JP2001273020A - Control system of production line - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a control system of a production line making it possible to decrease a cost of an introduction of the system and also to flexibly cope with a layout change of the production line. SOLUTION: A control data server 1 collects information on such as a trouble and operation situation of processing equipment 2A, 2B, etc., from controllers 3A, 3B, etc., controlling each process of the production line, then the collected information is put in order and preserved. The controlled data is transmitted through a net work 10 to information displays PC 11A, 11B, etc., arranged at important points, by a www function server. Each important display receives and indicates the information on trouble, operation situation or maintenance transmitted from the control data server by a browser function.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to general industries, in particular, having a plurality of processing devices and management devices such as machining and assembling processes, grasping the production status and the operation status of the devices, and transmitting failure information to a corresponding site. The present invention relates to a production line management system for distribution.

[0002]

2. Description of the Related Art Conventionally, in a manufacturing line of an assembly process such as a manufacturing industry, a management computer system and a large electronic display panel called "Andon" are used to display production plans and results, and to request supply necessities. In addition, information on failures is displayed, and on-site information is shared.

At the initial stage of the introduction of the computer management system, as shown in FIG. 11, a medium-sized dedicated management computer 100 displays a production plan, actual results, the status of parts for which supply is insufficient, etc. on a large display panel 101. Each processing device 10
The individual failure information of 2A, 102B,... Can be obtained, for example, by using the indicator lights 103A, 103B,.
We have been managing the state of the production line with "Lathe-2 Lighting of minor fault indicator light".

In recent years, as shown in FIG. 12, the state of each processing apparatus 102A, 102B,... Can be taken into the management computer 100 via a network 105 from controllers 104A, 104B,. And each of the processing devices 102A, 102B,
It has become technically possible to display the operation status of... On the large electric display panel 101.

[0005]

However, even such a recent production line management system has the following problems.

(1) The introduction price of a large-sized light-emitting display panel is high, and a large investment cost is required.

(2) 4 lines or 5 lines for a low cost system
A fixed number of lines is displayed on the order of the number of lines, but in such a case, it is impossible to cope with a case where a change is required depending on the use of the used line.

(3) A system capable of displaying the number of lines freely is very expensive.

(4) When the line configuration is changed, for example, when a product is changed, it is necessary to relocate a large display panel, which has a large effect on the cost of changing the line or when the existing position is not moved. This is a great restriction for changing the line layout.

[0010] For this reason, conventionally, the installation of a large-sized light-emitting display panel is limited to the introduction to a large-sized production processing line, but is not introduced to a small-to-medium-sized production line. In the assembly processing manufacturing industry, the emergence of an alternative system has been desired.

The present invention has been made to solve such a conventional technical problem, and can reduce the system introduction cost and can flexibly cope with a layout change of a manufacturing line. It is an object to provide a simple production line management system.

[0012]

According to the present invention, production line management information such as failure information and operation information from each processing device on a production line is transmitted to a network or a direct I / O system connecting the respective devices.
Collected through I / O wiring, multiple low-cost PCs (personal computers) are deployed as information display PCs at various points in the production line, and these are connected to a central management data server via a network to manage Production line management information collected from each processing device by the
A system for distributing and displaying information to each information display PC using the W server-browser function is introduced.

The manufacturing line management system according to the first aspect of the present invention collects and organizes information on the failure and operation status of the processing apparatus from a controller that manages individual processes of the manufacturing line,
A management data server for storing the information, a PC for displaying information installed at an important location, and a network for connecting the management data server and the PC for displaying information to perform information communication; Has a WWW server function, the information display PC has a browser function, and uses the WWW server function of the management data server and the browser function of the information display PC to provide failure information, operation status information or It distributes and displays the maintenance information.

In the manufacturing line management system according to the first aspect of the present invention, the management data server collects, organizes, and saves information on the failure and operation status of the processing apparatus from a controller that manages individual processes of the manufacturing line. WW of the management data
The information is distributed via the network to the information display PCs arranged at important places by the W server function. P for each information display
C receives and displays the failure information, operation status information, or maintenance information sent from the management data server by the browser function.

As a result, the following effects can be obtained.

(1) PC for displaying information installed on the line
For this, a low-priced ordinary PC or a network client computer having only a browser function can be adopted, and the investment cost for introducing the system can be reduced.

(2) The display contents of the information display PC are more flexible and can be realized at a lower price than the fixed display electronic display panel.

(3) Even if a request for strengthening a monitoring place or improving work after the operation is started, it is sufficient to simply connect an additional display PC to the network, so that it is possible to respond flexibly. .

