JP2002328973A - Production line controller and product production system - Google Patents

Abstract

PROBLEM TO BE SOLVED: To effectively perform reproduction work. SOLUTION: When information on a production objective matter 40 in some process does not meet the condition of a normal product set previously to the process, a line controller 200 controls transportation so as to make the reproduction work it possible perform reproduction work to the production objective matter 40 (step S650), thereby reworking becomes possible. In particular, when a CPU 210 returns the production objective matter 40 to the some process, reproduction work can be performed by simple transportation control.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a manufacturing line control device for controlling a manufacturing line configured to transport a product so that a finished product can be manufactured by a manufacturing operation in each of a plurality of processes, and a manufacturing line control device for the same. Related to a product manufacturing system.

[0002]

2. Description of the Related Art Various proposals have been made for conventional control devices of this type. For example, various proposals have been made such as increasing the line speed when the difference between the production plan of the manufactured product and the actual result is equal to or more than a predetermined value, or notifying the fact.

However, in this type of conventional proposal, even if an abnormal product is manufactured in a certain process, it is recovered and re-manufactured. There is no disclosure of a technique for performing effective line control for performing this remanufacturing operation. In addition, although determination using image processing or the like is being considered in order to identify in which process an abnormal product has occurred, there may be cases where such a shape determination alone lacks the identification accuracy.

The present invention has been made to solve such a conventional problem, and has as its object to provide a line control device capable of performing such a remanufacturing operation.
It is another object of the present invention to provide a product manufacturing system capable of accurately specifying a process that has generated an abnormal manufacturing target.

In order to achieve the above-mentioned object, the present invention provides a manufacturing method configured to transport an object to be manufactured so that a finished product can be manufactured by a manufacturing operation in each of a plurality of steps. In a device for controlling a line, when information on an object to be manufactured in a certain process does not satisfy certain normal manufacturing conditions set in advance for that process, the information is transferred so that remanufacturing work on the object can be performed. It is characterized by having a transport control means for performing control.

[0004] In the present invention, if the information on the object to be manufactured in a certain step does not satisfy certain normal manufacturing conditions set in advance for that step, a remanufacturing operation can be performed on the object to be manufactured. Since the transport control is performed
Remanufacturing work can be performed.

[0005] The transfer control means may be means for controlling the transfer so that the object to be manufactured is returned to the certain step.

[0006] Further, the apparatus further comprises a judging means for judging whether or not the information on the object to be manufactured in a certain step does not satisfy a certain normal manufacturing condition set in advance for the step. If the image information of the object to be manufactured does not match the normal product image information set in advance for the process, it may be determined that the normal manufacturing conditions are not satisfied.

[0007] Even if the determination means determines that the image information of the object to be manufactured in the certain process matches the normal product image information set in advance for the process, the normality set in advance for the process is determined. If the condition indicating the normal product weight indicating the weight of the product is not satisfied, a means for determining that the normal manufacturing condition is not satisfied can be further provided.

[0008] Further, a cumulative means for totaling the number of times that it is determined that the normal manufacturing conditions are not satisfied in each of the plurality of steps may be provided. In consideration of the cumulative result by the cumulative means, when a preset condition is satisfied for each of the plurality of processes, a notifying means for notifying that the number of abnormal occurrences is large may be provided. A second notifying unit may be provided for notifying the information indicating the steps in the descending order of the accumulated value or in the reverse order in consideration of the accumulated result by the accumulating unit.

In order to achieve another object, another embodiment of the present invention is configured to convey an object to be manufactured so that a finished product can be manufactured by a manufacturing operation in each of a plurality of steps. In a product manufacturing system including a manufacturing line and a line manufacturing device that controls the manufacturing line, a weight is provided at a position corresponding to each of the plurality of processes, and indicates a weight of a manufacturing target after a manufacturing operation in the process. A plurality of detecting means for outputting information; and the line control device includes an abnormal process specifying means for specifying a process in which an abnormal product manufacturing operation is performed based on weight information from each of the plurality of detecting devices. It is characterized by that.

