JP2002144024A - System for casting control - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a casting control system in which the condition of the job site can easily be inputted with a simple operation, even with a worker at the job site. SOLUTION: Terminal devices in a network 21 are set at the job sites 12, 13, 14, 16, 17, 18, 19, 20 related to the casting and these terminal devices have the inputting means of mouses, etc., selecting the corresponding item from plural items indicated on a display. This inputting means commands a lot already treated on detailed planning columns indicated on the display.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a casting management system.

[0002]

2. Description of the Related Art Conventionally, for example, a casting method of an aluminum product mainly occupies a sand mold, a mold, and a die cast. Problems at the production site are also different. Therefore, the conventional management often depends on the intuition of workers at the site. For this reason, conventionally, material management and sales management, that is, management of factory entrances and exits, can be accurately grasped, but production management in the factory during that time is left to the on-site workers, and the situation can be accurately determined. I couldn't figure out.

[0003]

The fact that the situation in the factory is difficult to be transmitted from the workers on site to the manager is that the workers on the site accurately communicate the situation they are aware of to the manager. This is not easy, and for example, it is not easy to operate the keyboard to input the status of the production line. In particular, in the case of a manual line, it is not easy because it is necessary to manually input the progress status and the like.

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a casting management system in which a worker at a site can easily input a situation at the site with a simple operation.

[0005]

According to the first aspect of the present invention,
A terminal device of a network is installed at a site related to casting, and this terminal device is a casting management system having input means for selecting a corresponding item from a plurality of items displayed on a display.

According to a second aspect of the present invention, the input means in the casting management system according to the first aspect indicates a digested lot in a detailed plan column displayed on a display.

[0007]

According to the first aspect of the present invention, a simple input operation of selecting a relevant item from a plurality of items displayed on the display of the terminal device is sufficient, so that production management on site is facilitated.

According to the second aspect of the present invention, when a manual line or the like is operated, an on-site worker designates a digested lot by an input means in a detailed plan column displayed on a display of a terminal device. In addition, the consumed lot can be easily erased, and the progress of the production line with respect to the detailed order plan can be monitored even in the case of a manual line.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to embodiments shown in the drawings.

FIG. 1 shows an outline of a production line network system of a casting factory for aluminum casting, in which a manufacturing office 11, a sand mold line production site 12, and a continuous gravitational casting (GRAVITY DIE CASTING) method using a mold. Casting line (hereinafter referred to as GD line) production site 13 and die casting line (hereinafter referred to as DC line) production site 14
And a maintenance office 15 and a core production site 16 with a core molding machine
, Heat treatment site 17, finishing site 18, machining site 19
A network terminal device (personal computer, hereinafter abbreviated to “PC”) is installed at each of the product storage site 20 and the product storage site 20.
Are connected by a local area network (hereinafter, referred to as LAN) 21 as a network. It is also connected to a value-added information network (VAN) 22 to take in external information.

In the manufacturing office 11, the LAN terminal device (PC) registers various part number information 23 related to the production process such as the part number, unit weight, casting line, pouring material, additive, customer, etc. in the database. I do.

This database, together with the part number information 23, receives order information (collects and manages orders from customers according to delivery dates) and production plan information (establishes a production plan while checking the line load based on the order information). , Line load information (change the load status of each casting line and core according to the production plan), sequence planning and production results (manage the status of work-in-progress and products based on production results and shipping status),
Operation monitor (files information on line operation such as start and end time of production line, person in charge, operation results, line stop reason, etc.), equipment management information (maintenance and maintenance of equipment related to production in the factory) Manage the situation).

The work standard of the product number information 23 is directly instructed from the manufacturing office 11 to machines such as the line production sites 12, 13, and 14 as control conditions through the LAN 21. Further, a mold system sequence plan 24 or a sand mold system sequence plan 25 is created from the order information and the line load information, and the machines at the line production sites 12, 13, 14 and the like are operated in accordance with the sequence plans 24, 25. In addition, information from order receipt to shipment (production lot completion status, etc.) is displayed in real time on the display of a personal computer, and production point-of-view information is managed while visually observing the progress of each site.

Each automated line production site 12, 13, 14
And the like, directly obtain a work standard from the product number information database through the network 21 and the line control controller, and operate according to the sequence plans 24 and 25. Also,
Production results and operation rates at each line production site 12, 13, 14, etc. are automatically totaled and recorded by LAN terminal equipment (PC). At this time, the order plans 24 and 25 are automatically applied at the same time. Further, the production line of the manual line and the outsourced product is indicated by a person at the site using the mouse as an input means to indicate the digested lot in a detailed plan column displayed on the display of the personal computer. This is used as a daily report to eliminate paper from the site.

