ES2782299A1 - PARTS AND PRODUCTS COLLECTION SYSTEM FOR ASSEMBLY OR ORDER PREPARATION (Machine-translation by Google Translate, not legally binding) - Google Patents

Abstract

Parts and products collection system for assembly or order preparation. The system comprises a structure (2) in which collection and/or storage boxes (5) are assembled with the products or parts used in production, each of which is assigned a slave module (6) that indicates when and how much to collect from each. The slave modules (6) are governed by a master module (7) that receives the production orders through an RFID tag reader (10), a barcode scanner (11) or the internal network through a SCADA terminal (8). The SCADA terminal (8) shows an interface on a monitor (9) with instructions and guidance for the operators according to the process. (Machine-translation by Google Translate, not legally binding)

Description

COLLECTION SYSTEM OF PARTS AND PRODUCTS FOR ASSEMBLIES OR

ORDER PREPARATIONS

Field of the invention

The invention is part of the industrial manufacturing and production sector, specifically any industry that has training needs for workers for assembly and digitization positions in its value chains.

The main object of the present invention is a scalable and adaptable assembly station to a great variety of types of assembly and / or collection and / or storage of parts and / or products with training and production capacities for Industry 4.0.

Background of the invention

In industrial production value chains, lean production methodologies (known by the term “lean manufacturintf) have led to the use of a semi-automated collection system called “ pick-to-light ”. The pickto-light systems use optical and / or acoustic devices to indicate the pick-up of products and / or parts on assembly stations or inventory racks. They have the advantage of drastically reducing errors due to product and / or part pick-up confusion, reducing the waiting time (“lead time”, the time that elapses from the beginning of a production process until it is completed) by being evident the collection process and are integrated into stock control systems, allowing great productive flexibility. In turn, there is the “put-to-light” system that serves to store inventory in the position itself as if it were a shelf using the same physical configuration to place the pieces in the boxes and that has the same advantages and capacities for this task.

Its applications are diverse and its field of action is expanding every day due to the benefits it provides. The automotive sector is where its use is most widespread but the pick-to-light and put-to-light system is capable of adapting to any type of industry that has flexible assembly and inventory needs.

In recent times the 4th industrial revolution has entered the scene, also known as Industry 4.0, which demands digital solutions to have total control and in real time of production. This new paradigm seeks a complete digitization of value chains by integrating data processing technologies, intelligent software and sensors, adding connectivity and intelligence to tools and machines as well as other common elements such as deposits or warehouses of materials that ensure communications. through an internal network. Therefore, it is capable of generating a regular and much higher flow of information than the more traditional modes, information that can also be exchanged and analyzed very quickly in internal networks and over the internet to allow adaptations to changing situations, responding in real time, avoiding batch or deferred processing and also perform procedural simulations or familiarize operators with the tools and elements of the job as well as exceptional circumstances.

Description of the invention

The present invention refers to a pick-to-light and put-to-light system for assembly and / or collection and / or storage positions of parts and / or products with training capabilities by levels and digital integration for Industry 4.0.

The parts and products collection system for assembly, storage or order preparation of the present invention comprises the following elements:

- A structure in the form of a shelf with shelves.

- A plurality of roller profiles with lateral stops arranged perpendicular to the shelves.

- A plurality of collection and / or storage boxes containing products and / or parts, each collection and / or storage box being arranged on each roller profile.

- A system for receiving orders.

- A master module attached to the structure and configured to receive orders for the collection and / or storage of products and / or parts from the order receiving system and, depending on the orders received, control the slave modules.

- A plurality of slave modules secured to the structure and forming a communication network with the master module. Each slave module is arranged in front of each collection and / or storage box and comprises:

• A warning led to indicate to an operator that at least one product or part must be collected from the corresponding collection and / or storage box or that at least one product or part must be stored in said collection and / or storage box .

• A display to indicate the number of products or pieces to collect or store.

• An operation button performed to, once pressed, notify the master module that the collection has been carried out or that the product or part has been stored in the collection and / or storage box.

