JP2522841B2 - Recovery method in case of production line failure and device used for its implementation - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial field of application) The present invention is directed to a case where a facility in a production line is subjected to sequence control of its operation, and when the facility fails, When the cause is eliminated, the recovery method for a production line failure, which is used to recover the equipment to a state in which the sequence control of the operation is properly performed, and the production line failure used for implementing the recovery method Regarding return device.

(Prior Art) In a production line such as an automobile assembly line, a sequence control unit having a built-in computer is provided for various installed facilities, and an operation that each facility should sequentially perform by the sequence control unit. It is known to perform the sequence control of. When such sequence control is performed, the sequence control program is loaded into the computer incorporated in the sequence control unit, and the sequence control unit controls each stage of operation control for each of various equipments installed in the production line. The sequence control program is used to proceed sequentially.

When sequence control is performed on the operation of various equipment installed in such a production line, failure diagnosis is performed in parallel with the sequence control by monitoring the control state and detecting a failure in each equipment. Is often done. The fault diagnosis related to the sequence control is assumed to take various forms. For example, Japanese Patent Laid-Open No. 60-238906 discloses sequence control under the condition that equipment is normally operated. The operating state of the components of the circuit section is set as a reference state, and the operating states of the components of the sequence control circuit section during the actual operation of the equipment are sequentially compared with the reference state,
It has been proposed as one of the fault diagnosis related to sequence control to perform abnormality detection based on the difference.

(Problems to be Solved by the Invention) As described above, under the sequence control for the operation of various equipment installed in a production line accompanied by the failure diagnosis, the failure of the equipment is detected by the failure diagnosis. In this case, it is desirable to eliminate the cause of the detected failure and to quickly return the equipment to a state where the sequence control of its operation is properly performed by an easy operation. It is hard to say that the restoration of the equipment to the sequence control state after the equipment failure is detected is performed as desired.

In view of such a point, according to the present invention, various operations to be performed are divided into a plurality of operation blocks as an operation block, which is a maximum unit of a series of operations that are independently performed from a start to an end under a normal state. At the same time, each of the plurality of operation blocks is divided into a plurality of operation steps, and sequence control is performed to sequentially execute the plurality of operation steps in each of the plurality of operation blocks in a preset order. Focusing on the equipment in the production line, when a failure occurs in such equipment, after the cause of the failure is eliminated, the equipment can be properly sequenced to control its operation quickly with easy operation. Method for recovering from a production line failure and a recovery method for a production line failure used for implementing such a recovery method And to provide a device.

(Means and Actions for Solving the Problem) In order to achieve the above-mentioned object, the method for recovering from a production line failure according to the present invention starts various operations to be performed by equipment in the production line under normal conditions. The maximum unit of a series of operations that will be performed independently from to end is divided into a plurality of operation blocks as an operation block, and each of the plurality of operation blocks is divided into a plurality of operation steps,
When a failure occurs in the equipment under the sequence control for the equipment to sequentially execute the plurality of operation steps in each of the plurality of operation blocks in the preset order, the recoverable operation of the plurality of operation blocks Specify the one that has been stopped at an intermediate operation step without reaching the step, and then activate it to sequentially advance each of the operation steps from the intermediate operation step to the recoverable operation step in the specified operation block. By specifying the actuating element to be performed, the specified actuating element is actuated to bring the specified operation block into a state in which it has reached the recoverable operation step.

In addition, the production line failure recovery device according to the present invention operates various operations that should be performed by the equipment in the production line in the maximum unit of a series of operations that are independently performed from the start to the end under normal conditions. The equipment is divided into a plurality of operation blocks as a block, each of the plurality of operation blocks is divided into a plurality of operation steps, and the plurality of operation steps in each of the plurality of operation blocks are sequentially executed in a preset order. When a failure occurs in equipment under sequence control, the one that has been stopped at an intermediate operation step without reaching the recoverable operation step among multiple operation blocks is specified as the failure operation block. The failure operation block identification means and the operation steps from the middle operation step to the recoverable operation step in the failure operation block Actuating element specifying means for specifying an operating element to be operated in order to sequentially proceed each of the operation steps, and operating element specifying means for specifying an operating element to be operated for operating the operating element specified by the operating element specifying means. According to the operation on the operation element specified by the operation element specifying means, each of the operation steps from the intermediate operation step to the recoverable operation step is sequentially advanced, and the failure operation block reaches the recoverable operation step. And an operation step increasing means.

