GB2511591A

GB2511591A - Operation management system and operation management method

Info

Publication number: GB2511591A
Application number: GB1316957.8A
Authority: GB
Inventors: Gang Wang; Hitoshi Yokoyama; Kozo Inoue; Yasutaka Sano
Original assignee: Hitachi Ltd
Current assignee: Hitachi Ltd
Priority date: 2013-03-05
Filing date: 2013-09-24
Publication date: 2014-09-10
Anticipated expiration: 2033-09-24
Also published as: GB2511591B; JP6041307B2; TW201435765A; JP2014170446A; LT2013120A; LT6096B; GB201316957D0

Abstract

The system 10 includes an operation tool 40 (such as a torque wrench) with a limit switch 42 which outputs an operation completion signal when an operation on operation target components provided in an operation target item reaches a setting value. An identification code reading portion (46, Figure 3A) is removably attached to each of the operation target components and can read an identification code capable of identifying each of the operation target components. An operation terminal 20 is electrically connected to the operation tool and can receive the operation completion signal output when the operation on the operation target components reaches the setting value and identification information on the identification code and can display position information on the operation target components identified on the operation target item illustrated on a display screen. The system may decrease operation failure such as failing to tighten a bolt or a screw, reduce the burden on an operator to make an operation record and can increase the management efficiency of the operation record.

Description

SPECIFICATION

OPERATION MANAGEMENT SYSTEM AND OPERATION MANAGEMENT METHOD

Technical Field

[0001] The present invention relates to an operation management system and an operation management method that can efficiently record and manage an operation of tightening a plurality of bolts and scrcws to a set torquc value.

Background Art

[0002] In a field operation of; lbr example, tightening the bolt of an equipment device at the time of maintenance and inspection, an operator tightens the bolt, then an operation group leader checks the operation and thus the bolt is prevented fixm failing to be tightened and a tightening failure and the like are prevented.

However, in an operation of lightening a plurality of bolts, a tightening failure and failing to tighten the bolt are more likely to occur, and thus it is difficult to completely prevent such artificial mistakes. The cxisting operation management and education that dcpend on human skills are insufficient, and thus it is difficult to prevent such mistakes.

Conventionally, in order to solve such operation failures, systems are disclosed in patent documents I to 4.

[0003] In the management system disclosed in patent document 1, an operator is made to previously perform the operation process of work, and a master image obtained by sensing an image of the operation position of the work is stored. Then, each time the operator pertbrms an operation in the operation position of an operation target item and completes such an operation, an image of the operation position is senscd. When the sensed image of the operation position is checked against the master image, if the master image substantially matching the sensed image is identified and the operation positions on all the mater images can be identified, the operation on the operation target item is determined to be completed.

However, the operation target item is likely to be changed by the environment of the field, aged deterioration, a flaw or the like, and when an image that is sensed afterward at the time of opcration is comparcd with thc master image, a diffcrence is likely to bc produccd to make it difficult to perform identification. Moreover, when the operation target item is a plurality of bolts formed on a circular flange or the like, which have a similar shape, it is difficult to identitv the bolts with other bolts, it is significantly difficult to perform the identification.

[0004] The management system disclosed in patcnt document 2 is a system that uses a torque wrench in which when a screw tightening set torque value is reached, a release mechanism is operated, that uses, as a tightening torque actually acting on the screw, the form of change of the tightening torque acting on the screw, for example, a peak value at which a tendency to incrcasc is changcd to a tendency to dccrcasc and that managcs the statc of tightcning the screw.

However, when a plurality of screws are present in the target, it is impossible to determine whether the screw is a screw on which the tightening operation has already been performed or a screw on which the tightening operation will be performed, and consideration is not given to such a determination. An identification code attached to a constituent component is used for obtaining a set torque for the target.

[0005] A management system disclosed in patent document 3 includes an output means that outputs operation completion information indicating that an opcration using a tool is completed, a positioning means that measures the position of the operation and a processing means that identifies an operation completion place based on the operation completion information and the operation positioning information, and can grasp, together with the position information, the fact that the performance of the operation is completed.

1-lowever, it is likely that, since a process and a device for measuring the position of thc opcration arc complicatcd, thc operation is complicated.

[0006] A management system disclosed in patent document 4 counts a tightening completion signal output when a bolt tightening torque becomes equal to or more than a predetermined value, and determines whether or not the counted value becomes equal to or more than a predetermined value that is previously determined according to the completion of all operations.

However, when an operation of tightening a plurality of bolts is performed, since a determination as to whether or not the bolt is a bolt that has been tightened is not made, it is likely that the same bolt is tightened.

Related Art Document Patent Document [0007] Patent document 1: Japanese Unexamined Patent Application Publication No. 2010-Patent document 2: Japanese Unexamined Patent Application Publication No. 2010-194702 Patent document 3: Japanese Unexamined Patent Application Publication No. 2004-118304 Patent document 4: Japanese Unexamined Patent Application Publication No. F17-1 05469

Disclosure of the Invention

Problems to be Solved by the Invention [0008] In a cunent operation process, an operator involving an operation makes a check record sheet in which operation conditions such as a measurement value are written. It takes a long time to fill out and make the check record sheet, and an error in writing, failing to perform thc writing or thc like is likely to occur. Moreover, sincc what is written is finally converted into data and is stored, it is desirable to reduce the burden on the operator who makes the record data.

Tn view of the foregoing problem, an object to be solved by the present invention is to provide an operation management system and an operation management method that decrease an operation failure such as failing to tighten a bolt or a screw, reduce a burden on an operator who makes an operation record and can increase the efficiency of the management of the operation record.

