EP0437475A1 - Procede et dispositif de production d'une piece a usiner - Google Patents

Procede et dispositif de production d'une piece a usiner

Info

Publication number
EP0437475A1
EP0437475A1 EP89911154A EP89911154A EP0437475A1 EP 0437475 A1 EP0437475 A1 EP 0437475A1 EP 89911154 A EP89911154 A EP 89911154A EP 89911154 A EP89911154 A EP 89911154A EP 0437475 A1 EP0437475 A1 EP 0437475A1
Authority
EP
European Patent Office
Prior art keywords
workpiece
station
part processing
stations
record
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP89911154A
Other languages
German (de)
English (en)
Other versions
EP0437475A4 (en
Inventor
Ltd. EL PASO TECHNOLOGIES
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
EL PASO TECHNOLOGIES, LTD.
Original Assignee
Individual
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Individual filed Critical Individual
Publication of EP0437475A1 publication Critical patent/EP0437475A1/fr
Publication of EP0437475A4 publication Critical patent/EP0437475A4/en
Withdrawn legal-status Critical Current

Links

Classifications

    • G—PHYSICS
    • G06—COMPUTING; CALCULATING OR COUNTING
    • G06Q—INFORMATION AND COMMUNICATION TECHNOLOGY [ICT] SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES; SYSTEMS OR METHODS SPECIALLY ADAPTED FOR ADMINISTRATIVE, COMMERCIAL, FINANCIAL, MANAGERIAL OR SUPERVISORY PURPOSES, NOT OTHERWISE PROVIDED FOR
    • G06Q10/00—Administration; Management
    • G06Q10/08—Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Programme-control systems
    • G05B19/02—Programme-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • G05B19/41815—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM] characterised by the cooperation between machine tools, manipulators and conveyor or other workpiece supply system, workcell
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the present invention relates, in general, to a method and apparatus for producing a workpiece and, more specifically, to a method and apparatus that tracks and maintains a part processing record during the production of the workpiece.
  • An example that will be used in describing the present invention is that of an automotive industry production line. However, it should be noted that the present invention is not limited to such production lines.
  • production lines, or systems are a combination of machines, or processes.
  • a machine is composed of one or more stations with each station having one or more mechanisms. These mechanisms can additionally be broken down into their constituent elements.
  • Errors in processing and damage to workpieces and stations occur from a failure of the individual stations to be informed of the part processing record of the workpiece.
  • the manufacture of automotive engine blocks will be used. If a hole is drilled in the block at one station and then the hole is tapped at another station, a great deal of damage can be done to the tapping station if the hole was not drilled, or drilled improperly, at the drilling station. Additionally, the block may be damaged in such an instance rendering it unrepairable.
  • probes such as a full depth probe in this example /
  • This inspection saves damage to the stations, and possibly the blocks, it has increased the operating time of the station to perform this check.
  • This additional time in processing can increase the cost of a completed product significantly.
  • these probes increase the cost of the station and insert another mechanism that may malfunctio .
  • Another problem that exists is that of having the same station performing multiple cycles on the same workpiece. This error can occur when several stations do not operate with equal cycle times.
  • U. S. Patent No. 4,509,123 issued to Vereen This patent describes an automated tracking process for manufacturing and inventory. More specifically, the patent describes a process for manufacturing garments by placing a tag, or similar item, having a machine readable code on the bundles. These tags are scanned at each work place to register the operator, machine, and time the bundle was completed at that station. However, there is no communication from the system storing the information back to the stations. As a result, there is no way to inform a downstream operator that an upstream operator, or station, has or has not performed its work on the bundle. In other words, there is no way to inhibit the present operator from working on the bundle based on some previous operators action.
  • a further object of the present invention is to provide a method and apparatus of monitoring a part processing record during the production of the workpiece. Another object of the present invention is to provide a method and apparatus of processing a workpiece in which operation at a work station can be inhibited by a part processing record of the workpiece. Still another object of the present invention is to provide a method and apparatus of processing a workpiece in which a current part processing record of all workpieces currently in process is maintained at each work station. Yet another object of the present invention is to provide a method and apparatus of processing a workpiece which is more economical to utilize.
  • a particular embodiment of the present invention provides a production line, or system, having a monitoring, or orchestrator, computer and a plurality of station computers, one at each work station.
  • a monitoring, or orchestrator, computer As a workpiece enters a station, an address is identified with the workpiece.
  • the computer will direct the work station to perform the work on the workpiece unless inhibited by an inhibit such as the part processing record which is s'tored in the memory address identified with the workpiece. This inhibit occurs if some data associated with the workpiece, such as some prerequisite work, directs it to inhibit.
