code reader 7 and receives them from the management monitoring data transmission means. Deliver to 45.

As shown in FIG. 3, a small resistance r that does not affect the operation of the electric driver 9 is inserted in series between the electric driver 9 and the AC power source 10. When an AC current signal, which is a motor current I, flows through the small resistor r when the operation switch SWd is turned on by holding the grip of the electric driver 9, the AC voltage signal generated at both ends of the small resistor r is AC / DC. It is converted into a DC signal by the converter 55, amplified by the amplifier 56, and then input to the electric driver I / F unit 80 as a digital signal Id through the A / D conversion unit 57.

The portion from the small resistance r through the AC / DC converter 55, the amplifier 56, and the A / D conversion means 57 to the electric driver I / F means 89 until the digital signal Id is obtained constitutes the detection means 60. It has become a thing. A clamp type current sensor may be used instead of the small resistance r.

Further, the value of the digital signal Id output from the A / D conversion means 57, that is, the amplified and digitized current value is supplied to the electric driver I / F means 80 described later via the current / torque conversion means 58. The torque data value converted in accordance with the I / T conversion coefficient K output from the I / T conversion coefficient storage means 81g (hereinafter sometimes referred to as the current torque value) is input to the electric driver I / F means 80.

A non-contact power switch 59 is also provided between the electric driver 9 and the AC power source 10, and a power supply circuit from the AC power source 10 (corresponding to the drive power supply path of the present invention) is provided by the electric driver I / F means 80. The electric driver 9 is operated or stopped by turning on / off.

Note that the power source of the electric driver 9 is not limited to an AC power source, and a DC power source may be adopted as shown by a broken line in FIG. In that case, the AC / DC converter 55 becomes unnecessary.

In the electric driver I / F means 80, arithmetic processing and signal input / output processing necessary for controlling and managing the electric driver 9 are performed. The configuration and function of the electric driver I / F unit 80 will be described below together with the operation of the electric driver management system with reference to FIGS.

5 shows the current change when the screw of the electric motor used in the electric driver connected to the slave station 4 with the slave station number 0 is tightened, and FIG. 6 shows the connection with the slave station 4 with the slave station number 0. The electric current change at the time of carrying out a no-load operation | movement (idling) of the electric motor currently used for the used electric driver is shown.

<Control variable settings>
First, before starting the work, the electric driver barcode 74 attached to the electric driver 9 connected to each of the slave stations 4 is read through the barcode reader 7 connected to the slave station 4. Then, the model of the electric driver 9 connected to the slave station 4 is stored for each slave station 4 in the storage means 29 of the management data unit 22 of the master station 2. Similarly, the electric drivers 9 connected to the other slave stations 4 are also stored in the storage means 29 for each.

In addition, the performance characteristics of the electric motor used in the electric driver 9 are grasped in advance, and control variables necessary for screw tightening operation according to the performance characteristics are controlled as set values for each model of the electric driver 9. Stored as data in part 1.

In the storage means 29 storing the model of the electric driver 9 for each slave station 4, the IDX table is obtained from the data stored in the control unit 1 in advance according to the performance characteristic values of the electric motor corresponding to the model of the electric driver 9. It is formed.

An example of the IDX table is shown in FIG. In this IDX table, IDX address data, setting values, and coefficients are specified for each table number.

On the other hand, in each of the slave stations 4, set values (control variables) corresponding to the performance characteristics of the electric motor used in the electric driver 9 connected to the own station are set as a set value group of common data signal lines DP. , Downloaded from the master station 2 via the DN.

Each set value of the set value group downloaded in this embodiment is T / U (shown with torque up omitted, the same applies hereinafter) set value IS, T / U time set value as shown in FIG. TS, normal operation set value YS, life set value MS, starting current set value SS, I / T (current / torque is omitted, the same applies hereinafter) conversion coefficient K, and screw hole number set value NS .

These downloaded set values are stored in the set value storage means 81 of the electric driver I / F means 80. In FIG. 4, in order to clarify the relationship between each set value and the calculation process, the storage area of the set value storage unit 81 is shown separately for each set value.

Thus, the performance characteristics of various electric motors are grasped in advance, and control variables corresponding to the electric motors necessary for the screw tightening operation are transferred to the slave station 4 via the master station 2 and the common data signal lines DP, By downloading via DN, it is possible to cope with a common system.

The predetermined control variables (T / U time set value TS, normal operation set value YS, life set value MS) can be set using the electric driver 9 that is actually used. When setting the control variable using the electric driver 9, an initial setting switch SWi (corresponding to the initial setting means of the present invention) is used.