Means for Solving thc Problem [0009] According to the present invention, as a first means for solving the foregoing problem, there is provided an operation management system including: an operation tool that includes a limit switch which outputs an operation completion signal when an operation on a plurality of operation target components provided in an operation target item reaches a setting value, and an identification code reading portion which is removably attached to each of the operation target components and can read an identification code capable of identif'ing each of the operation target components; and an operation terminal that is electrically connected to the operation tool, can receive the operation completion signal output when the operation on the operation target components reaches the setting value and identification information on the identification code, and can display position information on the operation target components identified on the operation target item illustrated on a display screen.

[0010] According to the present invention, as a second means for solving the foregoing problem, in the first solving means described above, the identification code reading portion can read the identification code when the limit switch outputs the operation completion signal.

[0011] According to the present invention, as a third means for solving the foregoing problem, in the first or second solving means described above, the operation terminal includes: a reading portion that can read, from outside, management data including at least an operation item of the operation target item and a detailed operation item of the operation item; a data input portion that can input to the operation item and the detailed operation item read by the reading portion; an image storage portion that can receive a sensed image of the operation target item and the operation target components of the detailed operation item; and a control portion that can receive the operation completion signal of the operation target components used for operation data and the identification information on the identification code and can display the position information on the operation target components identified on the operation target item illustrated on the display screen.

[0012] According to the present invention, as a fourth means for solving the foregoing problem, in the first to third solving means described above, the operation management system includes an image sensing terminal which is connected such that the sensed image can be transmitted to the image storage portion, and which can sense the image of the operation target item and the operation target components; and a management terminal which is connected such that the management data can be transmitted to the reading portion, which can produce the management data and which can input the operation data produced by the control portion.

[0013] According to the present invention, as a fifth means for solving the foregoing problem, in the first to fourth solving means described above, the operation tool includes an adjustment portion that can adjust a position relationship relative to the identification code on a position where the identification code reading portion is attached.

[0014]According to the present invention, as a sixth means for solving the foregoing problem, in the first to fifth solving means described above, the identification code is attached to an outer circumference of a cylindrical member of an identification jig that includes the cylindrical member surrounding the operation target components and a jig main body supporting the cylindrical member and removably attached to the operation target item.

[0015] According to the present invention, as a seventh means for solving the foregoing problem, in the first to fifth solving means described above, the identification code is attached to an outer circumference of a cylindrical member surrounding the operation target components and removably attached to the operation target item.

[0016] According to the present invention, as an eighth means for solving the foregoing problem, there is provided an operation management method in which, with an operation tool that includes: a limit switch which outputs an operation completion signal when an operation on a plurality of operation target components provided in an operation target item reaches a setting value; and an identification code reading portion which is removably attached to each of the operation target components and can read an identification code capable of identif'ing each of the operation target components, the operation is performed on the operation target components, an operation terminal receives the operation completion signal output when the operation on the operation target components reaches the setting value and identification information on the identification code of the operation target components and position information on the operation target components reading the operation completion signal and the identification code can be displayed on the operation target item illustrated on a screen of the operation terminal.

[0017] According to thc prcsent invention, as a ninth mcans for solving thc foregoing problem, in the eighth solving means described above, after the identification code of the operation target components is read, a sensed image of the operation target components is received and recorded.

Effects of the Invention [0018] In the present invention, as described above, it is possible to recognize the operation target component on which the operation has been completed, from the operation target item illustrated on the display screen. With the operation terminal, it is possible to easily record the measurement value at the time of the operation and the image after the operation. Then, after the operation, the operation target component on which the operation has been completed is marked on the display screen, and thus it is possible to identify a plurality of operation target components of the operation target item. Hence, it is possible to prevent an operation failure such as failing to tighten a screw and easily produce the operation record.

[0019] In the present invention, as described above, the identification information on the identification code of the operation target component on which the operation has been completed is acquired, and thus it is possible to accurately grasp the tightening information and position information on the bolt on which thc opcration has been complctcd, without depending on manpower, and to produce a check record. It is also possible to easily acquire, from the operation tool, the tightening information and position information on the bolt.

[0020] In the present invention, as described above, it is possible to produce the operation data in which the operation completion signal from the operation tool to the operation terminal, the identification information on the identification code and the sensed image from the image sensing terminal are transmitted and recorded. The produced opcration data is fransmitted to the external management terminal, and thus it is possible to illtegrally manage the data.

[0021] Tn thc prcsent invcntion, as described above, it is possiblc to casily idcntift a spccific operation target component from a plurality of operation target components in the sensed image.

In the present invention, as described above, it is possible to easily read the identification code from the outer circumference of the cylindrical member.

In the present invention, as described aboye, it is possible to easily attach the identification code to even a narrow arca. It is also possible to easily read the identification code from the outer circumference of the cylindrical member.

Bricf Dcscription of Drawings [0022] [Fig. 1] A schematic configuration diagram of an operation management system of the present invention; [Fig. 21 A block diagram of the operation management system of the present invention; [Fig. 3A] A side view of a schematic configuration diagram of an operation tool; [Fig. 3B] A plan view of the schematic configuration diagram of the operation tool; [Fig. 3C] A cross-sectional view taken along line A-A of Fig. 3A; [Fig. 41 An illustrative diagram of the operation tool; [Fig. 51 A flowchart of an operation process of an operation terminal of the present invention; [Fig. 6A] An illustrative diagram of a log-in screen of a management terminal; [Fig. 6B] An illustrative diagram of a menu screen of the management terminal; [Fig. 7A] An illustrative diagram of an operation registration screen of the management terminal; [Fig. 7B] An illustrative diagram of an update history screen of the management terminal; [Fig. 8A] An illustrative diagram of an operation time screen of the management terminal; [Fig. SB] An illustrative diagram of a detailed operation time screen of the management terminal; [Fig. 9A] An illustrative diagram of the log-in screen of the operation terminal; [Fig. 9B] An illustrative diagram of the log-in screen of the operation terminal; [Fig. IOA] An illustrative diagram of a check-in/check-out screen of the operation terminal; [Fig. lOB] An illustrative diagram of the check-in/check-out screen of the operation terminal; [Fig. 1 IA] An illustrative diagram of the log-in screen of the operation terminal; [Fig. 11 B] An illustrative diagram of the operation selection screen of the operation terminal; [Fig. l2A] An illustrative diagram of the pre-operation registration screen of the operation terminal; [Fig. 12B] An illustrative diagram of the pre-operation registration screen of the operation terminal; -10 - [Fig. I 3Aj An illustrative diagram of a torque wrench setting screen of the operation terminal; [Fig. 13B1 An illustrative diagram of an in-operation screen of the operation terminal; [Fig. 14A] An illustrative diagram of the performance of a tightening operation in the in-operation screen of the operation terminal; [Fig. 14B1 An illustrative diagram f the completion of the operation in the in-operation screen of the operation terminal; [Fig. 15] An illustrative diagram ofan identificationjig; [Fig. 16A1 A perspective view of a diagram of the identification jig of a variation; [Fig. IÔB] A side view of the diagram of the identification jig of the variation; [Fig. I 6Cj A bottom view of the diagram of the identification jig of the variation; [Fig. 17] An illustrative diagram of an operation data management list table.