By doing so, in the method for recovering from a production line failure according to the present invention or the production line failure recovery apparatus according to the present invention, a plurality of operation steps in each of a plurality of operation blocks are preset. When a failure occurs in equipment that is sequence-controlled to be executed sequentially in sequence, after the operating element that caused the failure is restored, the equipment can be properly sequence-controlled for its operation immediately. It is possible to return to the normal state, and as a result, it is possible to reduce the damage caused by the stagnation of the production line.

(Embodiment) Prior to description of a method for recovering from a production line failure according to the present invention, and a production line failure recovery apparatus used to implement such a recovery method, a method for recovering from a production line failure according to the present invention, An example of a vehicle assembly line to which the production line failure recovery device used to implement such a recovery method is applied will be described with reference to FIGS. 2 and 3.

In the vehicle assembly line shown in FIGS. 2 and 3, a positioning station for receiving a vehicle body 11 on a pedestal 12 and controlling the position of the pedestal 12 to position the body 11 on the pedestal 12 Docking station ST2 that combines ST1, the engine 14, the front suspension assembly (not shown), and the rear suspension assembly 15 and the body 11, which are mounted at a predetermined position on the pallet 13.
And the engine 1 combined with it for body 11
4. A fastening station ST3 for fastening and fixing the front suspension assembly and the rear suspension assembly 15 using screws is provided. In addition, the body is located between the positioning station ST1 and the docking station ST2.
An overhead type transfer device 16 for holding and transferring 11 is provided, and a pallet transfer device 17 for transferring the pallet 13 is provided between the docking station ST2 and the fastening station ST3.

The cradle 12 at the positioning station ST1 is a rail 1
It is supposed to move back and forth along 8, and also
Although not shown in the figure, the positioning station ST1 is arranged in relation to the pedestal 12 so that the pedestal 12 is orthogonal to the rail 18 (vehicle width direction) and along the rail 18 (front-back direction). Positioning means (BF) for moving and positioning the front part of the body 11 placed on the pedestal 12 in the vehicle width direction, positioning means (BR) for positioning the rear part of the body 11 in the vehicle width direction, Also, a positioning means (TL) for positioning in the front-rear direction is provided, and further engaged with the front left and right parts and the rear left and right parts of the body 11,
Elevating reference pins (FL, FR, RL, RR) for positioning the body 11 with respect to the pedestal 12 are provided. Then, the positioning device and the elevating reference pin constitute a positioning device 19 in the positioning station ST1.

The transfer device 16 includes a guide rail 20 arranged above the positioning station ST1 and the docking station ST2 so as to be laid between them, and a carrier 21 that is configured to move along the guide rail 20, An elevating hanger frame 22 is attached to the carrier 21, and the body 11 is supported by the elevating hanger frame 22. In addition, the pallet transport device 17 includes a pair of guide portions 24L and 24R provided with a large number of support rollers 23 that respectively receive the lower surface of the pallet 13, and a pair of transport rails 25L that extend parallel to the guide portions 24L and 24R. And 25R, 13 pallets each
Each has a pallet locking part 26 for locking
Pallet carrier that is supposed to move along L and 25R
27L and 27R, and a linear motor mechanism (not shown) that drives the pallet transfer tables 27L and 27R.