Since it is clear that the electric driver 9 operates normally before the start of use of the system or after the electric driver 9 is replaced, the torque value at that time is a normal torque value. Therefore, when setting the current torque value when it is clear that the current torque value becomes the normal torque value as the normal torque value (corresponding to the setting of the initial setting value of the present invention), the initial setting switch SWi is set to “ ON ”.

When the initial setting switch SWi is turned “ON”, an ON signal is output from the initial setting instruction means 63 to the electric driver I / F means 80.

In the electric driver I / F unit 80, when the ON signal is input from the initial setting instruction unit 63, the T / U time set value TS, the normal operation set value YS, and the life set value MS are stored in the set value storage unit 81. Is ready for setting. The elapsed time comparing means 88 stores the normal operation set value at the timing of manual setting time preset as an initial value in the T / U time set value storage means 81e (corresponding to the timing of TS / 2 described later). The initial value setting trigger signal is output to the means 81b.

Next, when the operation switch SWd of the electric driver 9 is set to “ON” and the electric driver 9 operates, the torque value obtained by the current / torque conversion means 58 (the electric signal that changes according to the output torque of the electric driver). The calculated value obtained based on this is input to the normal operation set value storage unit 81b, the life set value storage unit 81f, and the T / U comparison unit 87. When the initial value setting trigger signal is input from the elapsed time comparing means 88 at the timing of manual setting time, the torque value input to the normal operation setting value storage means 81b is set as the normal operation setting value YSn. The

Further, the measurement time from the rising edge of the operation signal obtained by the T / U time comparison means 90 is delivered to the T / U time set value storage means 81e. On the other hand, the torque value delivered from the current / torque conversion means 58 to the T / U comparison means 87 is compared with the T / U set value IS preset in the T / U set value storage means 81c to set the T / U setting. When the value IS is reached, a completion signal is output from the T / U comparison means 87 to the T / U time comparison means 90. Then, from the T / U time comparison unit 90 that has received the completion signal, the measured time at that time is transferred to the T / U time storage unit 81e and set as the T / U time set value TSn.

Therefore, the normal operation set value YSn and the T / U time set value TSn can be set by tightening the sample screw for initial setting. At this time, the life set value MSn has not been set yet.

When the normal operation set value YSn and the T / U time set value TSn are set, the electric driver 9 is operated in the idling state without using a sample screw.

Even when the operation switch SWd of the electric driver 9 is turned “ON” again and the electric driver 9 operates again, the torque value obtained by the current / torque conversion means 58 is the normal operation set value storage means 81b and the life set value. The data is input to the storage unit 81 f and the T / U comparison unit 87.

Further, a trigger signal is input to the life set value storage unit 81f from the elapsed time comparison unit 88 at a timing of 2TS (twice the T / U time set value TS).

The torque value input to the life set value storage means 81f is set as the life set value MSn at the timing of 2TS by the trigger signal input from the elapsed time comparison means 88.

On the other hand, in the elapsed time comparison means 88, the input of the trigger signal at the TS / 2 timing to the normal operation set value storage means 81b is prohibited, and the previously set normal operation set value YSn is maintained. Is done.

The T / U time set value TSn, the normal operation set value YSn, and the life set value MSn set by using the initial setting switch SWi are transferred to the management monitoring data transmission means 45, and the parent is set using the management monitoring data area. It is transmitted to the station 2 and stored in the IDX table described above.

In the setting using the initial setting switch SWi, the ON signal output from the initial setting instruction unit 63 to the electric driver I / F unit 80 may be output according to an instruction from the master station 2.

<Preparation of mounting target member>
When starting the screw tightening operation on the attachment target member 71, first, the barcode 72 assigned to the attachment target member 71 is read by the barcode reader 7 connected to the local station 4. If the completion of the work in the previous process is normal, the screw part shelf lid 6 storing the screws used for the attachment target member 71 is opened, and the instruction lamp 62 that is an instruction for taking out blinks. When the operator who has taken out the predetermined screw turns on the input operation lever 61, the instruction lamp 62 is turned off, the lid 6 is closed, and the removal of the designated screw is completed.

<Starting the electric driver>
Subsequently, it is confirmed that the number display lamp 49 of the own station is in a blinking state indicating a work instruction, and the operation switch SWd is turned on by grasping the grip of the electric driver 9.

Numeral indicator lamp 49 displays based on the signal from subtraction counter 86 as shown in FIG. The subtraction counter 86 outputs a signal for blinking the numeric display lamp 49 when the operation instruction signal j of the own station is input from the own station control data extracting means 47. Accordingly, the blinking of the number indicator lamp 49 indicates that an operation instruction has been given to the electric driver 9 connected to the own station.