Best Mode for Carrying Out the Invention

[0023] An embodiment of an operation management system and an operation management method of the present invention will be described in detail below with reference to accompanying drawings. Fig. I is a schematic configuration diagram of the operation management system of thc present invention. Fig. 2 is a block diagram of the operation management system of the present invention. In the present embodiment, a description will be given below on the assumption that a flange or the like used for a valve which is an operation target is an operation target item 12 and accompanying items, such as bolts and screws, of the valve on which a tightening operation is performed are operation target components 14.

[0024] As shown in the figures, the operation management system 10 of the present invention indudes, as the main basic configuration, an operation terminal 20 that can be brought to and operated in a field by an operator, an image sensing terminal 30 that can shoot the state of an operation and can transmit a sensed image to the operation terminal 20, an operation tool 40 that is a tool to be used in the operation and can transmit a measurement value to the operation terminal 20 and a management terminal 50 that is located in a management place such as an office away from the field and can transmit and receive data with the operation terminal 20.

[0025] The operation terminal 20 includes: a reading portion 22 that can read, from the outside, management data including at least an operation item of the operation target item and a detaflcd operation item of the operation item; a data input portion 24 that can perform input to the operation item and the detailed operation item read by the reading portion 22; an image storage portion 26 that can receive and perform processing on the sensed image of the operation target item and the operation target component of the detailed operation item; a control portion 28 that can receive the operation completion signal of the operation target component used in the detailed operation item and identification information on an identification code, illustrates the operation target item on a display screen, attaches a selection mark to the operation target component on which an operation on the operation target item selected in the detailed operation item is performed, records the sensed image of the operation target component and can produce operation data on which the selection mark on the display screen is changed to the completion mark, displayed and recorded; and a data storage management portion 29 that temporarily stores the operation data and the management data.

-12 - [0026] The reading portion 22 reads the management data transmitted from a data storage management portion 54 of the management terminal 50. The management data is data on the management No., the operation detail, the related device, the operation target, the detailed operation and the like of an operation that is previously recorded by a manager.

The data input portion 24 inputs or selects the names of an operator, an operation group leader and a field supervisor involving the field operation, operator information such as a password, the setting values of the operation item, the detailed operation item and the operation tool and the like.

The image storage portion 26 receives the image sensed by the image sensing terminal 30, and processes it into an image that can be displayed in a display place on the display screen of the operation terminal 20.

The control portion 28 controls the operation of the operation terminal 20. The measurement value transmitted from the operation tool 40 and the image data from the image storage portion 26 are input to the control portion 28. Based on the management data read from the management terminal 50, the control portion 28 records, in the operation data, the measurement value that is the operation completion signal of the field operation and the identification information of identification code and the sensed image. Then, the control portion 28 records the input data of the data input portion 24 on the operation data and produces an operation record. Based on the input data, the control portion 28 records an operation start time and an operation completion time. The control portion 28 acquires a difference between the number of operation target components of the operation target previously recorded and the number of actually performed operations, and thereby can determine the remaining number of operations.

-13 - [0027] The data storage management portion 29 receives and temporarily stores the operation data produced by the control portion 28 and the management data read from the management terminal 50.

The image sensing terminal 30 is a camera that can shoot the state where an operator actually performs an operation on the operation target item and the operation target component in the field. The image sensing terminal 30 is electrically connected to the image storage portion 26 of the operation terminal 20 by wire or wireless, and can transmit the sensed image to the image storage portion 26. The image sensing terminal 30 of the present embodiment is removably attached in such a position as to be able to sense an image of a state preceding the state where the operator actually performs the operation on the operation target item and the state where the operator performs the operation on the operation target component with the operation tool. When a plurality of operation target components are present on the operation target item, such an image sensing terminal 30 individually senses an image of the operation target component on which the operation has been completed. As an example, the image sensing terminal 30 can adjust automatic exposure and auto focus, and can use a CCD camera to convert optical information into an electrical signal.

[0028] Fig. 3A is a side view of a schematic configuration diagram of the operation tool.

Fig. 3B is a plan view of the schematic configuration diagram of the operation tool. Fig. 3C is a cross-sectional view taken along line A-A of Fig. 3A. Fig. 4 is an illustrative diagram of the operation tool. The operation tool 40 is a tool for performing a tightening operation on the operation target components 14 such as a bolt and a screw. In the present embodiment, a description will be given using a torque wrench as an example. In the torque wrench, a limit switch 42 (not shown in Figs. 3A, 3B, 3C), a tool control portion 44 (not shown in Figs. 3A, -14 - 3B, 3C), an identification code reading portion 46, an adjustment portion 48 and a transmission means 49 are provided.

