JP2008070147A - Product sorting method, apparatus for executing the method, and product sorting program - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve the yields of products that differ in conditions of use by each user. <P>SOLUTION: A conditions of use receiving part 11 receives conditions of use for eachuser, to store this in a user data table 21. A required lifetime calculation part 14 calculates the required lifetime which satisfies the conditions of use for each user, to store the same in a user data table 21. An inspection data receiving part 12 receives the inspection data for each product, to store the same in a product data table 22. A predicted lifetime calculating part 15 calculates the predicted lifetime, corresponding to the inspected data of each product and stores the same in the product data table 22. A sorting part 19, constituted to compare the required lifetime stored in the user data table 21, with the predicted lifetime stored in the product data table 22 and allots the product, of which the predicted lifetime is longer than the required lifetime, to the user who requests the required lifetime. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for sorting manufactured products having different use conditions for each user, an apparatus for executing the method, and a program for sorting manufactured products.

  Conventionally, as a method for sorting manufactured products, for example, there is a method described in Patent Document 1 below.

  This method performs an appearance inspection of a manufactured product, determines whether the manufactured product satisfies a predetermined quality standard, and determines whether it is a non-defective product according to the result of the visual inspection. If it is determined that this is the case, this product is removed.

  By the way, in the case of gas turbine parts, for example, moving blades, stationary blades, and the like, those that do not satisfy a predetermined quality standard are treated as defective products by visual inspection, as in the above method. This gas turbine component is often a cast article because it is exposed to hot combustion gases. Even if such a cast article is manufactured after familiarizing with its manufacturing method, its yield is not so high.

JP-A-5-278838

  Gas turbine components often have different usage conditions for each user. For this reason, as in the prior art, when a part is classified as a non-defective product or a defective product according to a uniform quality standard, the usage conditions presented by the user are cleared even for the defective product. There is something. Therefore, in the prior art, even those that clear the usage conditions presented by the user may be handled as defective products, and the yield of components cannot be increased, resulting in a high manufacturing cost. is there.

  The present invention has been made paying attention to such conventional problems, and a method of sorting manufactured products that can increase the yield of manufactured products and reduce the manufacturing cost, an apparatus that executes this method, and The purpose is to provide a product sorting program.

A method for sorting manufactured products to solve the above problems is as follows.
A use condition accepting step for accepting a user's use condition for a manufactured product;
Using the required life calculation formula indicating the correlation between the use condition of the manufactured product and the required life of the manufactured product necessary to satisfy the use condition, the user use condition received in the use condition receiving step A required life calculation process to obtain the required life according to
An inspection result receiving step for receiving results of post-manufacturing inspection of the plurality of manufactured products;
For each of the results of each post-manufacturing inspection for each of a plurality of results of the post-manufacturing inspection received in the inspection result receiving step, using a predicted life calculation formula indicating a correlation between the result of the post-manufacturing inspection and the life of the manufactured product. A predicted life calculation step to obtain a predicted life according to
Among the plurality of manufactured products, a manufactured product that supplies the user with a product having a longer predicted life calculated in the predicted life calculation step than the required life calculated in the required life calculation step. Sorting process and
It is characterized by including.

Here, the method of sorting the manufactured products is as follows:
A classifying step for determining which class of the life class divided into at least three or more of the manufactured products for which the predicted life is calculated in the predicted life calculation step;
In the sorting step, among the plurality of manufactured products divided into three or more life classes, a product of a life class having a predicted life longer than the required life determined in the required life calculation step is sent to the user. It may be a manufactured product to be supplied.

In addition, a product sorting program for solving the above problems is as follows:
A use condition accepting step for accepting a user's use condition regarding the manufactured product;
Using the required life calculation formula indicating the correlation between the use condition of the manufactured product and the required life of the manufactured product necessary to satisfy the use condition, the user use condition received in the use condition receiving step The required life calculation step to obtain the required life according to
An inspection result receiving step for receiving results of post-manufacturing inspections of the plurality of manufactured products;
For each of the plurality of post-manufacturing inspection results received in the inspection result receiving step, each post-manufacturing inspection result is calculated using a predicted life calculation formula indicating the correlation between the result of the post-manufacturing inspection and the life of the manufactured product. A predicted life calculation step for obtaining a corresponding predicted life,
Among the plurality of manufactured products, a manufactured product having the predicted life calculated in the predicted life calculation step longer than the required life calculated in the required life calculation step is a product supplied to the user. Sorting steps;
Is executed by a computer.

In addition, a product sorting apparatus for solving the above problems is
The program is installed on a computer.