  • FIG. 1 is a block diagram of a production line illustrating three work stations
  • FIG. 2 is a block diagram of a logic module memory utilized by the system of FIG. 1;
  • FIGS. 3A-3F are block diagrams of a flow of workpieces through a production line
  • FIG. 4 is a block diagram of a communication network utilized by the present invention
  • FIGS. 5A and 5B are block diagrams of information packets utilized by the present invention
  • FIGS. 6A-6F are block diagrams of a communication network utilized by the present invention.
  • FIG. 7 is a graphical representation, in the form of a table, of a zone logic processing method.
  • Production system 20 consists of three work stations 21-23, having station computers 24-26, respectively.
  • System 20 also comprises a clamp station 27 and a transfer station 28 each having a station computer 30 and 31, respectively.
  • Station computers 24- 26, 30 and 31 are monitored and controlled by an orchestrator computer 32.
  • Communication among station computers 24-26, 30 and 31 and orchestrator 32 occurs over a communication loop 42.
  • Communication loop 42 is preferably an optical loop.
  • Station computer 24 operates a drill 33 through a stepper motor 34 and a transmission 35. Transmission 35 is coupled to drill 33 through a shaft 36.
  • Station computer 25 operates reamer 37 through a stepper motor 38 and a transmission 40. Transmission 40 is coupled to reamer 37 through a shaft 41.
  • Station computer 26 operates a tapper 43 through a stepper motor 44 and a transmission 45. Transmission 45 is coupled to tapper 43 through a shaft 46.
  • Station computer 30 operates a clamp motor 47 which, through a shaft 48, operates a clamp bar 50 and a plurality of clamps 51.
  • Station computer 31 operates transfer motor 52 which, through a shaft 53, operates a transfer bar 54.
  • Transfer bar 54 having a plurality of guides 55 disposed thereon.
  • system 20 processes through the steps of: transferring a workpiece 56, clamping workpiece 56, working on workpiece 56 (cycling the station), and unclamping workpiece 56.
  • transfer guides 55 are withdrawn from and clamps 51 are in contact with workpieces 56. This position indicates that stations 21- 23 are preparing to cycle or have just completed cycling.
  • FIG. 2 a block diagram of a logic module memory map, generally designated 61 , is illustrated.
  • logic module memory 61 is the same for all station computers 24-26, 30 and 31 and orchestrator 32; but that it is not the entire memory at those computers. Further, the information contained in logic module memory 61 is relatively the same at each location, except for the real time updates which continually occur. Any changes in the memory will be
  • Logic module memory 61 is divided into several areas: a network memory 62, a task memory 63, and file memory 64.
  • Network memory 62 is further divided into a receive portion 65 and a send portion 66.
  • File memory 64 is further divided into a header 67 and a body 68. It is in body 68 where the part processing records for workpieces 56 are maintained. Header 67 contains the index to body 68 which indicates what address in body 68 contains the part processing record of which workpiece
  • Transfer line 70 contains two work stations 71 and 72.
  • Header 67 of file memory 64 contains an index, by memory address, of which data block, or part process record, is associated with a particular station containing that part, or workpiece. Initially, this index will appear similar to the index of Table 2.
  • Table 2 is just one example of an initial part process index.
  • the system can be programmed to commence at any initial index.
  • the workpiece associated with data block 1 is in station X, this is a nonexistent station whose use will become evident in the following discussion.
  • the workpiece associated with data block 2 is in station 1 and the workpiece associated with data block 3 is in station 2.
  • a transfer station such as station 28, FIG. 1, will index the workpieces. Now workpiece 73 is presented to station 71 and workpiece 74 is moved into position to enter line 70, as illustrated in FIG. 3B.
  • an orchestrator which may be the transfer station in this example, will send out the transfer order of Table 3 directing the part process index to be modified.
  • the part processing record for workpiece 73 at station 2 is in data block 1 ; the record of workpiece 74 at station 1 is in data block 3; and the record of the workpiece at station X is in data block 2, station X being the nonexistent station.
  • part processing record contained within the data blocks can contain as much information as desired.
  • a particular embodiment of a part process record is set forth in Table 11.
  • the reject data only requires one bit since the part is either rejected or not rejected. If rejected, this bit can be used to inhibit cycling of down stream stations and cause the workpiece to be removed from the line when a removal station is encountered.
  • the part present and no part present data have a number of bits ⁇ equal to the number of positions on a line. At each position, information is gathered as to whether the workpiece is present or not present. Since there are three possibilities (part present, no part present, and no sensor at that position) two bits are * required for each position. Therefor, part present and no part present are both utilized.
  • the final group of data is labeled variables. This area can be used to keep track of any type of data in which the user may be interested. Such as how long did it take to drill a hole, how deep was the hole, etc.
  • every computer on a network has a logic module memory such as that represented by FIG. 2.