[0029] The limit switch 42 is a switch that is released when the tightening of a bolt or a screw by the torque wrench reaches a predetermined torque setting value to apply a tightening force equal to or more than the torque setting value. The limit switch 42 generates and transmits, to the control portion 28 of the operatioll terminal 20 and the tool control portion 44, which will be described later, the operation completion signal indicating that the tightening force by the torque wrench has reached the setting value and the tightcning opcration has been completed.

When the operation completion signal of the limit switch 42 is input to the tool control portion 44, thc toM control portion 44 transmits, to the identification codc rcading portion 46, a control signal that starts up the identification code reading portion 46.

[0030] The identification code reading portion 46 is a means that reads the identification code which can identif' each of a plurality of the operation target components 14 provided in the operatioll target item 12. As examples of the identification code reading portion 46, a barcode reader, a REID reader or the like can be used.

The idcntification code of the prcscnt embodiment is identification information that indicates the position information and the like of a plurality of operation target components provided in the operation target item. Fig. 15 is an illustrative diagram of an identification jig. As shown in thc flgurc, thc idcntification codes 70 are attached to the idcntification jig 80. The identification jig 80 is formed with cylindrical members 82 and ajig main body 84.

The cylindrical member 82 is a cylindrical member that surrounds, as seen in plan view, the outer circumference of a bolt or a screw which is the operation target component 14. The -15 -cylindrical member 82 is set shorter than the length of the socket of the torque wrench. This prevents the cylindrical members 82 and the torque wrench from being brought into contact when the torque wrench is tightened, and thus it is possible to prevent the amount of lightening of being insufficient. The jig main body 84is formed to be ring-shaped as shown in the figure such that the jig main body 84 can fit to the flange of the operation target item 12.

The jig main body 84 may be formed to be ring-shaped by connecting two semicircular members to each other. With the jig main body 84 configured as described above, it is possible to attach cvcn a flange that is providcd halfway along the piping. In a place of the jig main body 84 opposite the operation target component 14, a hole to which the bolt or the screw which is the operation target component 14 is exposed is formed. The cylindrical member 82 is attached to the hole. On the outer circumference of the cylindrical member 82, the identification code 70 is circumferentially formed. The identification code 70 indicates position information that identifies, among a plurality of operation target components 14, the operation target component 14 on which the operation has been performed. As an example, a one-dimensional code, a RF ID or the like can be used.

[0031] Fig. 16A is a perspective view of a diagram of an identification jig of a variation.

Fig. 16B is a side view of the diagram of the idcntification jig of the variation. Fig. 16C is a bottom view of the diagram of the identification jig of the variation. As shown in the figure, the identification jig 80A of the variation is formed with only the cylindrical member described previously. On the outer circumference of the cylindrical member 82A, the identification code 70 is circumferentially formed. On the bottom surface of the cylindrical member 82A, a removable mcans 86, such as an adhesive tape or a magnet, is formed. The identification jig A described above is attached to each of a plurality of operation target -16 -components 14 formed in the operation target item 12. With the identification code 70 configured as described above, it is possible to recognize, with the identification code reading portion 46, the identification code 70 in all directions of the side surface of the cylindrical member 82.

[0032] The adjustment portion 48 can adjust a position relationship relative to the identification code 70 with respect to the position of the attachment of the identification code reading portion 46. Specifically, the adjustment portion 48 includes, as the main basic configuration, an L-shapcd member 48a, a cover 48b and a spacer 48c.

In the L-shaped member 48a, one surface is fixed to the upper surface of the torque wrench when seen in plan view, and the other surface is arranged a predetermined distance apart from and parallel to the side surface of the torque wrench. On the one surface of the L-shaped member 48a, the transmission means 49, which will be described later, is attached.

In the other surface of the L-shaped member 48a, two long holes 48d parallel to the direction in which the socket 40a of the torque wrench extends are formed. Screws 48e are inserted into the two long holes 48d, and are screwed into a cover 48d arranged in a space between the other surface of the L-shaped member 48a and the side surface of the torque wrench, and thus it is possible to attach the cover 48b to the L-shapcd member 48a. The cover 48b is a member which is formed substantially in the shape of a letter U so as to sandwich and support the upper surface and the lower surface of the identification code reading portion 46. In the space between the L-shapcd member 48a fixed with the screws 48c and the cover 48b, a spacer 48c can be inserted. With the adjustment portion 48 configured as described above, by arbitrarily setting the thickness of the spacer 48c or using a plurality of spacers 48c, it is possible to adjust the space (Z direction) between the L-shaped member 48a and the cover -17 - 48b. The position of the identification code reading portion 46 sandwiched by the cover 48b is moved along the ongitudinal direction of the torque wrench, and thus it is possible to adjust the distance (X direction) between the socket 40a of the torque wrench and the identification code reading portion 46. Furthermore, the position of the screws 48e inserted into the long holes 48d is moved along the longitudinal direction of the long holes 48d, and thus it is possible to adjust the distance (Y axis direction) between the identification code reading portion 46 and the torque wrench. As described above, by adjusting the position of the identification code reading portion 46 in the X, Y and Z dircctions, and thus it is possible to coincide with the position relationship with the identification code 70 according to the optical characteristics (for example, beam spread angle resolution) of the identification code reading portion 46.

[0033] The transmission means 49 that can transmit, when the operation on the operation target components 14 reaches the setting value, the operation completion signal and the identification information on the identification code 70 to the control portion 28 of the operation terminal 20 by wireless or wire is attached to the operation tool 40. Thus, it is possible to electrically connect the operation tool 40 and the control portion 28 of the operation terminal 20.

The management terminal 50 is a management computer on which the manager can previously register the operation detail. The management terminal 50 can transmit or receive the operation data and the management data to or from the operation terminal 20.

The management terminal 50 includes, as the main basic configuration, the reading portion 52, the data storage management portion 54, the data input portion 56 and the document production portion 58. -18-

[0034] The reading portion 52 reads the operation data transmitted from the data storage management portion 29 of the operation terminal 20. The operation data is data produced by the operation terminal 20, such as the measurement value of the operation tool recorded by performance of the field operation by the operator and the sensed image of the operation target item or the operation target component.