In the present invention, the line control device includes:
Since the process in which the abnormal manufacturing operation was performed is specified based on the weight information from each of the plurality of detecting means, the process can be used together with the abnormal process specifying process using, for example, image information, and an abnormal manufacturing target is generated. The process is specified with high accuracy.

[0011] Further, a relay device for assisting in transporting a product to be manufactured in a normal direction and a direction opposite to the normal direction, and the relay device are mounted between two successive steps of the manufacturing line. The detection means may be provided.

[0012] The abnormal process specifying means may include means for starting the specifying operation when the weight information from the detecting means changes from an initial value indicating the weight of the relay device. good.

The above operation can be executed by a computer executing a program recorded on a recording medium. Examples of such a recording medium include a ROM, a semiconductor IC, and the like. Recording media capable of recording and reading digital contents, such as semiconductor recording media, optical recording media such as DVDROM and CDROM, magnetic recording media such as flexible disks, and magneto-optical recording media such as MO. Further, such a program can be downloaded from a predetermined information processing device via a communication network and recorded on a recording medium.

Embodiments of the present invention will be described below with reference to the drawings.

(Overall Configuration of Manufacturing Line 1000) FIG.
FIG. 1 is a schematic explanatory diagram of a configuration of a production line 1000 according to an embodiment of the present invention. A central shaft 2 extending in the longitudinal direction of the external cylindrical roller 1 is supported by a support member 6 on the left end side of the drawing, so that the roller 1 is rotatably supported, and an external cylindrical roller 1 on the right end side of the drawing. A central shaft 4 extending in the longitudinal direction of the roller 2 is connected to a central shaft (not shown) of a motor 10, and the motor 10 is supported by a support member 7. Therefore, the rotation of the motor 10 controls the rotation of the center shaft 4 so that the roller 3 rotates.

Further, since the endless belt 30 is stretched between the two rollers 1 and 3, the belt 30 is rotated when the motor 10 rotates the roller 3 in the direction b.
The whole is also rotated in this direction, and the object 40
Is transported in the A direction.

On the other hand, if the motor 10 drives the roller 3 to rotate in the direction a, the entire belt 30 is also rotated in this direction, and the object 40 above the belt 30 is conveyed in the direction B. Thus, by changing the rotation direction of the motor 10, the conveyance direction of the object 40 is also changed.

The manufacturing line 1 includes a plurality of processes A,..., N, and a final part of each process is a CC for taking in image information of a product manufacturing work product in the process.
The image information obtained by installing the D cameras 110a,..., 110n is transmitted to the line control device 200 together with the process name.

Further, the CCD camera 110 and the belt 30
The relay device 20 is provided at a position corresponding to the relay device. A belt 3 is provided on the upper surface of the relay device 20 shown in FIG.
Roller 21 to assist in guiding 0 in any direction
Is rotatably provided. And this relay device 2
0 is mounted on a weight sensor 100 that outputs weight information of an object mounted on the upper surface thereof. Further, the square of the weight sensor 110 is provided with a leg 22 extending in the vertical direction.
0 is allowed to pass. Therefore, the weight sensor 1
10 outputs the initial weight information based on the tension of the relay device 20 and the belt 30 according to the installation position.

.., SN are assigned to each process, and each worker performs a required product manufacturing operation. Then, normally, after a product manufacturing operation from the first step A to the last step N, one finished product is manufactured. Further, the display device 50 is installed at a position where each worker can visually recognize the worker.

(Configuration of Line Control Device 200) FIG.
FIG. 3 is a block diagram of the line control device 200. The line control device 200 includes a CPU 210 and a program 2
ROM 220 as a recording medium on which the C.21 is recorded, a RAM 230 as a work area, a mouse 240 as an example of an input device, and a CRT as an example of an output device
250 and a hard disk (HD) 260 capable of storing tables and the like, and the following operations can be realized by the CPU 210 executing the program 221.

The CPU 210 controls each of the weight sensors 100a,
…, Weight information from 100n, each CCD camera 110
a,..., 110n, and the like, and can transmit drive control signals for the motor 10, display information to the display device 50, and the like.