• Two unit management buttons, a first button to increase the quantity shown on the display and a second button to decrease said quantity.

• An ultrasound sensor to detect the collection or storage of the product or part in the corresponding collection and / or storage box.

• An acoustic warning device configured to emit an alarm signal when the ultrasound sensor detects a collection or storage of the product or part in an incorrect collection and / or storage box.

The order receiving system preferably comprises an RFID tag reader connected to the master module. The order receiving system may comprise a barcode scanner.

In one embodiment, the order receiving system comprises a SCADA terminal connected to the master module and to a local communication network. The system may comprise a monitor through which the SCADA terminal is configured to display:

- Images and / or a list of the products and / or parts to collect and / or store; - Instructions on the assembly process of the reference in current production once the collection orders have been made, or instructions on the part to be stored according to the storage orders.

The system may also comprise a traceability label printer through which the SCADA terminal is configured to print a label with traceability data for the container of the reference.

The roller profiles are preferably arranged on a slope with respect to the shelf and have a front stop to retain the collection and / or storage boxes.

Brief description of the drawings

A series of drawings that help to better understand the invention and that expressly relate to an embodiment of said invention that is presented as a non-limiting example of this, will now be described very briefly.

In Figure 1 the complete configuration of the present invention is represented.

Detailed description of the invention

The present invention refers to a pick-to-light and put-to-light system that integrates lean manufacturing solutions for Industry 4.0.

An embodiment of the present invention is depicted in Figure 1. System 1 comprises a metallic structure 2 with a plurality of shelves 3 on which roller profiles 4 are placed and, in turn, on these, collection and / or storage boxes 5 containing the products and / or parts. In front of each shelf 3, and vertically of each collection and / or storage box 5, a slave module 6 is located.

On one side of structure 2 are located the rest of the components, attached to structure 2:

- A master module 7.

- A SCADA terminal 8.

- A monitor 9 for the SCADA terminal.

- An RFID tag reader 10.

- A barcode scanner 11.

- A traceability label printer 12.

SCADA terminal 8 and monitor 9 are connected using an HDMI cable. The master module 7 and the SCADA terminal 8 are connected to each other by a micro-USB cable. SCADA terminal 8 and label printer 12 are connected via USB cable. Master module 7 connects to barcode scanner 11 via USB cable, RFID tag reader 10 via 4-wire cable, and module closest slave 6 using a 4-wire cable. Each slave module 6 is connected to the next one by means of a 4-wire cable until all of them are connected so that only two 4-wire cables come out of each of them. The master module 7, the SCADA terminal 8, the monitor 9 and the printer 12 are connected to the electrical network through their respective feeders.

The system is configured in a series of slave modules governed by a master module in turn connected to a SCADA terminal. The modules are governed by an Arduino microcontroller and the SCADA terminal by a Raspberry Pi micro-pc. The entire system operates at a voltage of 5 volts in direct current fed through a typical 230 volt network in single-phase alternating current.

The SCADA terminal 8 connects to the monitor 9, the label printer 12 and the master module 7. The SCADA terminal is programmed in the Python language on the Linux-based Raspbian operating system.

Master module 7 consists of an Arduino UNO microcontroller with a USB accessory shield. The master module 7 receives the production order and governs the activity of the slave modules 6. A barcode scanner 11 is connected through the USB accessory and the communication network with the slave modules 6 and the reader is connected to the I2C pins. RFID tags 10. Through the microUSB port it is connected to the SCADA terminal 8 through the serial port.