Struts in the front suspension assembly and struts in the rear suspension assembly 15 are assembled to the docking station ST2 when the front suspension assembly and the rear suspension assembly 15 are assembled.
A pair of left and right front clamp arms 30L and 30R for supporting 15A respectively and taking a mounting posture, and a pair of left and right rear clamp arms 31L and 31R are provided. The left and right front clamp arms 30L and 30R are attached to the mounting plate portions 32L and 32R, respectively.
In addition, the left and right rear clamp arms 31L and 31R are attached to the mounting plate portions 33L and 33R in a direction orthogonal to the transport rails 25L and 25R, respectively, while being attached to the transport rails 25L and 25R so as to be movable back and forth. It is attached so that it can be moved back and forth to the left and right front clamp arms 30L and 3
0R mutually facing tips and left and right rear clamp arms 31
Each of L and 31R has an engaging portion that engages with the strut in the front suspension assembly or the strut 15A in the rear suspension assembly 15. Then, the mounting plate 32L is attached to the fixed base 35L by the arm slide 34L, and
It is movable in the direction along 25L and 25R, and the mounting plate 32R
Can be moved in a direction along the transfer rails 25L and 25R with respect to the fixed base 35R by the arm slide 34R, and the mounting plate portion 33L is fixed to the fixed base 37L by the arm slide 36L and can be moved to the transfer rails 25L and 25R. The mounting plate portion 33R is movable by the arm slide 36R in the direction along the transfer rails 25L and 25R with respect to the fixed base 37R. Therefore, the left and right front clamp arms 30L and 30R can be moved forward, backward, leftward and rightward under the condition that their tips are engaged with the struts in the front suspension assembly.
The left and right rear clamp arms 31L and 31R are movable in the front-rear direction and the left-right direction while the front ends of the left and right clamp arms 31L and 31R are engaged with the struts 15A in the rear suspension assembly 15. , Arm slides 34L and 34R, Left and right rear clamp arms 31L and 31
The R and the arm slides 36L and 36R form a docking device 40.

Further, in the docking station ST2, a pair of slide rails 41L and 41R and a slide rail 41L installed so as to extend in parallel with the transport rails 25L and 25R, respectively.
And a movable member 42 adapted to slide along 41R,
A slide device including a motor 43 and the like for driving the movable member 42
45 is provided, and the movable member 42 of the slide device 45 is provided with an engaging means 46 for engaging a movable engine support member (not shown) provided on the pallet 13.
Is provided. Also, two lifting pallet reference pins which are supposed to position the pallet 13 at a predetermined position.
There are also 47. The slide device 45 is a body supported by the lifting / hanging hanger frame 22 in the transfer device 16.
When the engine 14, the front suspension assembly and the rear suspension assembly 15 arranged on the pallet 13 are combined with the pallet 11, the engaging means 46 of the engine 14 is the lifting pallet reference pin.
The movable engine support member on the pallet 13 positioned by 47 is moved back and forth, thereby moving the engine 14 back and forth with respect to the body 11 and avoiding interference between the body 11 and the engine 14. To be done.

At the fastening station ST3, the engine 14 combined with the body 11 and the robot 48A that is supposed to perform screw tightening work for fastening the front suspension assembly, and the rear suspension assembly 15 combined with the body 11 to the body 11 are provided. A robot 48B, which is supposed to perform screw tightening work for fastening, is installed, and also at the fastening station ST3, two lifting pallet reference pins that are supposed to position the pallet 13 at a predetermined position. 47 are provided.

In the vehicle assembly line as described above, the positioning device 19 in the positioning station ST1, the transfer device 16, the docking device 40 and the slide device 45 in the docking station ST2, the pallet transfer device 17, and the robots 48A and 48B in the fastening station ST3. Equipment (sequence control target equipment) in which the sequence control units connected to them respectively perform sequence control of their operations based on the sequence control program.
It has been.

The operation performed by each of these sequence control target equipment is divided into operation blocks that are defined as the maximum unit of a series of operations that can be independently performed from the start to the end. 12 motion blocks of B11 are obtained.