When the contactless power switch 59 is on, the electric driver 9 is activated by turning on the operation switch SWd.

As shown in FIG. 4, the non-contact power switch 59 is turned on or off based on a signal from the operation means 91. The operation means 91 turns on the non-contact power switch 59 when the condition establishment signal from the delivery condition means 82 or the local no-load operation instruction signal i from the local station control data extraction means 47 is input. Output a signal.

The delivery condition means 82 receives a condition satisfaction signal when the operation instruction signal j of the own station is inputted from the own station control data extracting means 47 and the previous process completion signal k is inputted from the reference station control data extracting means 48. Output to the operating means 91. Therefore, since the electric driver 9 is started by turning on the operation switch SWd only when there is a no-load operation instruction or when the previous process is completed, an erroneous operation by an operator is prevented in advance. The

In addition, as a pre-process, the removal of the screw of the screw accommodating portion provided with the slave station 5 serving as the reference station is completed, or the electric driver 9 connected to the other slave station 4 serving as the reference station. Although completion of the work is assumed, details will be described later.

<Screw tightening>
When the screw tightening operation is performed using the designated screw, that is, when the work is performed after the completion of the previous process, when the electric driver 9 is started, the motor current I increases rapidly due to the start current, and then the motor operation Is lowered to a stable state (horizontal state in FIGS. 5 and 6), and the current in that state is continued. In the following description, a period until the motor operation is in a stable state is referred to as a startup period.

In the electric driver I / F unit 80, in order to detect the starting current corresponding to various electric motors, the starting current set value SS which is a threshold of the starting current and the motor current I delivered from the A / D conversion unit 57 are detected. The start detection means 83 compares the data value of the digital signal Id proportional to.

The start detection means 83 obtains a start signal in a period in which the data value of the digital signal Id proportional to the motor current I is equal to or greater than the start current set value SS in the start period. Then, as shown in FIG. 5, the operation signal is output to the elapsed time comparing means 88 and the T / U time comparing means 90 from the falling edge of the start signal.

Since the data value of the digital signal Id proportional to the motor current I indirectly represents the motor current I, in FIG. 5, for convenience of explanation of the current change, the motor current Id and the starting current set values SS, T / The U set value IS and the normal operation set value YS are shown in association with the motor current Id and the life set value MS in FIG. 5 and 6 relate to the slave station with the slave station number 0, and are displayed in a form with the slave station number 0 added like SS0. The same applies to other setting values and measurement values.

The motor current Id is in a stable state while the screw tightening is in progress. When the tightening operation proceeds and the screw to be tightened is seated in the screw hole 73 of the mounting target member 71, the tightening torque increases and the motor current Id increases rapidly (torque up).

The electric driver I / F means 80 obtains a torque value obtained by converting the motor current Id in accordance with the I / T conversion coefficient K from the current / torque conversion means 58, and the torque value is passed through the tightening means 84 described later. The T / U set value IS delivered from the T / U set value storage means 81d is compared with the T / U comparison means 87.

In the T / U comparison means 87, when the torque value delivered from the current / torque conversion means 58 reaches the T / U set value IS delivered via the tightening means 84, a completion signal is sent to the subtraction counter 86, It outputs to the T / U time comparison means 90 and the operation means 91. Further, the data value at that time is delivered to the input means 50 as a T / U value (data indicated by c in FIGS. 4 and 8).

The operation means 91 having obtained the completion signal turns off the non-contact power switch 59, and the electric driver 9 is in an operation stop state. That is, when the torque is increased, the electric driver 9 can be brought into an operation stopped state. Note that the operating means 91 also turns off the non-contact power switch 59 and puts the electric driver 9 in a non-operating state even when operation error data d described later is “1”.

The T / U time comparison means 90 that has obtained the completion signal has the T / U time setting passed from the T / U time setting value storage means 81e at the timing when the completion signal is obtained. Compare with value TS. If the measurement time is within a predetermined allowable range including the T / U time set value TS, a normal (“0”) value and an abnormal (“1”) value outside the range are set as T / U. As time error data (data indicated by a in FIGS. 4 and 8), it is delivered to the input means 50. Further, the data value at that time is transferred to the input means 50 as T / U time value data (data indicated by b in FIGS. 4 and 8).

The subtraction counter 86 that has obtained the completion signal sets the screw hole number setting value NS delivered from the screw hole number setting value storage means 81c as an initial value, and subtracts the number of screw holes every time a completion signal is obtained, and becomes a work target. The remaining number of screw holes is handed over to the number indicator lamp 49. Further, when the remaining number of screw holes becomes 0, the work completion status data (data indicated by h in FIGS. 4 and 8) “1” is delivered to the input means 50.