  According to the present invention, while predicting the respective lifetimes of a plurality of manufactured products based on the inspection results, the required lifetime satisfying the usage conditions of the manufactured products is obtained for each user, and the predicted lifetime is longer than this required lifetime. Assign products to users. For this reason, for example, even if there is a manufactured product that does not satisfy the conventional quality standard, if there is a user whose use conditions are relatively mild, the manufactured product is assigned to this user without being removed. Therefore, the number of manufactured products that are removed as defective products is reduced, and the yield of manufactured products can be increased. In addition, since a product with a long predicted life is assigned to a user who has severe use conditions, a product that satisfies the user is supplied rather than simply assigning a product exceeding the quality standard as in the prior art. be able to.

  Hereinafter, a product sorting apparatus according to an embodiment of the present invention will be described with reference to the drawings.

  First, manufactured products to be sorted by the sorting apparatus of this embodiment will be briefly described. The manufactured product targeted in this embodiment is a moving blade of a gas turbine. This moving blade is a cast article, and its life population distribution is almost normal with a certain life as the center, as shown in FIG. In the prior art, as described above, products that do not satisfy the predetermined quality standard S as a result of the appearance inspection are removed as defective products.

  Next, the sorting apparatus of this embodiment will be described.

  As shown in FIG. 1, the sorting device 10 according to the present embodiment includes a use condition receiving unit 11 that receives a user use condition of a moving blade from an input device 1 such as a keyboard, and a wireless such as a LAN from an inspection data input device 4. An inspection data receiving unit 12 for receiving moving blade inspection data via the wired network N, an output unit 13 for outputting various arithmetic processing results to an output device such as the display 2 and the printer 3, and the like according to user usage conditions A required life calculating unit 14 for obtaining a required life of a manufactured product, a predicted life calculating unit 15 for obtaining a predicted life of a manufactured product according to inspection data, a sorting unit 15 for sorting a plurality of manufactured products according to user use conditions, And a storage area 20 in which various data are stored.

  The predicted life calculation unit 15 includes a quality index calculation unit 16 that calculates a quality index Qi corresponding to the inspection data of the manufactured product, a predicted life calculation unit 17 that predicts the life Le of the manufactured product corresponding to the quality index Qi, A life classifying unit 18 that divides each product whose life has been predicted into life classes to be described later.

  In addition, the storage area 20 is required to satisfy this usage condition from a user information table 21 storing user usage conditions and the like, a manufactured product information table 22 storing product information, and user usage conditions. There is a first calculation formula storage area 25 in which a required life calculation formula is stored for obtaining a required life Lr of a manufactured product, and a quality index calculation formula for determining the quality index Qi of the manufactured product from the inspection data of the manufactured product. A second arithmetic expression storage area 26 to be stored and a third arithmetic expression storage area 27 in which a predicted life expression for obtaining the predicted life Le of the manufactured product from the quality index Qi of the manufactured product is stored. Is set. In each arithmetic expression storage area 25, 26, 27, each arithmetic expression derived by the user himself / herself from past results is set before actually sorting manufactured products.

  In the user information table 21, as shown in FIG. 3, a field for storing a user ID for identifying the user, a field for storing a scheduled total operation time of the turbine, which is one of user use conditions, Similarly, a field for storing the total number of times the turbine is scheduled to start, which is one of the user usage conditions, a field for storing the required life of manufactured products necessary to satisfy these user usage conditions, and an actual condition that satisfies this required life And a field in which the number of the manufactured product is stored.

  Further, as shown in FIG. 4, the manufactured product information table 22 includes a field for storing a manufactured product number for identifying an actual manufactured product and a field for storing post-manufacturing inspection data of the manufactured product. A field in which a predicted life predicted based on this data is stored, a field in which a life class corresponding to the predicted life is stored, and a field in which a user ID to which the manufactured product is supplied are stored. is there.

  The sorting apparatus 10 described above is actually a computer as shown in FIG. 2, and is executed by an interface 31 for performing input / output processing with the outside, a CPU 32 for executing various calculations, and the CPU 32. A program memory 33 in which a sorting program for storing the data is stored, a work memory 34 used when the CPU 32 executes various calculations, and a hard disk device 35 in which various data and the like are stored. In this computer, the above-mentioned required life calculation unit 14, expected life calculation unit 15, and sorting unit 19 all have a program memory 33 in which a sorting program and the like are stored, and a CPU 32 that executes this sorting program. Configured. Each of the use condition receiving unit 11, the inspection data receiving unit 12, and the output unit 13 includes an interface 31, a program memory 33 in which a sorting program and the like are stored, and a CPU 32 that executes the sorting program and the like. Configured. The storage area 20 includes a hard disk device 35.