B0: An operation block (positioning block operation block) for positioning the body 11 on the pedestal 12 by the positioning device 19.

B1: An operation block for preparing the transfer of the body 11 by the transfer device 16 (transfer device preparation operation block).

B2: Left and right front clamp arm 3 by docking device 40
Front suspension assembly strut is clamped by 0L and 30R, and left and right rear clamp arms 31L
Strut 1 of rear suspension assembly 15 by 31R
Operation block that prepares to clamp 5A (strut clamp preparation operation block).

B3: An operation block in which the body 11 on the pedestal 12 positioned by the positioning device 19 is transferred to the elevating hanger frame 22 of the transfer device 16 and conveyed (transfer device receiving operation) block).

B4: An operation block (slide device preparation operation block) for preparing for engaging the engaging means 46 provided on the movable member 42 by the slide device 45 with the movable engine support member on the pallet 13.

B5: Operation block for returning the pedestal 12 to the original position by the positioning device 19 (reception block original position returning operation block).

B6: The engine 11 arranged on the pallet 13 and the body 11 supported by the elevating hanger frame 22 in the transfer device 16, and arranged on the pallet 13 and clamped by the left and right front clamp arms 30L and 30R. An operation block that combines the strut of the front suspension assembly and the strut 15A of the rear suspension assembly 15 clamped by the left and right rear clamp arms 31L and 31R (engine / suspension docking operation block).

B7: Operation block for returning to the original position by the transfer device 16 (transfer device original position return operation block).

B8: Left and right front clamp arm 3 by docking device 40
Operation block for returning 0L and 30R and left and right rear clamp arms 31L and 31R to their original positions (clamp arm original position return operation block).

B9: An operation block for operating the linear motor by the pallet transfer device 17 to transfer the pallet 13 on which the body 11 in which the engine 14, the front suspension assembly and the rear suspension assembly 15 are combined is placed to the fastening station ST3 ( Linear motor propulsion block).

B10: An operation block (screw tightening operation block) for performing screw tightening work for fastening the engine 14 and the front suspension assembly combined with the body 11 by the robot 48A.

B11: An operation block (screw tightening operation block) for performing screw tightening work for fastening the rear suspension assembly 15 combined with the body 11 by the robot 48B.

Further, each of the above operation blocks B0 to B11 is divided into a plurality of operation steps each involving an output operation.For example, for the pedestal positioning operation block B0, 10 operations of B0S0 to B0S9 are performed as follows. It is divided into steps.

B0S0: Operation step to check various conditions (condition confirmation operation step).

B0S1: An operation step in which the cradle 12 is moved by the positioning means BF to position the front part of the body 11 in the vehicle width direction (BF positioning operation step).

B0S2: An operation step (BR positioning operation step) in which the cradle 12 is moved by the positioning means BR and the rear portion of the body 11 is positioned in the vehicle width direction.

B0S3: An operation step (TL positioning operation step) in which the cradle 12 is moved by the positioning means TL and positioning is performed in the direction along the rail 18 of the body 11 (front-back direction).

B0S4: Operation step in which the lifting reference pin FL is engaged with the front left portion of the body 11 (FL engagement operation step).

B0S5: Operation step in which the lifting reference pin FR is engaged with the front right portion of the body 11 (FR engagement operation step).

B0S6: Operation step in which the up-and-down reference pin RL is engaged with the rear left side portion of the body 11 (RL engagement operation step).

B0S7: Operation step in which the lifting reference pin RR engages with the right rear portion of the body 11 (RR engagement operation step).

B0S8: Operation step in which the positioning means BF returns to the original position from the state in which the front portion of the body 11 is positioned in the vehicle width direction (BF original position return operation step).

B0S9: Operation step in which the positioning means BR returns to the original position from the state where the rear portion of the body 11 is positioned in the vehicle width direction (BR original position return operation step).