Each slave module 6 consists of an Arduino Nano microcontroller connected by the I2C pins to the master module 7, with a warning led 13, an operation performed button 14, two unit management buttons 15 (one above the other, the upper one being to increase the displayed quantity and the lower one to reduce it), an acoustic alarm 19, an ultrasound sensor 17 and a 2-digit numerical display 18. This module can be placed above, below or on one side of the collection and / or storage box 5 of the corresponding product / part. In the "pick-to-light" mode, led 13 of the slave module 6 that contains the required product or part lights up to indicate to the operator the product and / or part to be picked, while the numeric display 18 indicates the quantity due to withdraw. After this, the operator presses the operation performed button 14 to indicate that the operation has been carried out and that the master module 7 indicates the next product or piece to be collected. In put-to-light operation the led 13 of slave module 6 lights up to indicate where to place the piece, where pressing the unit management buttons 15 indicates the quantity to be entered. After this, the operator presses the operation performed button 14. In both modes, if the operator tries to insert or remove a part from a tray other than the one indicated, the ultrasound sensor 17 of the corresponding slave module 6 detects the hand ( since it is positioned facing upwards) and the buzzer 19 (which is inside the case of the slave module 6) beeps intermittently and the led 13 flashes intermittently to warn of the error.

The invention works as follows according to pick-to-light:

1. From the SCADA terminal 8, the system's formative or productive operating mode is indicated between a series of levels, from the most basic to the most advanced. The operating mode is also indicated: “pick-to-light” in this case. The SCADA terminal 8 also displays information about the operator, expected production, current production, and current assembly / pick-up reference.

2. Master module 7 receives the order. This can be an entry by barcode, RFID tag or communication through an internal ethernet or WiFi network.

3. The master module 7 orders the corresponding slave modules 6 to illuminate its warning led 13 and show the quantity to be withdrawn on the numerical displays 18. Depending on the level used, this light indication can be progressive and in a certain order or of all the corresponding slave modules 6 at the same time.

◦ In the first case, the operation performed button 14 must be pressed so that the master module 7 processes the response and indicates the next slave module 6 that should illuminate its led 13.

◦ In the second case, the master module 7 commands the LEDs 13 of all the slave modules 6 involved to light up at the same time.

At the same time, and in both cases, the SCADA terminal 8 shows on the monitor 9 the photographs and the list of parts / products to be collected and sends the traceability label printer 12 to print a label with traceability data for the reference container.

4. After having pressed all the buttons 14 of the operation performed of the slave modules 6 involved in the process, the SCADA terminal 8 shows on the monitor 9 the assembly process of the reference in current production.

5. If the operator places his hand on a tray other than the one indicated by the system of the product to be mounted, the ultrasound sensor 17 detects it and makes the buzzer 19 beep intermittently and the LED 13 also light up intermittently .

6. When a new order enters the system, the cycle begins again. Throughout this process, the SCADA 8 terminal has been monitoring the collection, assembly, total and traceability times of each reference to integrate them into a real-time statistical system accessible from the internal network, updating the inventory that can be integrated into a Kanban system.

The invention works as follows according to put-to-light:

1. From the SCADA terminal 8, the system's formative or productive operating mode is indicated between a series of levels, from the most basic to the most advanced. The operating mode is also indicated: “put-to-light” in this case. The SCADA terminal 8 also displays information about the operator, the planned storage, the current storage and the current storage reference.

2. Master module 7 receives the storage order. This can be an entry by barcode, RFID tag or communication through an internal ethernet or WiFi network.

3. The master module 7 orders the corresponding slave module 6 to illuminate its warning led 13. After this, the operator, using the unit management buttons 15, indicates the quantity to be entered, which is reflected on the 2-digit numerical display 18. Then press the operation done button 14 to confirm the quantity.

At the same time, the SCADA terminal 8 shows on the monitor 9 the photograph of the parts / products to be stored and sends the traceability label printer 12 to print a label with traceability data for the part's packaging.

4. If the operator inserts his hand into a tray other than the one indicated by the system of the product to be mounted, the ultrasound sensor 17 detects it and makes the buzzer 19 will beep intermittently and the led 13 will also light up intermittently.

5. When a new order enters the system, the cycle begins again.

Throughout this process, the SCADA 8 terminal has been monitoring storage times and traceability of each reference to integrate them into a statistical system in real time accessible from the internal network, updating the inventory that can be integrated into a Kanban system.

Due to its configuration in master module 7 and slave modules 6, system 1 is easily scalable by adding or reducing slave modules 6 to the communication network and its corresponding modification in the database.