  Next, the operation of the sorting apparatus 10 of this embodiment will be described.

  First, processing when a user use condition is accepted will be described with reference to the flowchart shown in FIG.

  First, an operator or the like operates the keyboard 1 or the like to input the ID of a user who wishes to deliver a manufactured product and the usage conditions of the user. The use condition receiving unit 11 receives this (S10) and stores it in the corresponding field of the user information table 21 (S11). Here, as the user use conditions, as described above, the planned total operation time Tr of the turbine and the planned total number of times N of startup of the turbine.

  When the user usage conditions are stored in the user information table 21, the required life calculation unit 14 uses the required life calculation formula shown in the following formula (1) stored in the first calculation formula storage area 25. The required life Lr of the manufactured product required to satisfy the user use condition is obtained (S12).

Lr = Tr + 20 · N (1)
Tr: Total planned operation time of turbine
N: Scheduled total number of start-ups of the turbine This required life calculation formula treats the number of start-ups of the turbine as 20 times the time corresponding to the operation time of the turbine. The above formula (1) is an example of the necessary life calculation formula, and the present invention is not limited to this.

  Specifically, for example, the required life Lr required for the manufactured product of the user ID “a01” in the user information table 21 shown in FIG. 3 is the estimated total operating time Tr of the turbine of 11500 (hr), Since the number of activations N is 50 (times), it is 12500 (hr) according to the equation (1).

  When the required life calculation unit 14 obtains the required life Lr, it stores it in the corresponding field of the user information table 21 (S14).

  This is the end of the process when accepting the user use conditions.

  Next, a method for acquiring inspection data will be described with reference to FIG.

  FIG. 7 shows a central section (solid line) of the actually manufactured moving blade and a central section (broken line) of the designed moving blade. In this embodiment, the total deviation area of the central cross section of the production rotor blade relative to the central cross section of the design rotor blade, that is, the total area of the hatched portion in FIG. To do. In this embodiment, as described below, the data indicating the distortion amount of the manufacturing blade is used as inspection data, and the quality index and the predicted life of the manufactured product are obtained based on this data. Is not limited to this. For example, the inspection data is the total number of cracks found on the blade surface, the total length of all cracks, etc. You may ask for it.

  Next, processing when test data is received will be described according to the flowchart shown in FIG.

  The inspection data of a plurality of manufactured products is input to the inspection data input device 4 by an operator or the like. The inspection data receiving unit 12 of the sorting apparatus 10 receives inspection data from the inspection data input device 4 via the network N for each manufacturing number that is an identifier of a manufactured product (S20), and receives this data in the manufactured product information table 22. (S21).

  When the inspection data of a plurality of manufactured products is stored in the manufactured product information table 22, the quality index calculating unit 16 of the predicted life calculating unit 15 stores the following formula ( The quality index Qi of the manufactured product corresponding to the inspection data S is obtained using the quality index calculation formula shown in 2) (S22).

Qi = -2.5 · S + 10 (2)
In this quality index calculation formula, when the inspection data S is almost 0, that is, when the total deviation area of the central section of the manufacturing blade relative to the central section of the design blade is almost 0, the highest quality index 10 is obtained. It is determined that the quality index gradually decreases as the inspection data (distortion amount) S increases.

  When the quality index calculation unit 16 obtains the quality indexes Qi of a plurality of manufactured products, the predicted life calculation unit 17 stores the predicted life calculation shown in the following formula (3) stored in the third calculation formula storage area 27. Using the equation, the predicted life Le of the manufactured product corresponding to the quality index Qi is obtained (S23).

Le = 800 ・ Qi + 7000 (3)
In addition, the above Formula (3) is an example in a prediction lifetime calculation formula, and this invention is not limited to this. Here, the quality index Qi is obtained from the inspection data S, and the predicted life Le is obtained from this Qi. The expression (2) is substituted into Qi of the expression (3), and the inspection is performed using this new expression. The predicted life Le may be obtained directly from the data S.

Specifically, for example, in the case of the manufactured product with the product number “1” in the product information table 22 shown in FIG. 4, since the inspection data is 2.0 (cm ² ), the quality index Qi is 5 and The predicted life Le is 11000 (hr). Further, in the case of the manufactured product with the production number “3”, since the inspection data is 0.2 (cm ² ), the quality index Qi is 9.5, and the predicted life Le for this quality index is 14600 (hr).