(4) Even when there are a plurality of manufacturing lines, a plurality of WWW servers and a display PC are connected to one network, and individual URLs are provided for each management data server which manages each line on the network. Can be managed simply by setting the display line. In addition, when the status of the display line is changed due to a line change or the like, the display P
It can be reused simply by changing and registering the URL of the management data server accessed from C to the corresponding one,
It can respond flexibly to line changes.

According to a second aspect of the present invention, in the manufacturing line management system according to the first aspect, the management data server pushes the failure information, the operation status information, or the maintenance information to the information display PC by a push type or a Java program. If the failure information, the operation status information or the maintenance information is sent from the management data server, it can be automatically displayed even if the operator does not operate,
The operation of accessing the management data server sequentially for information collection from the information display PC is not required, and the monitoring function of the production line can be enhanced.

According to a third aspect of the present invention, in the production line management system according to the first or second aspect, an alarm device is provided at each part of the production line, and the management data server directly transmits the alarm device at the corresponding location. Or through the information display PC in charge, and when a failure occurs, an alarm can be generated near the location of the failure to notify the worker.

According to a fourth aspect of the present invention, in the manufacturing line management system of the first aspect, the management data server calls a mobile telephone number set in advance when a failure occurs. Can be called directly.

According to a fifth aspect of the present invention, in the manufacturing line management system according to the third aspect, the management data server transmits an operation command to the alarm device and the information display PC.
A CGI or Java program for displaying an alarm confirmation button on the PC, and canceling the operation command when a confirmation button operation signal is received from the information display PC. The alarm can be activated only for a certain period of time, and the alarm does not continue to operate for a certain period of time regardless of whether or not the alarm has been confirmed, and does not stop when the alarm has not been confirmed.

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below in detail with reference to the drawings. FIG. 1 shows a system configuration according to a first embodiment of the present invention. The production line management system includes a management data server 1, a processing device 2A on the production line,
2B, 2C,..., The respective processing devices 2A, 2B, 2
.., And controller information (I / F) 5A, 5B, 5C,.
Reference numerals 4A, 4B,... Indicate alarms similar to those of the related art, and an alarm is issued by sounding (and, in some cases, blinking of a lamp).

The device controllers 3A, 3B, 3C,...
Is composed of a PLC and a sequencer. The controller interfaces 5A, 5B,...
, And transmits the information to the management data server 1. For example, as shown in FIG. 3B, the controllers 3A, 3B,.
0, the interface unit corresponds to the interface unit. If the network interface does not have a unified network interface, the interface unit 21 becomes a common unit as shown in FIG. The signal wiring 22 may be a direct signal wiring 22 from the site to the management data server as shown in FIG.

As a feature of the present embodiment, the manufacturing line management system further includes an L
Several information display PCs 11 connected by AN 10
A, 11B,... Are provided. The management data server 1 incorporates a WWW server function, and each of the information display PCs 11A, 11B,... Has a web browser function.

Next, the operation of the production line management system having the above configuration will be described. As shown in FIG. 2, the processing devices 2A,
Control and monitoring of 2B,... Are performed by device controllers 3A, 3B,. Each controller 3A,
Information relating to operation and maintenance from 3B,... Is collected in the management data server 1 via the controller interfaces 5A, 5B,. The collected information 51 includes failure information, production information, and the like of each of the processing devices 2A, 2B,.
This is management information such as device operation information.

As shown in FIG. 3, the controllers 3A, 3A
If the means for providing information from B,... To the management data server 1 has a unified specification, the unified network 2
0 (FIG. 6 (b)), if not unified, use a gateway-like interface unit 21 as shown in FIG. 7 (a), or use PI / The O signal wiring 22 is used.

As shown in FIG. 4, the management data server 1
Is composed of a data collection unit 31, a data editing unit 32, and a WWW server unit 33. The data collection unit 31 collects management information of each processing device, and organizes the management information in the data editing unit 32. Although the contents of data arrangement are not particularly specified, if it is failure information, the occurrence time, serious failure / light failure is determined, and if it is operation information, the operation rate and operation time are calculated,
In the case of management information such as a refueling time or a blade which requires preventive maintenance, it includes a process of cumulatively calculating a use time. Then, the data arrangement contents are registered in the WWW server unit 33.

The operating status management LAN 10 connects the management data server 1 to the information display PCs 11A, 11B,... Using a standard protocol, for example, a TCP / IP protocol. The management information 52 collected and edited by the management data server 1 and registered in the WWW server 33 is
Via this LAN unit 10, the information display PCs 11A, 1A
.. Are received and displayed by the general-purpose browser software 1B,.