<Retightening>
The retightening means 84 can be switched between a valid state and an invalid state by a retightening switch SWm. In the invalid state, the T / U set value IS delivered from the T / U set value storage unit 81d is delivered to the T / U comparison unit 87 without being changed. On the other hand, in the valid state, a value obtained by appropriately increasing the T / U set value IS is delivered to the T / U comparison means 87. When the T / U set value IS is increased, the torque value (torque-up value) when the screw is seated in the screw hole 73 is increased and can be tightened.

In the retightening means 84 of this embodiment, the surplus with respect to the T / U set value IS is 10%, but the ratio is not limited and may be set according to the use situation.

<Abnormality detection>
The electric driver I / F unit 80 also detects an error due to a screw selection error or a screw arrangement error from the torque value in a stable state after a predetermined time has elapsed since the start of the electric driver 9.

Specifically, first, in order to obtain the elapsed time from the start of the electric driver 9, the elapsed time comparing means 88 measures the time from the rise of the operation signal with a timer using the operation signal as a trigger signal. When a predetermined time based on the T / U time set value TS delivered from the T / U time set value storage means 81e, in this embodiment, reaches TS / 2, the trigger signal is sent to the normal operation comparison means 85. Output.

In the normal operation comparison means 85, the torque value delivered from the current / torque conversion means 58 is compared with the normal operation set value YS delivered from the normal operation set value storage means 81b. When the trigger signal (TS / 2 timing signal) from the elapsed time comparison unit 88 is valid, the torque value delivered from the current / torque conversion unit 58 is a predetermined allowable value including the normal operation set value YS. If it is within the range, the value of normal (“0”), and if it is out of the range, the value of abnormal (“1”) is transferred to the input means 50 as operation error data (data indicated by d in FIGS. 4 and 8). Further, the data value at that time is transferred to the input means 50 as operation T value data (data indicated by e in FIGS. 4 and 8).

If the torque value at the timing TS / 2 is in a range lower than the normal operation set value YS (i01 in FIG. 5), it means that the screw diameter is idling.

On the other hand, if the torque value at the timing TS / 2 is higher than the normal operation set value YS (i0h in FIG. 5), the screw diameter is small, or the screw is arranged obliquely, and the screw is in an adapted state. Means not.

When the operation error data d is “1”, the operation means 91 turns off the non-contact power switch 59 as described above, and the electric driver 9 enters an operation stop state. That is, the electric driver 9 can be stopped when an abnormality occurs such as the idling of the screw or the screw not being in a suitable state.

In the electric driver I / F unit 80, when a no-load operation (idling operation) is performed without performing a screw tightening operation, the torque value in a stable state after a predetermined time exceeding the T / U time setting time has elapsed. Thus, the life detection of the mechanical parts of the electric driver 9 is performed.

Specifically, first, a predetermined time in which the time from the rising edge of the operation signal from the elapsed time comparison means 88 exceeds the T / U time set value TS delivered from the T / U time set value storage means 81e, this implementation is performed. In the embodiment, when 2TS is reached, a trigger signal is output to the life comparison means 89.

In the life comparison means 89, the torque value delivered from the current / torque conversion means 58 is compared with the life set value MS delivered from the life set value storage means 81f. When the trigger signal (2TS timing signal) from the elapsed time comparison unit 88 is valid, the torque value delivered from the current / torque conversion unit 58 exceeds the predetermined allowable value range including the life set value MS. If it is within the range, the value of normal (“0”) is passed to the input means 50 as life error data (data indicated by f in FIGS. 4 and 8). Further, the data value at that time is transferred to the input means 50 as life T value data (data indicated by g in FIGS. 4 and 8).

When the service life of the electric driver 9 due to wear of bearings and mechanical parts such as lubricating oil is approaching, a torque cross occurs in the electric driver 9 and the motor current Id increases. Therefore, if the torque value at the timing 2TS is a value larger than the lifetime setting value MS (m0h in FIG. 6), it means that the lifetime of the mechanical component or the like is approaching.

In the electric driver I / F unit 80, as described above, the electric driver 9 is also changed according to the state of the previous process related to other devices based on the reference station control data delivered from the reference station control data extracting unit 48. Is in an operable state or inoperable state.

Specifically, when a predetermined slave station 5 that controls the lid 6 is set as a reference station, when the screw removal operation is completed in the predetermined slave station 5, the delivery condition means 82 Is output to the operating means 91. Then, the contactless power switch 59 is turned on, and the electric driver 9 for tightening the screw is made operable.