Subsequently, a method for recovering from a production line failure according to the present invention, which is applied to a vehicle assembly line in which the equipment to be sequence-controlled as described above is installed, and a recovery from a production line failure used for carrying out such a recovery method An example of the device will be described. FIG. 1 shows that an example of a method for recovering from a production line failure according to the present invention will be carried out, and a failure diagnosis / recovery system forming a production line failure recovery apparatus according to the present invention, a sequence control target facility and Shown with the sequence controller connected to them. Sequence controlled equipment 50
As described above, the positioning device 19, the transfer device 16, the docking device 40, the slide device 45, the pallet transfer device 17, and
Each of the robots 48A and 48B has a sequence control unit 51.
It is supposed to be subject to sequence control by.

Equipment 50 subject to sequence control by the sequence controller 51
Sequence control for the operation of
It is performed based on the sequence control program loaded in 51. When creating such a sequence control program, first, the operation block described above is used.
B0 to B11 are put together in an action block map showing respective attributes as shown in Table-1. In the operation block map of Table-1, "SC-REG" represents a 16-bit register, and each operation step provided for each of the operation blocks B0 to B11 is executed,
The step number is written. “FROM” represents an operation block immediately before the condition for starting the operation of the operation block, and “TO” is an operation block immediately following the operation block that is started when the operation of the operation block is completed. The "clear condition" represents an operation block in which the equipment related to the operation block returns to the original state, and the "equipment" represents equipment for sequence control related to the operation block.

Further, for each of the operation blocks B0 to B11, a plurality of operation steps in the operation blocks B0 to B11 are summarized in an operation step map in which respective attributes are shown. For example, for the operation steps B0S0 to B0S9 in the operation block B0 described above, first, the input / output map for the positioning device 19 as shown in Table 2 is created. In the input / output map of Table-2, “comment” indicates the content of each operation step.

Then, by calling the "comment" in Table-2, the operation step map as shown in Table-3 is compiled. Further, each of the operation blocks B1 to B11 is also grouped in the same operation step.

Then, based on the data about each of the operation blocks B0 to B11 and their attributes shown in the operation block map of Table-1, the operation blocks as shown in FIG.
An operation block flowchart showing the mutual relationship of B0 to B11 in time series is formed, and as shown in FIG. 5, from the operation block flowchart and the operation step map for the operation block B0 shown in Table-3. , A ladder program for the operation block B0 is created, and the operation steps for each of the operation blocks B1 to B11 are obtained in the same manner as the operation block flowchart and the operation step map for the operation block B0 shown in Table 3. A ladder program for each of the operation blocks B1 to B11, which is similar to the ladder program for the operation block B0 shown in FIG. 5, is created from the map. Then, the ladder programs relating to each of the operation blocks B0 to B11 are sequentially linked to form a sequence control ladder program. Therefore, the sequence control target equipment 50 in which the sequence control unit 51 performs sequence control of its operation,
A plurality of operation steps in each of the operation blocks B1 to B11 are sequentially executed according to the sequence control ladder program created as described above.

The failure diagnosis / recovery system is a failure diagnosis / recovery control device.
52 and a CRT (cathode ray tube) operation panel device 53.

The failure diagnosis / recovery control device 52 has a central processing unit (CPU) 62, a memory 63, an input / output interface (I / O interface) 64, and a transmission / reception interface 65 which are connected via a bus line 61. A hard disk device 66 as an auxiliary memory connected to the / O interface 64, a CRT 67 for display, and a keyboard 68 for inputting data and control codes are provided.
Further, the CRT operation panel device 53 has a central processing unit (CPU) 72, a memory 73, transmission / reception interfaces 74 and 75, and an input / output interface (I / O interface) 76 connected through a bus line 71. , In addition, I
A hard disk device 77 as an auxiliary memory connected to the / O interface 76, a CRT 78 for a display and a keyboard 79 for inputting data and control codes, and a touch panel 80 connected to the transmission / reception interface 74 are provided. As shown in Figure 6, touch panel
80 is attached to the outer surface of the face plate of the CRT78. Then, the transmission / reception interface 65 provided in the failure diagnosis / recovery control device 52 and the transmission / reception interface 51A provided in the sequence control unit 51 are interconnected, and C
Transmission / reception interface 75 provided on the RT operation panel device 53
And a transmission / reception interface 51A provided in the sequence control unit 51 are mutually connected, and further, a transmission / reception interface 65 and a CRT provided in the failure diagnosis / recovery control device 52.
A transmission / reception interface 75 provided in the operation panel device 53 is interconnected.