In a method of accessing a normal WWW server on a homepage, an information display PC 1 as a terminal is used.
The data update request and the "update with browser" process are used on the WWW server side from 1A, 11B,. However, in the case of this system, the information is forcibly transmitted from the homepage side to the information display PCs 11A, 11A.
By using a push-type distribution method of transmitting to B,... Or a method using a Java applet, information can be automatically updated without an operator operating the information display PCs 11A, 11B,. I have to. FIG. 5 shows a PC 1 for information display by such push-type distribution.
Management information 52 distributed and displayed on 1A, 11B,...
Is shown.

Each of the information display PCs 11A, 11B,.
Automatically starts the W of the management data server 1
The startup processing shown in FIG. 6 is executed so as to be connected to the WW server function. That is, when the power is turned on and started, the basic OS is started first (step S1), the web browser is started (step S2), the WWW server function of the management data server 1 is accessed, and the information to be distributed is obtained. If there is, download it (step S3). Thereafter, the display information is updated each time data is distributed from the management data server 1 (step S4).

The above-mentioned manufacturing line management system operates as follows.

<When an alarm occurs> Processing devices 2A, 2
When a failure occurs in any of B,..., The worker knows the occurrence of the failure by sounding or lighting the alarms 4A, 4B,. Next, the worker refers to the display contents of the information display PCs 11A, 11B,. The information display PCs 11A, 11B,...
The management information is transmitted from the PC, and the cause of the alarm can be determined from the display contents of the PC. Therefore, the worker checks the contents, determines the priority of the work, and performs work such as maintenance.

<Provision of Preventive Maintenance Information> Information Display PC 1
1A, 11B,..., In addition to the display of the failure, maintenance of lubricating oil and maintenance information in accordance with a predetermined rule are displayed in order of priority. If there is no other failure or the like, the deadline of several days ahead or even several hours ahead is displayed with the “scheduled deadline” added. Therefore, the worker can see the display information, grasp the relationship between other tasks, and perform maintenance preparatory work, or perform the maintenance work somewhat earlier.

As described above, the production line management system according to the first embodiment has the following advantages.

(1) An information sharing system on a factory line can be easily realized at low cost.

(2) By providing the preventive maintenance information, efficient on-site work can be realized. In other words, in the past, work was performed systematically because reporting of equipment failure, provision of the start of periodic maintenance such as refueling and maintenance, and provision of production information were separate systems. However, according to the present embodiment, all information can be shared at the work site, so that work efficiency can be improved.

(3) The place where information can be browsed is arbitrary. That is, the management information can be viewed anywhere near the place where the information display PC is installed.
The number of display PCs can be increased simply by increasing the number of information display PCs connected to the LAN 10. Thus, each time the alarm sounds, the contents can be checked from the information display PC closest to the worker without having to rush to the central management data server or individual devices to check the contents.
Unnecessary movement can be avoided, and work efficiency can be improved.

(4) Compared with the server / client type system, when software is changed, only the WWW server is modified, so that less maintenance is required.

(5) It is possible to flexibly cope with a change in display contents and an increase or decrease in the number of installed units. In other words, a conventional fixed electro-optical display panel only displays characters (a display panel capable of displaying graphics is expensive and cannot be used in a production line), but if it is compatible with a WWW server, it can reduce the character size and display contents. Can respond flexibly.

(6) It is possible to flexibly cope with rearrangement of lines. 1 and 2 show the configuration and function of the management system for a single production line. However, in the management system for a plurality of production lines as shown in FIG. Are installed so as to correspond to the lines A and B, respectively, and the required number of information display PCs is also installed individually for each line. And each information display PC
To identify which management data server the server belongs to, the URL of the management data server accessed by the server is set to that of the corresponding server. As a result, even for a management system for a plurality of production lines, all necessary devices can be connected by a single LAN 10.

Also, the information display P
When it is necessary to increase or decrease C, as shown in FIG. 7B, an information display PC connected to the LAN 10 is interchanged between the lines A and B, unnecessary parts are removed, and shortages are added. It can be dealt with only.

Next, a manufacturing line management system according to a second embodiment of the present invention will be described with reference to FIG.
The second embodiment differs from the first embodiment shown in FIGS. 1 and 2 in that the management data server 1 has the sound control right of the alarm device.