The data storage management portion 54 stores and manages the operation data produced by the operation terminal 20 and the previously set management data on the field operation.

[0035] The data input portion 56 previously inputs the management data such as the management No. of the operation, the operation detail, the related device, the operation target and the detailed operation.

The document production portion 58 produces a document such as a daily operation report such as an operation data management list table based on the operation data read from the operation terminal.

An operation management method using the operation management system 10 of the present invention configured as described above will now be described below.

[0036] Fig. 6A is an illustrative diagram of a log-in screen of the management terminal. Fig. 6B is an illustrative diagram of a menu screen of the management terminal. Fig. 7A is an illustrative diagram of an operation registration screen of the management terminal. Fig. 7B is an illustrative diagram of an update history screen of the management terminal. Fig. SA is an illustrative diagram of an operation time screen of the management terminal. Fig. 8B is an illustrative diagram of a detailed operation time screen of the management terminal. As shown in Fig. 6A, the supervisor first logs in the management system with the management -19 -terminal 50. The input of the name of the supervisor is completed by pressing down a selection button 300, selecting from a plurality of supervisors A to C previously registered and pressing down an OK button 301. Then, when a password is input and an OK button 302 is pressed down, the screen is switched to a menu screen shown in Fig. 6B. When logging in is performed, a menu screen 200 is displayed. The menu screen 200 is broadly divided into registration, browsing, data output and setting.

[0037] In the registration, there are an operation registration button 201 and an update history button 310. Whcn the operation registration button 201 is pressed down, the screen is switched to the operation registration screen 202 of Fig. 7A, and thus it is possible to register the operation detail. When the update history button 310 is pressed down, the screen is switched to the update history screen 311 of Fig. 7B, and thus it is possible to display the history of addition, edition and deletion when the operation is registered.

In the browsing, there are an operation time button 312, an operation result button 313 and a procedure manual button 314. When the operation time button 312 is pressed down, the screen is switched to the operation time screen 315 of Fig. SA, and thus it is possible to display the operation start of persons in charge (the operator and the operation group leader), the completion of thc opcration and an elapsed time. When the reference button 316 of a detailed operation time is pressed down, the screen is switched to the detailed operation time screen 317 of Fig. 8B, and thus it is possible to display persons in charge, the start of the operation of operation target components (a screw No. 1 and a screw No. 2) of an operator A as an example, the completion of the operation and an elapsed time. -20 -

[0038] When the operation result button 313 shown in Fig. 6B is pressed down, it is possible to display the operation data. When the procedure manual button 314 is pressed down, it is possible to display the procedure manual of the operation.

In the data output, there is a CSV output button 318, and, when the CSV output button 318 is pressed down, it is possible to output data in a CSV format.

In the setting, there are an operator qualification setting button 319, a torque wrench setting button 320, a torque value setting button 321, a plant setting button 322, an operation classification setting button 323 and an import button 324, and thus it is possible to perform various types of settings.

[0039] Fig. 7A is the operation registration screen 202, and the items of the management No. 203, the operation detail 204, the related device 205, the operation target 206 and the detailed operation 207 are displayed. As an example, when the operation detail 204 is a scrum valve operation, the items of the related device 205 and the operation target 206 can be selected.

Then, when in the item of the operation target 206, the scrum valve that is the operation target item is selected, on the detailed operation 207, a hood-body tightening bolt and an actuator lid tightening bolt that are the operation target components are displayed. In the detailed operation 207, it is also possible to press down a change button 208 to select a plurality of other detailed operations. After the completion of the registration, an OK button 209 is pressed down to store the operation detail. After the completion of the storage, the screen is returned to the management menu screen 200 shown in Fig. 6B.

[0040] Fig. 5 is a flowchart of an operation process of the operation terminal according to the present invention. -21 -

In the operation terminal 20, an operation related person is first registered (step 1).

Figs. 9A, 9B arc iHustrativc diagrams of the log-in scrccn of the operation terminal. In thc present embodiment, a supervisor 210, an operation group leader 211 and an operator 212 are registered. As shown in Fig. 9A, a name 213 and a password 214 each are input, and a registration button 215 is pressed down. A plurality of operators 212 can be registered.

After the completion of the registration, the display fields of the supervisor 210, the operation group leader 211 and the operator 212 are changed in color. Then, as shown in Fig. 9B, an opcration start button 216 is made effective, and thus it is possible to makc thc opcration proceed.

[0041] Figs. IOA, lOB are illustrative diagrams of the check-in/check-out screen of the opcration terminal. Whcn a cheek-in/check-out button 217 shown in Fig. 9B is prcsscd down, as shown in Fig. bA, the screen is switched to a check-in/check-out screen 218. In an office PC field 219 on thc screen of thc management terminal 50, thc operation itcm is displayed. Then, when the operation item to be checked out is selected, the display is changed in color, and, when a check-out button 220 is finally pressed down, as shown in Fig. lOB, the operation item that has been checked out is displayed in a terminal field 221 on the scrccn. By this operation, thc opcration itcm data on thc management terminal 50 is transmitted to the side of the operation terminal 20. Finally, a back button 222 is pressed down, and thus the check-in/check-out screen 218 is closed.

[0042] Fig. 1 1A is an illustrative diagram of the log-in screen of thc opcration terminal. Fig biB is the operation selection screen of the operation terminal. As shown in Fig. 1 IA, when the cffcctivc opcration start button 216 is pressed down, thc opcration by thc opcrator is -22 -started (step 1 00), the operation start time is recorded and the operation time measurement is started (stop 101).

As shown in Fig. I lB. on the screen, the operation selection screen 223 is displayed.