  When the predicted life calculation unit 17 obtains the predicted life Le of each manufactured product, the life classifying unit 18 divides each manufactured product into life classes according to the predicted life Le (S24). Here, as shown in FIG. 7, the reference life Ls is 10000 (hr), 1.3 Ls or more is A class, less than 1.3 Ls is 1.1 Ls or more is B class, less than 1.1 Ls is L class or more is C class, Less than Ls and 0.9 Ls or more is D class. Therefore, for example, a product with a production number “1” with an estimated life Le of 11000 (hr) is class B, and a product with a production number “3” with an estimated life Le of 14600 (hr) is in class A. . In addition, the number with a circle in FIG. 8 has shown the serial number of the manufactured goods which exist in each class.

  As described above, when the predicted life calculating unit 15 obtains the predicted life Le and the life class for each manufactured product, the predicted life calculating unit 15 stores them in the corresponding fields of the manufactured product information table 22 (S25).

  When the life class of each manufactured product is stored in the manufactured product information table 22, the sorting unit 19 stores the life class for each manufactured product stored in the product information table 22 and the user information table 21. The required life for each user is compared, and a product of a life class in which a life longer than the required life is set is assigned to a user who requests the required life. Specifically, for the user with the user ID “a01”, the product of the life class “A” whose life is longer than the necessary life 12500 (hr), that is, the product number “3”. Of manufactured goods. In addition, since the life class of the product with the product number “3” is “A”, this product is a user who requires a required life 12500 (hr) shorter than the life of this life class, That is, it can be said that the user ID “a01” is assigned. Hereinafter, the product with the production number “1” is assigned to the user with the user ID “a02”, the product with the production number “2” is assigned to the user with the user ID “d01”, and the product with the production number “4”. Is assigned to the user with the user ID “b01”, and the product with the production number “5” is assigned to the user with the user ID “c01”. When the sorting unit 19 determines the assigned user of each manufactured product, the sorting unit 19 stores the corresponding user ID in the user ID field of the manufactured product information table, and stores the corresponding manufactured number in the manufactured product number field of the user information table 21.

  This completes the process from receiving the inspection data to sorting.

  When an operator or the like wants to know the above sorting results, he calls the data of the user information table 21 or the manufactured product information table 22 using the keyboard 1 or the like, and causes the display 2 or the printer 3 to output the data.

  As described above, in the present embodiment, while predicting the respective lifetimes of a plurality of manufactured products based on the inspection results, the required lifetimes that satisfy the usage conditions of the manufactured products are obtained for each user, Products with a long expected life are assigned to users. For this reason, for example, as shown in FIG. 7, when the life of a product manufactured according to the conventional quality standard S is the standard life Ls, there is a product that does not satisfy the quality standard S (manufactured product number “5”). However, if there is a user whose use conditions are relatively mild, the manufactured product is assigned to this user without being removed. Therefore, the quantity of manufactured products that are removed as defective products is drastically reduced, and the yield of manufactured products can be increased. In addition, products with a long expected life are assigned to users with severe usage conditions, so products that satisfy the user are supplied rather than simply assigning products that exceed the quality standard S as in the prior art. can do.

It is a functional lineblock diagram of a sorting device in one embodiment concerning the present invention. It is a hardware block diagram of the sorting apparatus in one Embodiment concerning this invention. It is explanatory drawing which shows the data structure of the user information table in one Embodiment which concerns on this invention. It is explanatory drawing which shows the data structure of the manufactured goods information table in one Embodiment which concerns on this invention. It is a flowchart which shows operation | movement of the sorting apparatus when the use condition in one Embodiment is received in this invention. It is a flowchart which shows operation | movement of the sorting apparatus when the test | inspection data in one Embodiment which concerns on this invention is received. It is explanatory drawing for demonstrating the test | inspection data of the moving blade which is a manufactured product. It is explanatory drawing which shows the lifetime population distribution curve of manufactured goods.