FIGS. 4 and 5 are explanatory diagrams of the tables 270 and 271 stored in the HD 260. FIG. Table 270
Are weight sensors 100a corresponding to the respective steps A,.
,... 100n, normal conditions indicating that the weight information indicates that the manufacturing operation is normally performed, and the CCD camera 1 corresponding to each of the steps A,.
.., 110n are stored in association with normal images. For example, the weight sensor 100a outputs the initial value D1 in a state where the object 40 is not conveyed. When the object 40 is conveyed to a position corresponding to the relay device 20, the output information of the weight sensor 100a changes from the initial value D1, but the value x at this time is "m1".
When the condition of ≦ x <m2 is satisfied, the CPU 210 determines that the product manufacturing operation has been performed normally. On the other hand, when the condition is not satisfied, it is determined that the product manufacturing operation has an abnormality.

When the image information acquired by the CCD camera 110a matches the normal image G1, the CPU 210 determines that the product manufacturing work in this step A has been performed normally, but when this condition is not satisfied. Determines that there is an abnormality in the product manufacturing operation.

FIG. 8 is an explanatory diagram for explaining the principle of the judgment based on the image in more detail. That is, as shown in FIG. 8A, when the acquired image matches the normal image, the CPU 210 determines that the product manufacturing operation in that process has been performed normally.
As shown in FIG. 8B, the shape difference (part 800 and part 80)
In the case where the shape of the component 1 is different) or the color is different as shown in FIG. 8C (the component 802 and the component 803 have different colors), it is determined that there is an abnormality in the product manufacturing operation.

The table 271 stores an abnormality occurrence step in which an abnormal product manufacturing operation has been performed, a line reversion control pattern corresponding to the abnormality occurrence step, the number of occurrences of the abnormality in the step, and a warning threshold value in association with each other. When the CPU 210 specifies the process in which the abnormal product manufacturing operation has been performed, the number of occurrences of the abnormality for this process is increased by one. I have. Then, when the number of times of occurrence of the abnormality exceeds the threshold value set for each process, the CPU 210 transmits to the display device 50 information for performing a message notification for warning of occurrence of an abnormal situation in this process.

The display device 50 that has received this information,
As shown in "I have many troubles in the process XX!
! , Etc., is displayed and notified, so that all workers can perform work while referring to this.

The line reverse control pattern is a control pattern for transporting the object 40 to a process in which an abnormal product manufacturing operation has occurred.
When the abnormal product production occurs in the process A, the motor 10 is driven and controlled by the control pattern 1 so as to return the object 40 to the start position of the process A. Similarly, when abnormal product production of the production target 40 occurs in the process N, the drive of the motor 10 is controlled by the control pattern n so as to return the production target 40 to the start position of the process N.

If the intervals between the steps are the same, the control patterns can be the same.
Further, when an abnormal product is produced in a certain process, the production object 40 is returned to a step one or more steps before that process, instead of returning the production object 40 to the start position of the process. You may do it. In the present embodiment, for the sake of simplicity, an operation will be described on the assumption that when an abnormal product is produced in a certain process, the production target 40 is returned to the start position of the process. .

(Operation Example 1) First, operation example 1 will be described. If the CPU 210 detects that any of the weight information has changed from the initial value in step S600 (Y
es) Start the following operation. On the other hand, in other cases (No), a wait state is set in step S600.

In step S610, referring to the contents of the table 270, it is determined whether the image information captured by the CCD camera 110 corresponding to the weight sensor whose weight information has changed from the initial value matches the corresponding normal image. Is determined. If they do not match (No), the process moves to step S630. On the other hand, if they match (Yes), step S
At 620, it is determined whether the weight information satisfies the corresponding normal condition. If the normal condition is satisfied (Yes), the process is terminated assuming that the product has been manufactured normally. Thus, the double check of the image information and the weight information can be performed.

On the other hand, if the normal condition is not satisfied (No), the process also proceeds to step S630. Step S
In 630, the CPU 210 updates the cumulative value of the number of occurrences of the abnormality by increasing the number of occurrences of the abnormality corresponding to the abnormality occurrence step in the table 271 by one. Next, in step S640, the drive of the motor 10 is controlled by the control pattern corresponding to the abnormality occurrence step, and
Transport in the direction.