In the operation selection item, a list of the operation items previously read from the management terminal 50 is displayed. The operation item (in the present embodiment, the serum valve operation) in which the operation is performed is selected, the display field is changed in color and thereafter the 01K button (then the button 224) is pressed down (step 2).

[0043] Figs. 12A, 12B arc illustrative diagrams of the prc-operation registration scrccn of the operation terminal. As shown in Fig. 12A, on the pre-operation registration screen 225, the serum valve operation is displayed in the field of an operation detail 226, and a device number is displayed in the field of a related device 227, and thus it is possible to constantly check the operation detail and the related device that have been selected. Then, the operation target itcm is checked (step 3). In order to perform operation target registration, the image sensing terminal 30 that is connected to the operation terminal 20 is used to shoot the related device (operation target item). After it is checked that the related device is displayed on a preview screen 228, a shooting button 229 is pressed down to perform the shooting.

[0044] An image of the related device that has been shot is reflected on a screen 230. Then, as shown in Fig. l2B, the detailed operation (in the present embodiment, a hood-body tightening bolt 231) of a detailed operation selection field is selected (step 4), the OK button (then a button 232) is pressed down and the screen is sitehed to an operation item setting screen.

In the present embodiment, a description will be given using a torque wrench as the operation tool. Fig. 13A is an illustrative diagram of a torque wrench setting screen of the -23 -operation terminal. Fig. 13B is an illustrative diagram of an in-operation screen of the operation terminaL On the torque wrench setting screen 233, operator information is first input to perform operator registration (step 5). As shown in Fig. 13A, operators in charge of the items of an operator 234, an operation group leader 235 and a supervisor 236 on the display screen are selected. In the present embodiment, the tightening operation by the operator is performed, and then the tightening operation by the operation group leader is described. Then, the setting registration on the operation tool is performed. A management number 237 for torque wrench setting registration on the display screen is registered. The management number is a management number for the torque wrench previously set, and can be selected from a registration list. Then, when the management number for the torque wrench is set, a target value 238 for the torque value of the selected torque wrench and a range 239 are displayed on the screen. In the field of a setting value 240 on the display screen, the operator references the target value 238 for the torque value of the torque wrench and the range 239 on the display screen to input and register the torque value set in the torque wrench (step 6). When the setting value is input, the OK button (then, a button 241) is made effective. If the input value does not fall within the range of the target value, the OK button is not made effective. When the OK button is pressed down, the screen is switched to the in-operation screen.

[0045] As shown in Fig. 13B, on the in-operation screen 242, the items of an operation detail 243, a component No. 244 and a supervisor, an operation group leader and an operator 246 are displayed, and a number field corresponding to the number of operation target components, a diagram 249 of the operation target item and the operation target component (in the present embodiment, as an example, a schematic plan view of 12 tightening bolts -24 -attached to the flange), the torque value 252 and an operator 250 are displayed. In this way, the operator can constantly check the torque value set in the operation.

[0046] Then, a bolt tightening operation is started (step 7). With respect to the start time of the entire operation, when the operation start button 216 effective on the log-in screen of the operation terminal shown in Fig. 1 IA is pressed down, the operation by the operator is started (step 100), the operation start time is recorded and the operation time measurement is started (step 101).

Before the start of the bolt tightening operation, the identification jig 80 is prcviously attached to the operation target item 12. The operator can select an arbitrary bolt from a plurality of bolts.

[0047] The operator uses the torque wrench specified by the tightening operation to tentatively tighten all the bolts of the operation target components 14 and then perform main tightening on an arbitrary bolt.

When the screen is switched to the in-operation screen 242 shown in Fig. 13B, the bolt lightening start time is recorded (step 102). Then, the operator performs the tightening operation of tightening the bolt with the torque wrench. When the tightening of the bolt reaches the setting value, the limit switch is operated (step 103), the tightening is released and the tightening completion signal that is the measurement value of the torque value is transmitted to the control portion 28 of the operation terminal 20.

[0048] When the operation completion signal is transmitted to the control portion 28, the box 248 of bolt number 1 on the screen of the operation terminal 20 is changed in, for example, color. A selection mark (° mark) 254 is provided to a place corresponding to bolt number 1 -25 -of the operation target item 12 shown in Fig. 249 on the screen, and thus it is possible to recognize thc tightening bolt in operation.

A re-operation button 251 is a button that is pressed down when the operation is performed again, for example, because it is impossible to continue the operation on the bolt in the tightening operation.

[0049] Fig. 14A is an illustrative diagram for the performance of the tightening operation on the in-operation screen of the operation terminal. Fig. 14B is an illustrative diagram for the completion of the operation on thc in-operation screen of the operation terminal. The tightening completion signal is also transmitted to the tool control portion 44 of the operation tool 40. When the operation completion signal of the limit switch 42 is input, a control signal for starting up is transmitted from the tool control portion 44 to the identification code reading portion 46. The identification code reading portion 46 reads the identification code attached to each of the operation target components. Position information on the identification code that has been read is transmitted to the control portion 28 of the operation terminal 20. The control portion 28 recognizes, from the position information of the identification code, the bolt on which the tightening operation has been completed (step 104), and the box 248 of bolt number 1 is changed in, for example, another color.

[0050] Then, the bolt on which the tightening operation has been completed is shot (step 105).

The sensed image is transmitted from the image sensing terminal 30 to the image storage portion 26 of the operation terminal 20. Whether or not this shooting is started within 4 seconds is determined (step 106). If the shooting is started within 4 seconds after the reading of the identification code, the shooting of the bolt on which the tightening operation has been completed is determined to be completed (YES). On the other hand, if the shooting -26 -is started after 4 seconds, the shooting of the bolt on which the tightening operation has been completcd is dctermincd not to be complcted. In this case, the operation of tightcning thc bolt is performed again, and the process returns to the step of the limit switch operation (NO).