At the heat treatment site 17, the finishing site 18 and the machining site 19, when the movement between the processes is automatic, the product position is inputted from the line conveyor to the personal computer and is automatically stored. In the case of a manual line or an outsourced product, a person in the field gives an instruction using a mouse as an input means on the display of the personal computer display according to the movement of the production lot. This is used for daily operation reports and outsourcing data.

At the product storage site 20 as well, the lots used for stocking the products in lots (which are also data for receiving and storing the product inventory and completing the production) and shipping are input to the detailed plan column displayed on the display of the personal computer. (Using the shipping data).

FIG. 2 shows a manufacturing office 11 and production sites 12, 13, and
Shows online network with 14, manufacturing office 11
, Sand mold line production site 12, maintenance office 15, GD
Terminal equipment (PC) 31 of the LAN 21 is installed at the production site 13 of the line, the core production site 16 and the production site 14 of the DC line, respectively, and the manufacturing office 11 and the production sites 12, 13,
14 are connected by a LAN 21. 32 indicates a lamp port, 33 indicates a communication cable, 34 indicates an optical terminal, and 35 indicates an optical cable.

In the manufacturing office 11, input number means such as a keyboard 36 or a mouse 37 of the personal computer 31 is used to create a part number information database (register and change work standards, cycle times, etc.), create an order plan, and the like. . In addition, management of work progress status (management of production lot digestion status, etc.), quality management (instruction of work standards, acquisition of defect information for production lots, etc.), line operation management (production results, line stop causes,
Various kinds of information relating to line failure status, operation rate calculation, etc.) are displayed on the display 38 of the personal computer 31, and the records are output from the printer.

In the sand mold line production site 12, the LAN 21
Information such as work standards (pour material, sand, mold, storage address of mold plate 42 to be fitted to master plate 41, size, type, required core, etc.), production sequence plan, etc. The sand casting line 44 is operated by the line control controller 43. Also, this sand casting line 44
Is automatically tabulated by the personal computer 31 directly connected to the line control controller 43, and the operation time, the number of result frames, the operation rate and the like are automatically recorded. At this time, the order plan is also cleared. The reason for the line stop and the waiting time thereof are also displayed on the personal computer 31, so that the production results and the line stop state can be used as an operation daily report to eliminate paper from the site. Further, the line failure status such as the line failure location, the number of times, and the time is also specified, and these are monitored. The above information is provided to the network 21.

At the sand mold line production site 12, the LAN 21
If there is a molding machine or a grooming line that is not connected to the computer, the on-site person indicates the digested lot with the mouse 37 in the detailed plan column displayed on the display 38 of the personal computer 31 so that the keyboard 36 is Try to capture data without using it.

At the maintenance office 15, each line production site
Search the failure history automatically created for each production line from the failure location, number of times, and time of individual equipment obtained from 12, 13, and 14, maintain the equipment, and manage spare parts.

At the GD line production site 13, information such as a work standard (a type-specific pouring amount, a mold temperature control, a tilting speed, a suction time, a solidification time, etc.), a production sequence plan, and the like, which are instructed through a network 21, are acquired. The continuous casting GD line 47 is automatically controlled via a line control controller 46. The production results of the GD line 47 are automatically recorded as described above, and the sequence plan is automatically deleted. In addition, line stop causes,
A failure location and the like are specified, and these pieces of information are provided to the network 21.

In the core production site 16, a network 21
The work standard and the production sequence plan instructed through the terminal device (the personal computer 31) are acquired by the terminal device (the personal computer 31), and the core molding machine 48 is operated. When the core molding machine 48 is operated manually or in the case of an outsourced core, the lot that has been digested at the site is indicated by using the mouse 37 in the detailed plan column displayed on the display 38 of the personal computer 31.

At the DC line production site 14, 330 to 20
In the case of each DC line 51 of 00t, the work standard (injection speed,
The DC line 51 is automatically controlled by directly instructing the pressure rising time, the release material blow, the die height adjustment, the mold opening time, the water cooling time, and the like. And controller for line control
The operation status of each DC line 51 obtained through 52
Information is provided from the network 31a to the network 21 to automatically obtain production results, automate operation records, erase sequence plans, specify the reasons for line stoppages, and specify fault locations.

In the case of a 2500t DC line 54 having a dedicated microcomputer 53 for controlling the die casting machine, instructions to the main body of the die casting machine (injection speed, boosting time, clamping force, casting pressure, biscuit thickness, etc.) The status of the machine itself (measurement of the mold clamping force, die height position, etc.) is performed through its dedicated microcomputer 53, and instructions to peripheral devices (product take-out devices, etc.) and the status of the line are monitored by the controller 55 connected to the personal computer 31b. Performed by

FIG. 3 shows a production management system of a foundry.