The failure diagnosis / recovery control device 52 receives the program processing data representing the progress state of the sequence control for the sequence control target equipment 50 from the sequence control unit 51 through the transmission / reception interfaces 51A and 65 in response to the operation of the keyboard 68, and in the CPU 62, According to the loaded failure diagnosis program, for example, the sequence control unit 51
Based on the execution time of each operation block in the sequence control target equipment 50 detected from the program processing data from, the occurrence of a failure in the sequence control target equipment 50 is detected, and if the occurrence of a failure is detected, the sequence control is performed. After investigating the operating element that caused the failure in the target equipment 50 and performing a failure diagnosis that prompts the repair of that operating element, after repairing the operating element that caused the failure, the sequence control target equipment 50 is The sequence control for the operation is performed by the sequence control unit 51 to perform a return control for returning to the state. Data representing each step ladder element in the sequence control ladder program loaded in the sequence control unit 51 is stored in the hard disk device 66 in a state of being individually read out. It is supposed to build a database for.

Further, in the CRT operation panel device 53, the touch panel 80 attached to the outer surface of the face plate portion of the CRT 78 is formed as a transparent body as a whole and responds to the contact position when a finger or the like is brought into contact with the surface. In addition to generating an output signal, the CRT7
A plurality of types of operation panels, each of which is configured by arranging operation elements such as switches, are selectively displayed on the face plate portion of 8. Then, on the surface of the touch panel 80, by touching the position corresponding to the selected one of the operation elements of the operation panel displayed on the face plate portion of the CRT 78 with a finger or the like, the output obtained from the touch panel 80 at that time Signal on the touch panel
As the operation input that means that the selected one of the operation elements of the operation panel corresponding to the contact portion in 80 is operated,
It can be supplied through the transmission / reception interface 74. Display data representing a plurality of types of operation panels selectively displayed on the face plate portion of the CRT 78 is stored in the hard disk device 77. Also, CR
On the face plate of the T78, in addition to the operation panel, an illustration showing the operating part of the equipment 50 subject to sequence control is also displayed, and the display data for that is also stored in the hard disk device 77.
Is supposed to build a database. The operation input supplied through the transmission / reception interface 74 by touching the touch panel 80 with fingers or the like is the CPU 7
2 is provided to the sequence control unit 51 from the transmission / reception interface 75.
It is supplied through 51A so that the operation control of the operation elements in the equipment 50 to be sequence-controlled can be performed.

As described above, when the operation panel input unit is formed by the CRT 78 and the touch panel 80, each time the operation panel selected on the face plate of the CRT 78 is displayed,
Correspondence between the position of each operation element on the operation panel displayed on the face plate portion of the CRT 78 and the position on the touch panel 80 is set.

When the failure diagnosis / recovery system has such a configuration, when a failure occurs in the equipment 50 subject to sequence control, an example of the method for recovering from a production line failure according to the present invention is carried out. , The process below is No. 8
A description will be given along the flowchart shown in the figure.

First, the failure diagnosis by the failure diagnosis / recovery control device 52 determines whether or not a failure has occurred in the equipment 50 subject to sequence control (step P1). Then, when a failure occurs in the equipment 50 subject to sequence control, failure analysis is performed (step P2), and as a result, one of the plurality of operation blocks shown in the flowchart of FIG. That is, the faulty operation block is identified, and further, the one of the plurality of operation steps in the identified action block that has caused a failure, that is, the faulty operation step is identified, and the faulty operation element that caused the failure is identified. Is specified (step P3).