[0051] As shown in Fig. 14A, when the photograph is shot and stored, if in the box 248 of bolt number 1, the completion mark 257 indicating the completion of the operation and the completion mark 258 where the selection mark (° mark) on the operation target component 14 of the operation target itcm 12 in thc figurc is filled arc displaycd, the bolt tightcning completion time is recorded (step 107). Near the completion mark 258 of the operation target component on which the tightenillg operation has been completed, an icon 259 with which the shot photograph can be referenced is provided. Then, if the tightening operation is performed in the order of bolt numbers 1 to 12, the box 260 of bolt number 2 on which the operatioll is subsequently performed is changed in, for example, color, and the selection mark 261 (° mark) on the operation target component of the operation target item in the figure is provided.

[0052] Then, ill the data storage management portion 29 of the operation terminal 20, the operatioll data including the photograph produced in the control portion 28 is temporarily recorded (step 108). Thereafter, an operation number counter counts the number of times the tightening operation on the tightening bolt is performed (step 109).

Then, the tightening bolt number is determined. In the specific determination of the tightening bolt number, it is possible to dctermine the remaining number of times the operatioll is performed by obtaining a difference between the bolt number of the previously registered operation target component (step 110) and the number of times the operation is actually performcd (step 111).

[0053] As a result of the determination, if the operation of tightening the bolt is perfbrmed, on bolt numbers 2 to 12, the operations in steps 103 to 109 are repeatedly performed.

As shown in Fig. 14B, when the operation of tightening a plurality of bolts is all completed, the completion mark 257 is provided in the display fields of all bolt numbers on the in-operation screen, and the completion mark 258 is provided on all the operation target components of the operation target item in the figure. Then, a pop-up screen 262 of the operation completion is displayed. When an OK button 263 is pressed down, the pop-up screen is closed. Whcn an opcration completion button 264 on thc display scrccn is prcsscd down, the screen is switched to the torque wrench setting screen 233 shown in Fig. 13A.

When the tightening operation by the operator is completed, the display of the operator 234 is changed, and thus it is possible to check that the operation is completed. Then, after the completion of the operation by the operator, if the tightening operation by the operation group leader is performed, the person in charge of the operation in the operation group leader 235 in the operator registration shown in Fig. 13A is selected. On the operation group leader, the same tightening operation as on the operator is also performed.

[0054] When the tightening operation by the operation group leader is completed, and the operation completion button 264 on thc display scrccn shown in Fig. 14B is pressed down, the screen is switched to the operation selection screen 223 shown in Fig. IIB. When an operation completion button 265 on the operation selection screen is pressed down, the operation time measurement is completed (step 112), the operation completion tune of the operator is recothed and the selected operation item is completed (step 113).

When all the detailed operations are completed, and data is input, the operation is completed (step 8).

[0055] Fig. 17 is an illustrative diagram of an operation data management list table. In the document production portion 58 of the management terminal 50, based on the operation data read from the operation terminal 20, documents such as the operation data management list table and a daily operation report are produced. In the operation data management list table of the present embodiment, as an example, fbr each of the operation target components of the detailed operation item, the person in charge, the operation start time, the operation completion time, a torque wrench management number, the torque value, photograph rccording and thc like arc displayed.

With the operation management system of the present invention described above, it is possible to easily recognize the operation target component in operation from the operation target item shown in the figure on the display screen. With the operation terminal, it is also possible to easily record the measurement value at the time of operation and the image after the operation. Then, after the operation, on the display screen, the operation target component on which the operation has been completed is marked, and thus it is possible to identify a plurality of operation target components of the operation target item. Hence, it is possible to prevent an operation failure such as failing to tighten a bolt and easily produce the operation record.

Industrial Applicability

[0056] The present invention can be widely applied, for example, especially when an inspection operation and recording are performed on an equipment device to which a plurality of bolts are attached. -29 -

List of Reference Symbols [0057] 10: operation management system, 12: operation target item, 14: operation target component, 20: operation terminal, 22: reading portion, 24: data input portion, 26: image storage portion, 28: control portion, 29: data storage management portion, 30: image sensing terminal, 40: operation tool, 40a: socket, 42: limit switch, 44: tool control portion, 46: identification code reading portion, 48: adjustment portion, 48a: L-shaped member, 48b: coyer, 48c: spacer, 48d: long hole, 48e: screw, 49: transmission means, 50: management terminal, 52: reading portion, 54: data storagc management portion, 56: data input portion, 58: document production portion, 70: identification code, 80, 80A: identification jig, 82, 82A: cylindrical member, 84: jig main body, 86: removable means, 200: menu screen, 201: operation registration button, 202: operation registration screen, 203: management No., 204: operation detail, 205: related device, 206: operation target, 207: detailed operation, 208: change button, 209: OK button, 210: supervisor, 211: operation group leader, 212: operator, 213: name, 214: password, 215: registration button, 216: operation start button, 217: check-lit/check-out button, 218: check-in/check-out screen, 219: office PC field, 220: check-out button, 221: terminal field, 222: back button, 223: operation selection screen, 224: subsequent button, 225: pre-opcration registration screen, 226: operation detail, 227: related device, 228: preview screen, 229: shooting button, 230: screen, 231: hood-body tightening bolt, 232: subsequent button, 233: torque wrench setting screen, 234: operator, 235: operation group leader, 236: supervisor, 237: management number, 238: target value, 239: range, 240: setting value, 241: subsequent button, 242: in-operation screen, 243: operation detail, 244: component No., 246: supervisor, operation group leader, operator, 248: box, 249: figure, 250: operator, 251: re-operation button, 252: torque value, 254: selection mark (° mark), 257: -30 -completion mark, 258: completion mark, 259: icon, 260: box, 261: selection mark (° mark), 262: pop-up screen, 263: OK button, 264: operation completion button, 265: operation completion button, 300: selection button, 301: OK button, 302: OK button, 310: update history button, 311: update history screen, 312: operation time button, 313: operation result button, 314: procedure manual button, 315: operation time screen, 316: reference button, 317: detailed operation time screen, 318: CSV output button, 319: operator qualification setting button, 320: torque wrench setting button, 321: torque value setting button, 322: plant setting button, 323: operation classification setting button, 324: import button