Then, in step S650, it is determined whether or not the number of times of occurrence of the abnormality in the abnormality occurrence step exceeds a corresponding threshold value.
Ends the process, but on the other hand, exceeds (Yes)
Then, the process proceeds to step S660 to transmit information to the display device 50 for notifying that a large number of abnormalities have occurred in the abnormality generating process. In response to the reception of this information, the display device 40 performs message notification as shown in FIG. 7 described above.

Since the number of abnormal occurrences in the table 271 is cleared for a predetermined period of time, for example, every day, it is possible to obtain the total value of the number of abnormal occurrences in each process in the predetermined period.

Therefore, according to the operation example 1, the CPU 2
Reference numeral 10 denotes a case where the information on the object 40 to be manufactured in a certain process does not satisfy certain normal manufacturing conditions set in advance for the process (conditions in which it can be determined that the product was normally manufactured in the process). Since the transport control is performed so that the remanufacturing operation for the object 40 can be performed, the remanufacturing operation can be performed.
If 0 returns the object 40 to a certain step, the remanufacturing operation can be performed with a simple transport control.

If the image information of the object 40 in a certain process does not match the normal image (normal product image information) set in advance for that process,
Even if it is determined that the normal manufacturing conditions are not satisfied, or if it is determined that the image information of the manufacturing target 40 in a certain process matches the normal image set in advance for that process, the When the normal product weight condition indicating the weight of the set normal product is not satisfied, it is determined that the normal manufacturing condition is not satisfied, so that a precise determination can be made.

Further, the CPU 210 accumulates the number of times that it is determined that the normal manufacturing conditions are not satisfied in each of the plurality of processes, enables the number of abnormal occurrences in each process to be grasped, and further considers the accumulated results, When a preset condition is satisfied for each of a plurality of processes, for example, when a threshold value is exceeded, a notification that the number of times of occurrence of abnormality is large is sent, so that each worker can grasp the state of occurrence of abnormality in the process. It becomes possible.

(Operation Example 2) In step S900 of FIG. 9, the CPU 210 determines whether or not an appropriately determined display timing has arrived. If not arrived (No)
Enters the wait state in step S900, and if it has arrived (Yes), the process proceeds to step S910.

At step S910, CPU 210
Retrieves the number of occurrences of abnormality in each step of the table 271 in FIG. 5, grasps the number of occurrences of abnormality in each searched step in descending order or the reverse order, and displays the step name and the number of occurrences of abnormality in that order. Is transmitted to the display device 50. Then, as shown in FIG. 10, for example, the display device 50 displays the process name and the number of occurrences of the pair in descending order of the number of occurrences of the abnormality.

Therefore, according to the operation example 2, the CP
U120, in consideration of the cumulative result, notifies the information indicating the process in the order of larger cumulative value or in reverse order, so that each worker can easily grasp the abnormality occurrence state in each process while working. Becomes

According to the embodiment of the present invention described above, the line control device 200 performs the abnormal product manufacturing operation based on the weight information from each of the plurality of weight sensors 100a,..., 100n. Since the process is specified, it can be used in combination with an abnormal process specifying process using, for example, image information, and the process that generated the abnormal manufacturing object is specified with high accuracy. Also, a relay device 20 for assisting in transporting a product to be manufactured in a normal direction and a direction opposite to the normal direction, and a relay device 2 between the two continuous processes on the manufacturing line.
The weight sensor 100 is placed on the belt 30 because the weight sensor 100 is placed on the belt 30.
It doesn't stop you from running.

The line control device 200 starts the specific operation of the abnormality occurrence step when the weight information from the weight sensor 100 changes from the initial value indicating the weight of the relay device 20. A series of specific operations can be started by logic.

While the embodiments of the present invention have been described above, various modifications and alterations to the embodiments of the present invention may be made without departing from the spirit of the present invention, for example, by appropriately changing the number of steps and the like. Changes are possible.

As described above, according to the present invention, it is possible to perform a remanufacturing operation, and to accurately specify a process in which an abnormal object is generated. can get.

[Brief description of the drawings]

FIG. 1 is an overall configuration diagram of a production line 1000 according to an embodiment of the present invention.