Next, after the failure diagnosis / recovery control device 52 makes a recommendation for repairing the malfunctioning operation element, the repairing of the malfunctioning operation element is awaited (step P4). Then, when the malfunction operating element is repaired, all of the plurality of operation blocks shown in the flowchart of FIG.
It is determined whether or not the control has reached the resumable operation step indicated by B999 shown in (1), and the sequence control unit 51 can restart the sequence control (step P5), if the restart is possible, the sequence control by the sequence controller 51 is immediately restarted (step P6). On the other hand, when all the plurality of operation blocks are not in the state where the control has reached the recoverable operation step and the restart cannot be performed, the recovery control in the failure diagnosis / recovery control device 52 is performed. An uncompleted operation block that is in a state where control has not reached the recoverable operation step among the plurality of operation blocks after switching to the operation mode is specified. The control stop operation step whose control is stopped is specified (step P7).

Subsequently, the data representing the step ladder element corresponding to the specified control stop operation step is read from the hard disk device 66, and the display is made on the CRT67 based on the data, and the control is stopped on the face plate part of the CRT67. The step ladder element corresponding to the operation step is displayed (step P8). Then, the step ladder element displayed on the face plate portion of the CRT67 is referred to and analyzed, and the actuating element causing the control stop operation step is specified (step P9) and is specified. The actuating element to be actuated for manually actuating the actuating element is sought (step
P10). That is, the actuating element to be actuated to be brought into the state of proceeding from the control stop actuating step to the next actuating step is specified, and the actuating element to be actuated to actuate the actuating element to be actuated is specified. It is sought out.

The operation element data representing the operation element thus found is sent from the transmission / reception interface 65 of the failure diagnosis / recovery control device 52 and supplied to the CRT operation panel device 53 via the transmission / reception interface 75 (step P11). ). In the CRT operation panel device 53 to which the operation element data is supplied from the failure diagnosis / recovery control device 52, the display data corresponding to the operation panel including the operation element represented by the operation element data is read from the hard disk device 77. Is supplied to the CRT78, and the operation panel including the operation elements represented by the operation element data is displayed on the faceplate section of the CRT78, and the operation panel displayed on the faceplate section of the CRT78 on the surface of the touch panel 80 is displayed. Of the operation elements, a finger or the like is brought into contact with the position corresponding to the operation element represented by the operation element data from the failure diagnosis / recovery control device 52, and is represented by the operation element data from the failure diagnosis / recovery control device 52. The operation input indicating that the operated operation element is operated is supplied from the touch panel 80 through the transmission / reception interface 74. You. Then, such an operation input is supplied to the CRT operation panel device 53 from the transmission / reception interface 75 thereof and to the sequence controller 51 via the transmission / reception interface 51A (step P12). Thereby, by the sequence control unit 51 to which the operation input is supplied, the actuation element to be actuated in the sequence controlled equipment 50 is actuated, and the data indicating that the actuation element to be actuated is actuated, From the transmission / reception interface 51A provided in the sequence control unit 51, failure diagnosis /
It is supplied to the return controller 52 through the transmission / reception interface 65 (step P13).

In the fault diagnosis / recovery control device 52, which is supplied from the sequence controller 51 with data indicating that the actuating element to be actuated has been actuated, the control stop operation step advances to the next operation step by one step. The control to be performed is performed (step P14), and it is determined whether or not the next operation step advanced is the recoverable operation step, which is the operation step B999 in Table 3 described above (step P15). As a result, if the next operation step advanced is not a recoverable operation step,
The operation step is regarded as the specified control stop operation step, and again, the data representing the step ladder element corresponding to the specified control stop operation step is read from the hard disk device 66 described above, and the display based on the data is read. Each operation after the operation performed in the CRT67 is taken and the step ladder element corresponding to the control stop operation step is displayed on the face plate part of the CRT67 is sequentially performed, and the operation state is changed to the recoverable operation step. Repeated all the way. Then, when the recoverable operation step is reached, the sequence by the sequence control unit 51 is again in a state where all of the plurality of operation blocks shown in the flowchart of FIG. 4 have reached the recoverable operation step. It is determined whether or not the control can be restarted, and the above-described operation is repeated until the sequence control by the sequence control unit 51 is restarted.