The information managed by the WWW server function of the management data server 1 is management information such as failure information, operation status information, and preventive maintenance information. It is important that the worker recognizes the failure and confirms the location of the failure. Therefore,
In the first embodiment, the generation of the alarm is performed by the processing devices 2A and 2A.
B,... Alarms 4A, 4 installed directly on each
By operating B,..., The operator is notified of the processing apparatus in which the failure has occurred. However, in the second embodiment, the failure data is collected by the management data server 1 and the alarm output is also output to the management server. The data server 1 controls.

In the system shown in FIG. 8A, the management data server 1 determines failure information based on management information sent from the device controllers 5A, 5B,. , And the alarms 4A, 4B,... Are sounded directly.

The system shown in FIG. 2B utilizes the program transfer function for the contents transmitted from the WWW server unit of the management data server 1 and uses the information display PCs 11A, 11A.
B, ..., output a command to issue an alarm, and the information display PC 11
On the A, 11B,... Side, the alarms 4A, 4B,.

Thus, even if a common loud buzzer or the like is not used, it is possible to know new occurrence of trouble information and the like and to quickly grasp the situation by referring to the information display PC.

As shown in FIG. 9, the management data server 1 may automatically call the telephone number of the mobile telephone registered in advance and report failure information.

Next, a manufacturing line management system according to a third embodiment of the present invention will be described with reference to FIG. The manufacturing line management system according to the third embodiment is characterized in that a function for feeding back an alarm confirmation is further provided to the system according to the second embodiment shown in FIG.

In the case of the second embodiment, it is impossible to feed back the action that the worker has confirmed the alarm. Therefore, in the case of the second embodiment, the alarm is automatically stopped after sounding for an appropriate time from the beginning. Therefore, the management data server cannot confirm whether the worker has confirmed the alarm. Normally, at a site where several maintenance workers are waiting, it is not a problem because someone checks the alarm, but at a site where a large area is handled by a small number of people, the confirmation operation is performed when the alarm occurs. There is a problem that the sound is noisy because the alarm continues to sound until it ends. Also, in the alarm confirmation processing from the central operation panel or the management data server, the maintenance staff must move to a fixed place to check the alarm each time to reset the alarm, and the alarm reset is troublesome. There is.

Therefore, in the third embodiment, the information display PCs 11A, 11B,... Are provided with an alarm reset function by software. That is, as shown in FIG. 10, the management data server 1 is provided with a buzzer output function 34, and the buzzer output function 34 allows the buzzers 4A and 4B to be operated.
B,... Corresponding to the processing apparatus in which the failure has occurred is caused to ring. At the same time, the management data server 1
10 is used to display the contents of the failure in each information display PC 11A, 11P.
B, ... The distribution information 53 includes a "confirmation" button display function in its contents. This distribution information 5
3 displays a "confirmation" button together with the failure information on the information display PCs 11A, 11B,... As a CGI or Java program.

When the operator hears the output of the alarm (buzzer) to confirm the failure, and clicks a "confirmation" button on the screen with a mouse or performs an equivalent operation, the LAN 10
Is transmitted to the management data server 1, the server 1 knows that the alarm output has been confirmed, stops the output of the buzzers 4A, 4B,... And stops the sounding.

Thus, in the third embodiment, the alarm reset notification function from the information display PC allows the operator to transfer the failure information without moving to the location where the central management data server is installed. When the new occurrence is known, the sounding of the alarm can be stopped by operating from the information display PC, and confusion of the alarm occurrence and forgetting to confirm the alarm can be prevented.

[0055]

As described above, according to the first aspect of the present invention,
As the information display PC installed on the line, a low-priced ordinary PC or a network client computer having only a browser function can be adopted, the investment cost for introducing the system can be reduced, and the information display PC can be displayed. The contents are flexible compared to the fixed display lightning display board,
It can be realized at low cost. Further, even when a request for strengthening the monitoring place or improving the work after the operation is started, it is sufficient to simply connect an additional display PC to the network, so that it is possible to respond flexibly. Further, even when there are a plurality of manufacturing lines, a plurality of WWW servers and a display PC are connected to one network, and an individual URL is set for each management data server that manages each line on the network. Therefore, each production line can be managed, and even when the status of the display line is changed due to a line change or the like, simply change and register the URL of the management data server accessed from the display PC to the corresponding one. It can be reused and can flexibly respond to line changes.