  • every computer memory contains a full part process record (or data block) of every workpiece in the system. It will be appreciated by those of skill in the art that while the upstream stations do not need the process information from the down stream stations, it takes more programming and time to edit out such information than to accept the information.
  • Network 85 consists of an orchestrator 86 and stations 87 and 88.
  • Logic modules of stations 86, 87, and 88 are divided into send (90, 91, and 92) and receive (93, 94, and 95) portions, respectively.
  • information is passed on a line 96 between stations 86, 87, and 88.
  • the information is transmitted serially in time-division multiplexed information packets 97 such as illustrated in FIG. 5A.
  • Packet 97 consists of a send portion 98 and a receive portion 100.
  • send portions 90, 91, and 92 are logically ORed together.
  • the send data originates in send portion 90.
  • the data from portion 90 is then ORed with the information of send 91.
  • the result is then ORed with send portion 92 and transmitted to receive portion
  • FIGS. 3D and 3E Once in the condition illustrated in FIG. 3D, the information in data blocks 1 , 2 and 3 of all the memories, as shown in Table 8, are represented in information on line '96 of FIG. 5B.
  • the send data, 01 of block 1 representing that process 1 has been completed, is sent from send portion 90 to send portion 91.
  • send portion 91 this is ORed with the information in data block 1 of station 87, which is also 01.
  • This output 01 is then sent to station 88 where it is again ORed with 01 from data block 1.
  • the result is then transmitted to receive portion 93 of orchestrator 86 where it is stored. The same thing is done for data blocks 2 and 3.
  • this type of communication is conducted in a serial fashion and that the system does not wait for transmission of data block 1 to be completed before continuing.
  • the data is read out of receive portion 93 and down loaded into receive portions 94 and 95 before being returned to receive portion 93. Since no processing has been performed while the data stabilizes as in Table 8, the system will continuously read and write as set forth above.
  • the send portion will see the address of data block 1 come through.
  • the data for block 1 will be copied into send 66 and ORed with the information currently on the line for block 1.
  • the address identifies the address of block 1.
  • the data following the address is loaded into block 1 of file area
  • FIGS. 6A-6F a graphical Representation of the communication process is provided.
  • Three stations 101-103 are shown in FIG. 6A.
  • station 101 will be used as the network orchestrator.
  • Stations 101-103 contain send portions 104-106, receive portions 107-109, and file portions 110- 112.
  • FIG. 6A the system has reached equilibrium with a 01 stored in file portions 110-112. This represents that processing of this particular workpiece has been completed by station 102.
  • Station 103 then indexes passing the workpiece to station 103.
  • Station 103 then processes the workpiece and changes the data in file 112 from 01 to 11. This information then needs to be disseminated throughout network 85.
  • the data 01 is loaded from file portion 110 into send portion 104 and transmitted to station 102.
  • each part process record is utilized by the various stations to determine if the workpiece is ready to be processed. If the workpiece is not in condition for processing, the part process record acts as an inhibit, preventing the station from cycling.
  • FIG. 7 a graphical representation, in the form of a table, of a zone logic processing method is represented. This method operates as set forth in pending U.S. Patent Application having serial number 038,018 and incorporated herein by reference.
  • the zone logic table of FIG. 7 is a type of work sheet utilized to obtain the information needed to program a line equipped with the appropriate processing hardware. An example of a portion of that hardware is described in U.S. Patents 4,621,200 and 4,705,900 both invented by Rodger T. Lovrenich.
  • the table of FIG. 7 is for one particular mechanism, mechanical slide, of a station designated 5L.
  • a list of zone names and input/output names are organized in the table with a listing of the states of the inputs and outputs for each zone.
  • the maximum time in the zones if there is a maximum time, are set forth. If this maximum time is exceeded, the zone logic system moves to the next zone listed in column 180, in this example zone 10, the error zone.
  • Column 182 lists the allowed next zones, or the zones from which the current zone is permitted to pass. A change in either an input or output state can cause a change to another zone. The new zone is determined by comparing the new states of the inputs/outputs with the inputs/outputs in the table to find a match; rather than requiring that all potential zones be listed and having the system conduct a search through all of these zones.
  • a concept of zone logic lists the allowed next zones from which each valid zone is allowed to pass. This greatly reduces the amount of information that needs to be entered and greatly speeds up the operation of the mechanisms.
  • zone 3 Advanced From Returned
  • zones 4 Advanced Between
  • 9 Coasting to Stop
  • 10 Error
  • a part process inhibit is presented. This portion of zone logic will inhibit cycling of the mechanism if some data contained within the part processing record for the current workpiece is improper. For example, the workpiece may have been tagged as a rejected part, Table 8. If the system is set to inhibit cycling if the rejected part bit is set, the mechanism will be inhibited from operating. Another example is that for every process started, there must be a corresponding process done, otherwise cycling will be inhibited.