As a proposal for a preferred configuration of the invention, a design of all the components of system 1 is described below. Based on Figure 1, structure 2 is implemented in the form of shelves with shelves 3 made of metal aluminum profiles of 40x40 T-slot configuration. These profiles allow the realization of a structure tailored to the needs of the post and also the possibility of securing to it the rest of the necessary components with fixed connections. The separation of the shelves 3 from each other depends on the collection and / or storage boxes 5 used according to the needs of the station. The structure 2 has in its inner part wheels 16 with brakes so that it can be moved in case of need.

Roller profiles 4 or plastic wheel rails with lateral stops with a certain slope or inclination are placed perpendicularly to the shelves 3, and supported on them, which serve for the collection and / or storage boxes 5 of the products / parts roll to the front where the operator is positioned until they are stopped in their descent by a small metal stop.

The collection and / or storage boxes 5 are of a European standard of an appropriate size for their content. Right in the front of each collection and / or storage box 5, and secured in the structure 2, each slave module 6 is placed. Each one of them has two cable outlets to join it to other two adjacent slave modules 6, Except for the slave module 6 closest to the master module 7, which will join this and another slave module 6. These cables are secured to the structure 2.

According to the manual preference of the operator, the rest of the components of the station can be placed on one side or the other of the structure 2, secured to it. Both the master module 7 and the SCADA terminal 8 are placed in custom plastic boxes for their protection and anchorage in the upper part of the structure 2. At a height of a little less than the operator's view, the monitor 9 is located, and just below it is located the RFID tag reader 10, the barcode scanner 11 and the traceability label printer 12. The barcode scanner 11 is on a support that allows it to be manipulated by the operator outside structure 2 and then be put back in place.

one

Claims (7)

1. System for collecting parts and products for assembly, storage or preparation of orders, characterized in that it comprises: a structure (2) in the form of a shelf with shelves (3); a plurality of roller profiles (4) with lateral stops arranged perpendicular to the shelves (3); a plurality of collection and / or storage boxes (5) containing products and / or parts, each collection and / or storage box (5) being arranged on each roller profile (4); an order receiving system; a master module (7) attached to the structure (2) and configured to receive orders for the collection and / or storage of products and / or parts from the order reception system and, depending on the orders received, carry out the control of slave modules (6); a plurality of slave modules (6) secured to the structure (2) and forming a communication network with the master module (7), each slave module (6) arranged frontally to each collection and / or storage box (5) and comprising: a warning led (13) to indicate to an operator that at least one product or part must be collected from the corresponding collection and / or storage box (5) or that at least one product or part must be stored in said box collection and / or storage (5); a display (18) to indicate the number of products or pieces to collect or store; an operation performed button (14) to, once pressed, notify the master module (7) that the collection has been carried out or that the product or part has been stored in the collection and / or storage box (5); two unit management buttons (15), a first button to increase the quantity shown on the display (18) and a second button to decrease said quantity; an ultrasound sensor (17) to detect the collection or storage of the product or piece in the corresponding collection and / or storage box (5); an acoustic warning device (19) configured to emit an alarm signal when the ultrasound sensor (17) detects a collection or storage of the product or part in an incorrect collection and / or storage box (5). 2. System according to claim 1, wherein the order reception system comprises an RFID tag reader (10) connected to the master module (7). System according to any of the preceding claims, wherein the system for receiving orders comprises a barcode scanner (11). 4. System according to any of the preceding claims, wherein the system for receiving orders comprises a SCADA terminal (8) connected to the master module (7) and to a local communication network. System according to claim 4, comprising a monitor (9) through which the SCADA terminal (8) is configured to display: - images and / or a list of the products and / or parts to be collected and / or stored; me - instructions on the assembly process of the reference in current production once the collection orders have been made, or instructions on the part to be stored according to the storage orders. System according to claim 5, comprising a traceability label printer (12) through which the SCADA terminal (8) is configured to print a label with traceability data for the reference container. System according to any of the preceding claims, where the roller profiles (4) are arranged on a slope with respect to the shelf (3) and have a front stop to retain the collection and / or storage boxes (5).