On the other hand, when the screw removal operation is not completed, the delivery condition unit 82 does not output a condition satisfaction signal to the operation unit 91. Then, the non-contact power switch 59 is turned off, and the electric driver 9 for performing the screw tightening is made inoperable, thereby preventing erroneous use for other screw tightening.

In addition, when a predetermined other slave station 4 is set as a reference station, when the work using another electric driver 9 to be used in the previous process is completed, the delivery condition means 82 outputs a condition satisfaction signal. Output to the operating means 91. Then, the contactless power switch 59 is turned on, and the electric driver 9 for tightening the screw is made operable.

On the other hand, when the operation using another electric driver 9 to be used in the previous process is not completed, the delivery condition unit 82 does not output a condition satisfaction signal to the operation unit 91. Then, the non-contact power switch 59 is turned off, and the electric driver 9 of the own station is made inoperable, so that the wrong order can be prevented.

<History management>
The data shown in the table of FIG. 8 delivered from the electric driver I / F unit 80 to the input unit 50 is output to the common data signal lines DP and DN via the monitoring data transmission unit 51. These data are acquired by the master station 2 via the common data signal lines DP and DN, and the table data shown in FIG. 8 is formed. The control unit 1 can perform history management in combination with time stamp data based on the table data formed in the master station 2. That is, it is possible to manage the history of work data including a torque value at the time of screw tightening work on the mounting target member 71 that has been completed.

In this embodiment, a plurality of

slave stations

4 and 5 are connected to the common data signal lines DP and DN, and data is exchanged by the transmission synchronization method, but the data exchange method is not limited. For example, data may be exchanged with a plurality of slave stations connected by a transmission line by a command method. Further, a plurality of slave stations may be connected to a master station paired with each slave station without being connected by a transmission line, and the master station and the slave station may directly exchange data on a one-to-one basis. Note that the system in this case is configured by a plurality of sets of a master station and a slave station.

DESCRIPTION OF SYMBOLS 1 Control part 2

Master station

4, 5 Slave station 6 Cover 7 Bar code reader 9 Electric driver 10 Power supply 11 Output unit 12 Input unit 13 Control parallel data 14 Monitoring parallel data 21 Output data part 22 Management data part 23 Timing generation part 24 Parent Station output unit 25 Master station input unit 26 Input data unit 29 Storage means 31 OSC (oscillation circuit)
32 timing generation means 33 control data generation means 34 line driver 35 monitoring signal detection means 36 monitoring data extraction means 40 slave station input / output unit 41 transmission reception means 42 management control data extraction means 43 address extraction means 44 own station address setting means 45 management Monitoring data transmission means 46 Reference station address setting means 47 Own station control data extraction means 48 Reference station control data extraction means 49 Number indicator lamp 50 Input means 51 Monitoring data transmission means 52 Bar code reader means 53 Slave station line receiver 54 Slave station line Driver 55 AC / DC converter 56 Amplifier 57 A / D conversion means 58 Current / torque conversion means 59 Non-contact power switch 60 Detection means 61 Input operation lever 62 Instruction lamp 63 Initial setting instruction means 71 Attachment target member 72 Bar code 73 Screw Hole 74 Electric dry Bar code 80 Electric driver I / F means 81 Set value storage means 81a Startup current set value storage means 81b Normal operation set value storage means 81c Screw hole number set value storage means 81d T / U set value storage means 81e T / U time setting Value storage means 81f Life set value storage means 81g I / T conversion coefficient storage means 82 Delivery condition means 83 Start detection means 84 Retightening means 85 Normal operation comparison means 86 Subtraction counter 87 T / U comparison means 88 Elapsed time comparison means 89 Life Comparison means 90 T / U time comparison means 91 Operation means

Claims

Each of the plurality of electric drivers is connected to a slave station capable of exchanging data with the master station, and the slave station has detection means for obtaining an electric signal that changes in accordance with the output torque of the electric driver. The calculated value obtained based on the electrical signal at an arbitrary initial setting is stored as an initial set value, and the calculated value obtained based on the electrical signal during a normal operation is a predetermined value set in the initial set value. An electric driver management system that detects an operation abnormality when the torque is out of a range of allowable torque with or without a tolerance.
The electric driver management system according to claim 1, wherein the initial setting is instructed from the master station to the slave station.
The electric driver management system according to claim 1 or 2, wherein the initial setting time is instructed by an input operation via an initial setting means provided in the slave station.
The initial setting value is transmitted from the child station to the parent station, and the parent station transmits the initial setting value to a child station different from the child station that has transmitted the initial setting value. The electric driver management system according to 2 or 3.