According to the invention of claim 2, in addition to the effect of the invention of claim 1, the management data server is provided with a push type or a Java program for failure information, operation status information or security for the information display PC. Since information is distributed, if failure information, operation status information or maintenance information is sent from the management data server, it can be displayed automatically without any operation by the operator, and information can be collected from the information display PC. This eliminates the need for an operation to access the management data server sequentially, thereby increasing the monitoring function of the production line.

According to the invention of claim 3, claim 1 or 2
In addition to the effect of the invention, the management data server activates the alarm device at the corresponding location directly or through the information display PC, so that when a failure occurs, an alarm is generated near the failure location to notify the worker. it can.

According to the fourth aspect of the invention, in addition to the effect of the first aspect, the management data server calls a preset mobile telephone number when a failure occurs. Can be called directly.

According to the fifth aspect of the present invention, in addition to the effect of the third aspect, the management data server transmits an operation command to the alarm device and the CGI or the CGI for displaying the alarm confirmation button on the information display PC. Since the Java program is distributed and the operation command is canceled when the confirmation button operation signal is received from the information display PC, the alarm can be activated only for the time until the operator confirms the malfunctioning part. Does not continue to operate for a certain period of time regardless of the presence or absence of confirmation, and does not stop operation without confirmation.

[Brief description of the drawings]

FIG. 1 is a block diagram of a first embodiment of the present invention.

FIG. 2 is a block diagram illustrating an operation of the embodiment.

FIG. 3 is a block diagram of a communication interface between a management data server and a processing apparatus controller according to the embodiment.

FIG. 4 is a block diagram showing an internal configuration of a management data server according to the embodiment.

FIG. 5 is an explanatory diagram showing a display screen of an information display PC according to the embodiment.

FIG. 6 is a flowchart of a startup process of the information display PC in the embodiment.

FIG. 7 is an explanatory diagram showing a response when a production line is changed in the embodiment.

FIG. 8 is a block diagram showing a system configuration example according to a second embodiment of the present invention.

FIG. 9 is a block diagram showing another example of the system configuration of the embodiment.

FIG. 10 is a block diagram showing a configuration according to a third embodiment of the present invention.

FIG. 11 is a block diagram of a conventional example.

FIG. 12 is a block diagram of another conventional example.

[Explanation of symbols]

 1 management data server 2A, 2B, 2C, processing device 3A, 3B, 3C, device controller 4A, 4b, 4C, alarm device 5A, 5B, 5C, controller interface 10 LAN 11A, 11B, 11C, … PC for information display 20 Unified network 31 Data collection unit 32 Data editing unit 33 WWW server unit 34 Buzzer output function

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Akitomo Fukushima 1-1-1, Showa-cho, Kariya-shi, Aichi Prefecture Inside Denso Corporation (72) Inventor Yoshihiro Saito 1-1-1, Showa-cho, Kariya-shi, Aichi Co., Ltd. Inside DENSO (72) Inventor Tatero Koike 1-1-1, Shibaura, Minato-ku, Tokyo In the head office of Toshiba Corporation (72) Inventor Shunsaku Utsunomiya 1-1-1, Shibaura, Minato-ku, Tokyo In the head office of Toshiba Corporation F term (reference) 5B049 BB07 CC21 CC34 EE56 EE59 GG04 GG07 GG09 5H215 AA06 BB01 BB05 BB09 BB12 CC09 CX01 CX05 CX06 CX08 GG02 GG03 GG05 GG20 JJ14 JJ23 KK04 9A001 JJ44 KK54 LL09

Claims (5)

[Claims] 1. A management data server that collects, organizes, and stores information on the failure and operation status of a processing device from a controller that manages individual processes of a manufacturing line, and an information display that is installed at a key location. A PC for connecting the management data server and the information display PC to perform information communication, the management data server having a WWW server function, and the information display PC having a browser function. A production line management system for distributing and displaying failure information, operation status information, or maintenance information using a WWW server function of the management data server and a browser function of the information display PC. 2. The management data server is a push type or Java (registered trademark) for the information display PC.
The manufacturing line management system according to claim 1, wherein the failure information, the operation status information, or the maintenance information is distributed by a program. 3. An alarm device installed in each part of the production line, wherein the management data server activates the alarm device in a corresponding place directly or through the information display PC in charge. The production line management system according to claim 1 or 2, wherein: 4. The production line management system according to claim 1, wherein said management data server issues a call to a preset mobile telephone number when a failure occurs. 5. The management data server transmits a CGI or Java program for transmitting an operation command to the alarm device and displaying an alarm confirmation button on the information display PC, and confirming the information from the information display PC. The manufacturing line management system according to claim 3, wherein the operation command is canceled when a button operation signal is received.