Explanation of symbols

10: Sorting device, 11: Use condition receiving unit, 12: Inspection data receiving unit, 13: Output unit, 14: Required life calculating unit, 15: Expected life calculating unit, 16: Quality index calculating unit, 17: Expected life calculating Part: 18: life classifying part, 19: sorting part, 20: storage area, 21: user information table, 22: manufactured product information table

Claims (6)

In the method of sorting manufactured products with different usage conditions for each user,
A use condition accepting step for accepting a user's use condition regarding the manufactured product;
Using the required life calculation formula indicating the correlation between the use condition of the manufactured product and the required life of the manufactured product necessary to satisfy the use condition, the user use condition received in the use condition receiving step A required life calculation process to obtain the required life according to
An inspection result receiving step for receiving results of post-manufacturing inspection of the plurality of manufactured products;
For each of the results of each post-manufacturing inspection for each of a plurality of results of the post-manufacturing inspection received in the inspection result receiving step, using a predicted life calculation formula indicating a correlation between the result of the post-manufacturing inspection and the life of the manufactured product. A predicted life calculation step to obtain a predicted life according to
Among the plurality of manufactured products, a manufactured product that supplies the user with a product having a longer predicted life calculated in the predicted life calculation step than the required life calculated in the required life calculation step. Sorting process and
A method for assembling manufactured products, comprising: The method for sorting manufactured products according to claim 1,
A classifying step for determining which class of the life class divided into at least three or more of the manufactured products for which the predicted life is calculated in the predicted life calculation step;
In the sorting step, among the plurality of manufactured products divided into three or more life classes, a product of a life class having a predicted life longer than the required life determined in the required life calculation step is sent to the user. The product to be supplied by
A method for sorting manufactured products. In the method for assembling the manufactured product according to any one of claims 1 and 2,
The manufactured product is a turbine component,
The usage conditions of the turbine parts received in the usage condition reception step include a planned total operation time of the turbine and a planned total number of times the turbine is started,
The required life calculation formula is a formula using the planned total operation time and the planned total number of activations as variables,
A method for sorting manufactured products. In the sorter for manufactured products with different usage conditions for each user,
Use condition accepting means for accepting a user's use condition regarding the manufactured product;
Using the required life calculation formula indicating the correlation between the use condition of the manufactured product and the required life of the manufactured product required to satisfy the use condition, the use condition of the user received by the use condition receiving means A required life calculating means for obtaining the required required life,
An inspection result receiving means for receiving a result of a post-manufacturing inspection of the plurality of manufactured products;
For each of the plurality of post-manufacturing inspection results received by the inspection result accepting means, the result of each post-manufacturing inspection is calculated using a predicted life calculation formula indicating the correlation between the result of the post-manufacturing inspection and the life of the manufactured product. A predicted life calculation means for obtaining a corresponding predicted life;
Among the plurality of manufactured products, a manufactured product having a longer predicted life calculated by the predicted life calculation means than the required life calculated by the required life calculation means is a product supplied to the user. Sorting means,
A device for sorting manufactured products, comprising: In a product sorting program with different usage conditions for each user,
A use condition accepting step for accepting a user's use condition regarding the manufactured product;
Using the required life calculation formula indicating the correlation between the use condition of the manufactured product and the required life of the manufactured product necessary to satisfy the use condition, the user use condition received in the use condition receiving step The required life calculation step to obtain the required life according to
An inspection result receiving step for receiving results of post-manufacturing inspections of the plurality of manufactured products;
For each of the plurality of post-manufacturing inspection results received in the inspection result receiving step, each post-manufacturing inspection result is calculated using a predicted life calculation formula indicating the correlation between the result of the post-manufacturing inspection and the life of the manufactured product. A predicted life calculation step for obtaining a corresponding predicted life,
Among the plurality of manufactured products, a manufactured product having the predicted life calculated in the predicted life calculation step longer than the required life calculated in the required life calculation step is a product supplied to the user. Sorting steps;
A product sorting program characterized by causing a computer to execute the process. In the product sorting program according to claim 5,
In the use condition receiving step, the user identifier of the user is received together with the user use condition related to the manufactured product, and the user condition storage area preset in the computer is stored in association with the use condition and the user identifier.
In the required life calculation step, the use condition and the user identifier stored in the user information storage area are read out, the required life corresponding to the use condition is obtained, and the required life is associated with the user identifier. Storing in the user information storage area,
In the inspection result receiving step, the result of the post-manufacturing inspection of the manufactured product is received, the manufactured product identifier of the manufactured product is received, and the result of the manufacturing inspection is stored in the manufactured product information storage area preset in the computer. Store the product identifier in association with it,
In the predicted life calculation step, the result of the post-manufacturing inspection and the product identifier stored in the product information storage area are read out, the predicted life according to the result of the post-manufacturing inspection is obtained, and the prediction Storing the life in association with the product identifier in the product information storage area;
In the sorting step, the plurality of manufactured product identifications stored in the manufactured product information storage area are stored in the user information storage area rather than the respective predicted lifetimes associated with the manufactured product identifiers. Associating the user identifier with the short required lifetime;
A product sorting program characterized by that.

Images