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  • Engineering & Computer Science (AREA)
  • Business, Economics & Management (AREA)
  • Economics (AREA)
  • Quality & Reliability (AREA)
  • Physics & Mathematics (AREA)
  • General Physics & Mathematics (AREA)
  • Entrepreneurship & Innovation (AREA)
  • Operations Research (AREA)
  • Development Economics (AREA)
  • Manufacturing & Machinery (AREA)
  • General Engineering & Computer Science (AREA)
  • Human Resources & Organizations (AREA)
  • Marketing (AREA)
  • Automation & Control Theory (AREA)
  • Strategic Management (AREA)
  • Tourism & Hospitality (AREA)
  • General Business, Economics & Management (AREA)
  • Theoretical Computer Science (AREA)
  • Multi-Process Working Machines And Systems (AREA)
  • General Factory Administration (AREA)

Abstract

On décrit une chaîne de transfert ou de montage (20) utilisant un ensemble de postes (21-23) et comportant un ordinateur (24-26) à chaque poste. Chaque ordinateur présente un enregistrement de traitement de pièces (68) pour toutes les pièces présentes dans la chaîne. A mesure qu'une pièce à usiner défile le long de la chaîne, un indice (67) de traitement de pièces, contenu dans chacun des ordinateurs de poste, est mis à jour pour indiquer quel enregistrement de traitement de pièces est associé avec la pièce à usiner à chaque poste. Les informations contenues dans l'enregistrement de traitement de pièces sont utilisées par l'ordinateur de poste pour empêcher le poste d'effectuer un cycle de traitement lorsque l'enregistrement indique qu'une condition nécessaire n'a pas été remplie.
EP19890911154 1988-09-23 1989-09-14 Method and apparatus of producing a workpiece Withdrawn EP0437475A4 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US24877288A 1988-09-23 1988-09-23
US248772 1988-09-23

Publications (2)

Publication Number Publication Date
EP0437475A1 true EP0437475A1 (fr) 1991-07-24
EP0437475A4 EP0437475A4 (en) 1992-01-22

Family

ID=22940616

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19890911154 Withdrawn EP0437475A4 (en) 1988-09-23 1989-09-14 Method and apparatus of producing a workpiece

Country Status (5)

Country Link
EP (1) EP0437475A4 (fr)
JP (1) JPH04503632A (fr)
AU (1) AU4334889A (fr)
ES (1) ES2016171A6 (fr)
WO (1) WO1990003617A1 (fr)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2413017A2 (fr) 2010-07-30 2012-02-01 Penez Herman Dispositif d'éclairage pour l'illumination d'un mur érigé à partir de briques de verre.

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2781583B1 (fr) * 1998-07-22 2000-12-01 Cegelec Architecture de communication pour systeme industriel de conduite de procede et unite programmee correspondante
AUPQ916600A0 (en) 2000-08-03 2000-08-24 James Hardie Research Pty Limited Automated manufactured apparatus for aluminium window/door systems

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2544888A1 (fr) * 1983-04-25 1984-10-26 Merlin Gerin Ligne transfert automatisee et flexible de production

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4472783A (en) * 1980-07-21 1984-09-18 Kearney & Trecker Corporation Flexible manufacturing system
DE3137323A1 (de) * 1981-09-19 1983-11-24 Erwin Dr.-Ing. 1466 Luxembourg Gardosi Maschinenlesbarer informationstraeger
FR2547520B1 (fr) * 1983-06-17 1985-10-11 Prodel Maurice Installation modulaire pour l'assemblage et/ou l'usinage de pieces, avec dispositifs claviers-afficheurs a chaque poste
US4669047A (en) * 1984-03-20 1987-05-26 Clark Equipment Company Automated parts supply system
JPH0616282B2 (ja) * 1985-05-27 1994-03-02 ソニー株式会社 生産方法

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2544888A1 (fr) * 1983-04-25 1984-10-26 Merlin Gerin Ligne transfert automatisee et flexible de production

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See also references of WO9003617A1 *

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2413017A2 (fr) 2010-07-30 2012-02-01 Penez Herman Dispositif d'éclairage pour l'illumination d'un mur érigé à partir de briques de verre.

Also Published As

Publication number Publication date
EP0437475A4 (en) 1992-01-22
WO1990003617A1 (fr) 1990-04-05
JPH04503632A (ja) 1992-07-02
ES2016171A6 (es) 1990-10-16
AU4334889A (en) 1990-04-18

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