FIG. 2 is a schematic explanatory view of the appearance of a relay device 20 and a weight detection sensor 100 on which the relay device 20 is mounted.

FIG. 3 is a configuration diagram of hardware of a control device 200.

FIG. 4 is an explanatory diagram of a table 270.

FIG. 5 is an explanatory diagram of a table 271.

FIG. 6 is an explanatory diagram of an operation.

FIG. 7 is an explanatory diagram of a warning message notification.

FIG. 8 is an explanatory diagram of an abnormality determination operation by image processing.

FIG. 9 is an explanatory diagram of another operation example.

FIG. 10 is an explanatory diagram of a display example in another operation example.

[Explanation of symbols]

 Reference Signs List 1 roller 2 central axis 3 roller 4 central axis 6 support member 7 support member 10 motor 20 relay device 21 roller 22 foot 30 belt 50 display device 100 (100a, ..., 100n) weight detection sensor 110 (110a, ..., 110b) CCD camera 200 Line controller 210 CPU 220 ROM 221 Program 230 RAM 240 Mouse 250 CRT 260 HD 270 Table 271 Table 1000 Manufacturing line

Claims (10)

[Claims] 1. An apparatus for controlling a production line configured to transport a production object so that a finished product can be produced by a production operation in each of a plurality of processes, wherein information on the production object in a certain process is provided. A production line characterized by comprising transport control means for performing transport control so that a remanufacturing operation for the object can be performed when a predetermined normal manufacturing condition set for the process is not satisfied. Control device. 2. The production line control device according to claim 1, wherein said transport control means is means for performing transport control so as to return said object to said certain step. Control device. 3. The manufacturing line control device according to claim 1, wherein the information on the object to be manufactured in a certain process includes a certain normal product manufacturing condition set in advance for the process. A determination unit that determines whether or not the image quality is not satisfied; the determination unit determines that the image information of the object to be manufactured in the certain process does not match the normal product image information set in advance for the process; A production line control device, which is means for determining that production conditions are not satisfied. 4. The manufacturing line control device according to claim 3, wherein the determination unit determines that the image information of the object to be manufactured in the certain process matches the normal product image information set in advance for the process. If the determination does not satisfy the condition indicating the weight of the normal product indicating the weight of the normal product set in advance for the process, a means for determining that the normal manufacturing condition is not satisfied is further provided. Manufacturing line control device. 5. The manufacturing line control device according to claim 1, wherein the number of times that it is determined that the normal manufacturing condition is not satisfied in each of the plurality of processes is accumulated. A production line control device comprising a cumulative means. 6. The manufacturing line control device according to claim 5, wherein the number of times of occurrence of an abnormality is large when a condition set in advance for each of a plurality of processes is satisfied in consideration of a cumulative result by the cumulative means. A production line control device, comprising: a notifying unit for notifying the user of the fact. 7. The manufacturing line control device according to claim 5, wherein information indicating the steps in the descending order of the accumulated value or in the reverse order in consideration of the accumulated result by the accumulating means. A second notification means for arranging and notifying the production line. 8. A product manufacturing system comprising: a manufacturing line configured to transport an object to be manufactured so that a finished product can be manufactured by a manufacturing operation in each of a plurality of processes; and a line manufacturing apparatus that controls the manufacturing line. In the system, provided at a position corresponding to each of the plurality of steps,
A plurality of detecting means for outputting weight information indicating the weight of the object to be manufactured after the manufacturing operation in the process, wherein the line control device detects an abnormal product based on the weight information from each of the plurality of detecting means. A product manufacturing system comprising an abnormal process specifying means for specifying a process in which a manufacturing operation has been performed. 9. The product manufacturing system according to claim 8, wherein between two successive steps of the manufacturing line, a product to be manufactured is supported in a normal direction and in a direction opposite to the normal direction. A product manufacturing system, comprising: a relay device; and the detection means for mounting the relay device. 10. The product manufacturing system according to claim 9, wherein the abnormal process identification unit is configured to execute the identification when the weight information from the detection unit changes from an initial value indicating the weight of the relay device. A product manufacturing system comprising means for starting operation.