First, as shown in Table 1 below, the production processes such as product number, customer, manufacturing plant, casting line, unit weight, pouring material, additive, pouring amount, solidification time, cooling time, etc. Various information (work standards) are collectively registered for each item in a file of the personal computer 31, and a part number information database is created (A).

[0028]

[Table 1]

Next, when the individual part number information is accumulated, the load on each production line such as the sand casting line 44, the GD line 47, the core molding machine 48, and the DC lines 51 and 54 is determined. While adjusting the load amount to be within the capacity of each production line (B), a large schedule plan for 10 days to 1 month is created (C), and a detailed order plan is performed by a method described later. (D), and then a production lot is selected from the planning menu, and a setup such as instructing a worker in accordance with the work zone is performed (E). By this setup, a lot to be produced at the present time in a corresponding production line from among a wide variety of products is determined, and specific conditions for each product number can be set (F).

After the product number is specified in this manner, the pouring amount, solidification (mold opening) time, product cooling time, deburring method, determination of mold cooling time table, pouring material and sand storage in sand casting line 44 are determined. Various control conditions (work standard) such as the tilting speed and suction time in the GD line 47, the injection speed and the boosting time in the DC line 51, and the like to each production line through the LAN according to the detailed sequence plan. Directly instruct (G) and control the operation of each production line (H).

Then, line operation information is obtained from a controller for each production line or the like (I). For example, a computer directly connected to the line control controller automatically totals the production results and calculates the operating rate. If the production line is stopped, the cause of the line stoppage (waiting for hot water, setup, waiting for cooling) , Waiting for the core, failure of the production line, etc.), furthermore, the location of the failure is acquired and displayed by limit switches and various sensors attached to the production equipment, and the temperature of the mold is acquired by the radiation thermometer etc. To display.

The mold temperature detected during the operation of the line is fed back to instruct water-cooling and air-cooling conditions corresponding to the mold temperature to the cooling equipment of the production line (J).

The LAN personal computer counts the production results and simultaneously applies the detailed sequence plan created in D in lot units (K). Therefore, by looking at the display of the personal computer, it is possible to monitor the progress of the production line with respect to the detailed sequence plan (the progress of the production lot) in real time.

At the site, the product is checked for defects automatically or manually, and defect information for the lot is input (L).

An operation record such as a production line operation daily report automatically recorded after the operation information and product check (production results,
(M), and outputs and utilizes information on work standards, sequence plans, etc. (N). For example,
A defect countermeasure is performed based on the defect information obtained by the product check, and the defect countermeasure is fed back to the part number information database to improve a work standard of the database. The changed work standard (control condition) is directly instructed to the production line at G.

FIG. 4 shows the outline of a GD line (continuous casting line) 47, which includes a tilting machine 61, a mold opening / closing machine 62, and an automatic pouring machine.
63, mold transfer devices 64, 65, etc. are arranged.

The molds (upper and lower dies) are transported from a section to a section b by a traverser (cart) (not shown).
It is separated by the mold switch 62. Only the lower mold is moved to the c section by the traverser and the core is set, while b
In the section, the product in the upper mold is dropped into the take-out device 66 and carried out to the product cooling conveyor 67.

The mold matched in the part b is fed to the mold feeder 68
Thus, the molten metal pumped out of the holding furnace 69 by the automatic pouring machine 63 is poured into the mold clamped at the d portion of the tilting machine 61 through the tub attached to the mold.
At this time, the mold is rotated by 90 ° by the tilting machine 61 and the molten metal is cast into the mold while the air in the mold is sucked and exhausted to the outside.

After the completion of the feeder effect, the mold is released from the clamp and carried out to the portion e of the mold conveying device 64, is conveyed to the portion f by the mold conveying device 64, and is further molded by the mold feeder 70. The mold is conveyed to the g portion of the conveying device 65, where the mold is cooled by the mold cooling means such as the water injection means 71, the air cooling fan 72, and the water spray nozzle 73, and then is carried out to the a section.

A mold setting device 74 provided outside the continuous casting machine is for efficiently replacing a mold.
The prepared mold is made to stand by at the position h, and after the mold is carried out to the position i from the part e in the GD line (continuous casting line) 47, the mold setting device 74 is moved to move the mold set from the position h to the position i. The mold moved to the position is carried into the part e.