Claims

CLAIMS1. An operation management system comprising: an operation tool that includes: a limit switch which outputs an operation completion signal when an operation on a plurality of operation target components pmvided in an operation target item reaches a setting value; and an identification code reading portion which is removably attached to each of thc operation target components and can read an identification code capable of idcntiting each of the operation target components; and an operation terminal that is electrically connected to the operation tool, can receive the operation completion signal output when the operation on the operation target components reaches the setting value and identification intbrmation on the identification code and can display position information on the operation target components identified on the operation target item illustrated on a display screen.
2. The operation management system of claim 1, wherein the identification code reading portion can read the identification code when the limit switch outputs the operation completion signal.
3. The operation management system of claim! or 2, wherein the operation terminal includes: a reading portion that can read, from outside, management data including at least an operation item of the operation target item and a detailed operation item of the operation item; adatainputportionthatcaninputtotheoperationitemandthedetailed operation item read by the reading portion; an image storage portion that can receive a sensed image of the operation target item and the operation target components of the detailed operation item; and a control portion that can receive the operation completion signal of the operation target components used for operation data and the identification information on the identification code and can display the position information on the operation target components identified on the operation target item illustrated on the display screen.
4. The operation management system of any one of claims I to 3, further comprising: an image sensing terminal which is connected such that the sensed image can be transmitted to the image storage portion, and can sense the image of the operation target item and the operation target components; and a management terminal which is connccted such that thc management data can be transmitted to the reading portion, can produce the management data and can input the operation data produced by the control portion.
5. The operation management system of any one of claims 1 to 4, -33 -wherein the operation tool includes an adjustment portion that can adjust a position relationship relative to the identification code on a position where the identification code reading portion is attached.
6. The operation management system of any one of claims 1 to 5, wherein the identification code is attached to an outer circumference of a cylindrical member of an identification jig that includes the cylindrical member surrounding the opcration target components and a jig main body supporting thc cylindrical mcmbcr and removably attached to the operation target item.
7. The operation management system of any one of claims Ito 5, wherein the identification code is attached to an outer circumference of a cylindrical member surrounding the operation target components and removably attached to the operation target item..
8. An operation management method, wherein, with an operation tool that includes: a limit switch which outputs an operation completion signal when an operation on a plurality of operation target components provided in an operation target item reaches a setting value; and an identification code reading portion which is removably attached to each of the operation target components and can read an identification code capable of identifying each of the operation target components, the operation is performed on the operation target components, -34 -an operation terminal receives the operation completion signal output when the operation on the operation target components reaches the setting value and identification information on the identification code of the operation target components and position information on the operation target components reading the operation completion signal and the identification code can be displayed on the operation target item illustrated on a screen of the operation terminal.
9. The operation management method of claimS, wherein, after the identification code of the operation target components is read, a sensed image of the operation target components is received and recorded.Amendments to the claims have been filed as follows:CLAIMS1. An operation management system comprising: an operation tool that includes: a limit switch which outputs a respective operation completion signal when an operation on each of a plurality of operation target components provided in an operation target item reaches a sefting value; and an identification code reading portion which, when the operation tool is removably attached to each of the operation target components, can read an identification code capable of identifying each of the operation target components; and an operation terminal that is electrically connected to the operation tool, can receive the operation completion signal output when the operation on each of the operation target components reaches the setting value, and the identification code of the operation target 0 component, and can display position information on the operation target components identified on the operation target item illustrated on a display screen.2. The operation management system of claim L wherein the identification code reading portion can read the identification code when the limit switch outputs the operation completion signal.3. The operation management system of claim 1 or 2, wherein the operation tenninal includes: a reading portion that can read, from outside, management data including at least an operation item of the operation target item arid a detailed operation item of the operation item; a data input portion that can input to the operation item and the detailed operation item read by the reading portion; an image storage portion that can receive a sensed image of the operation target item and the operation target components of the detailed operation item; and a control portion that can receive the operation completion signal of the operation target components used for operation data and the identification information on the identification code and can display the position information on the operation target components identified on the operation target item illustrated on the display screen.0 4. The operation management system of any one of claims to 3, further comprising: an image sensing terminal which is connected such that the sensed image can be transmitted to the image storage portion, and can sense the image of the operation target item and the operation target components; and a management terminal which is connected such that the management data can be transmitted to the reading portion, can produce the management data and can input the operation data produced by the control portion.5. The operation management system of any one of claims 1 to 4, wherein the operation tool includes an adjustment portion that can adjust a position relationship relative to the identification code on a position where the identification code reading portion is attached.6. The operation management system of any one of claims 1 to 5, wherein the identification code is attached to an outer circumference of a cylindrical member of an identification jig that includes the cylindrical member surrounding the operation target components and a jig main body supporting the cylindrical member and removably attached to the operation target item.7. The operation management system of any one of daims I to 5, wherein the identification code is aached to an outer circumference of a cylindrical 0 member surrounding the operation target components and removably attached to the operation t*t 8. An operation management method, wherein, with an operation tool that includes: a limit switch which outputs a respective operation completion signal when an operation on each of a plurality of operation target components provided in an operation target item reaches a setting value; and an idcntification codc reading portion which, when the operation tool is removably attached to each of the operation target components, can read an identification code capable of identifying each of the operation target components, the operation is performed on each of the operation target components, an operation terminal receives the operation completion signal output when the operation on each of the operation target components reaches the setting value, and the identification code of the operation target component, and position information on the operation target components reading the operation completion signal and the identification code is displayed on the operation target item illustrated on a screen of the operation terminal.9. The operation management method of claim 8, wherein, after the identification code of the operation target components is read, a sensed image of the operation target component is received and recorded. c'J