FIG. 5 is a block diagram for controlling the GD line 47. The input means (keyboard) is connected to the continuous casting line.
36, mouse 37, etc.), display means (CRT display 38)
Etc.), calculation / storage means of electromagnetic information equipment (CPU, memory, etc.), information transmission means (communication cable 33, cable between personal computer and controller, etc.), control means (line control controller 46), mold temperature detection means ( A radiation thermometer, a temperature sensor, etc.), a pouring means (automatic pouring machine 63), and a mold cooling means (water pouring means 71, an air cooling fan 72, a water spray nozzle 73, etc.) are provided.

FIG. 6 schematically shows the DC lines 51 and 54,
Mainly a die casting machine body 81 equipped with a die 80, a mold storage area 82, a holding furnace 83 and an automatic water heater 84, a product removal device
85, a product transport conveyor 86, a product cooling device 87, a deburring device 88, and the like.

FIG. 7 is a block diagram for controlling the DC lines 51 and 54. Input means (keyboard, mouse, etc.), display means (CRT, etc.), calculation and Storage means (CPU, memory, etc.), information transmission means (optical cable 35, cable between personal computer and controller, etc.), control means (controllers 52, 55, dedicated microcomputer
53), mold temperature detection means (radiation thermometer, temperature sensor, etc.), mold cooling means (water injection means, water spray nozzles, etc.), hot water supply means (holding furnace 83, automatic water heater 84), product removal means (products) Take-out device 85), transfer means (product transfer conveyor 86 and the like), product cooling means (product cooling device 87), and deburring means (burr removing device 88) are provided.

FIG. 8 is a detailed sequence plan in the production line.
24 is a flowchart illustrating a method for creating 24 and 25. First,
By accumulating the individual part number information 23 stored in the database, the sand casting line 44, the GD line 47, the core molding machine
48, the load on each production line such as DC line 51, 54 etc. is determined, so that the load should be grasped and the load should not be concentrated on specific production equipment. Another leveling range is set (step 1).

Next, individual production lines (sand casting lines)
Leveling is performed for each casting line in consideration of the casting capacity and load of the 44, GD line 47 and DC lines 51 and 54) (step 2). In this case, it is determined whether or not the load is within the line casting capacity (step 3), and the sequence plans 24 and 25 are adjusted so that the load is within the casting capacity.

Next, in the melting furnace, since the amount of melting differs depending on the material of the molten metal, leveling is performed for each material in consideration of the melting capacity for each material and the load (step 4). In this case, it is determined whether or not the load is within the melting capacity of the melting furnace (step 5), and the sequence plan is adjusted so that the load is within the melting capacity.

Next, leveling is performed for each core production line while taking into consideration the core production capacity and the load amount of the core production line (step 6). In this case, it is determined whether the load is within the core supply capacity of the core production line (step 7),
Adjust the sequencing to keep the load within core production capacity.

As described above, while adjusting the sequence plan so that the load amount falls within the capacity of each production line, a sequence plan for each casting line is created (step 8), and a melting amount sequence plan for each pouring material is created. (Step 9), and a core line-based sequence plan is created (Step 10).

[0049]

According to the first aspect of the present invention, a simple input operation of selecting a relevant item from a plurality of items displayed on the display of the terminal device is sufficient, so that production management can be easily performed even on site.

According to the second aspect of the present invention, when a manual line or the like is operated, a worker at the site specifies the digested lot in the detailed plan column displayed on the display of the terminal device by the input means. As a result, the consumed lot can be easily erased, and the progress of the production line with respect to the detailed sequence plan can be monitored even in the case of a manual line.

[Brief description of the drawings]

FIG. 1 is a schematic diagram showing one embodiment of a casting management system according to the present invention.

FIG. 2 is a diagram showing a specific configuration example of a network in the casting management system.

FIG. 3 is a block diagram showing a control example based on product number information of the casting management system.

FIG. 4 is a plan view showing a layout of a GD line for implementing the casting management system.

FIG. 5 is a block diagram for controlling a GD line.

FIG. 6 is a plan view showing a layout of a DC line for implementing the casting management system.

FIG. 7 is a block diagram for controlling a DC line according to the embodiment.

FIG. 8 is a flowchart showing an example of creating a detailed sequence plan in the casting management system.

[Explanation of symbols]

 12, 13, 14, 16, 17, 18, 19, 20 Site 21 LAN as a network 31 Terminal equipment (PC) 37 Mouse as input means 38 Display

Claims (2)

[Claims] 1. A casting management system comprising: installing a network terminal device at a site related to casting; the terminal device having input means for selecting a corresponding item from a plurality of items displayed on a display; . 2. The casting management system according to claim 1, wherein the input means indicates a digested lot in a detailed plan column displayed on the display.