Next, as described above, the failure diagnosis / recovery control device 52
The operation performed in the CRT operation panel device 53 when the failure diagnosis and the recovery control by the above are performed will be described with reference to the flowchart shown in FIG.

First, under the condition that the failure diagnosis by the failure diagnosis / recovery control device 52 does not detect the occurrence of a failure in the sequence control target equipment 50, the display data representing the operating part of the sequence control target equipment 50 is displayed from the hard disk device 77. The CRT78 is read out and the display based on the read state is taken, and the CRT78 is supposed to perform the operation monitor display (step Q1). Thus, the determination of whether or not the operation element data representing the operation element to be operated to operate the operation element to be operated is supplied is repeated until it is determined that the operation element data is supplied (step Q2).

Then, when the operating element data representing the operating element to be operated to operate the operating element to be operated is supplied, the hard disk device 77 responds to the operating panel including the operating element represented by the operating element data. The display data to be read is read out, supplied to the CRT 78, and the operation panel including the operation element represented by the operation element data is displayed on the face plate portion of the CRT 78 (steps Q3 and Q4). Under such circumstances, the coordinate reference for the display on the face plate portion of the CRT78 and the coordinate reference on the touch panel 80 are matched, and the touch panel 80 displays the operation elements of the operation panel displayed on the face plate portion of the CRT78. The operation corresponding to the position corresponding to the operation element represented by the operation element data from the failure diagnosis / recovery control device 52, which means that the operation element represented by the operation element data from the failure diagnosis / recovery control device 52 is operated. It is set to be a specific touch operation unit that generates an input (step Q6).

Subsequently, the state in which the determination as to whether the finger or the like is brought into contact with the set specific contact operation unit is repeated until it is determined that the finger or the like is brought into contact (step Q7). Then, when a finger or the like is brought into contact with the set specific contact operation unit, the output signal obtained from the touch panel 80 thereby operates the operation element represented by the operation element data from the failure diagnosis / recovery control device 52. Send / receive interface 75
Is supplied to the sequence control unit 51 through its transmission / reception interface 51A (step Q8), and then again operated by the failure diagnosis / recovery control device 52 to operate the operating element to be operated as described above. The state in which the determination as to whether or not the operation element data representing the operation element to be supplied has been supplied is repeated until it is determined that the operation element data has been supplied.

(Effects of the Invention) As is apparent from the above description, according to the method for recovering from a production line failure according to the present invention or the production line failure recovery apparatus according to the present invention, various operations to be performed are performed under normal conditions. The maximum unit of a series of operations that is independently performed from the start to the end is divided into a plurality of operation blocks as an operation block, and each of the plurality of operation blocks is divided into a plurality of operation steps, When a failure occurs that causes the sequence control to be stopped in the equipment in the production line that is supposed to be sequence-controlled to sequentially execute the plurality of operation steps in each of the operation blocks in the order set in advance, the failure occurs. After the cause of the problem is eliminated, the equipment is properly sequenced for its operation promptly with easy operation. It is possible to return to a state in which the production line is stopped, and as a result, damage caused by the stagnation of the production line is reduced.

[Brief description of drawings]

FIG. 1 shows an example of a method for recovering from a production line failure according to the present invention. A failure diagnosis / recovery system forming a production line failure recovery apparatus according to the present invention is a sequence control target facility and a sequence. 2 and 3 are diagrams showing the configuration together with the control unit, a method for recovering from a production line failure according to the present invention, and a vehicle assembly line to which a production line failure recovery apparatus used for carrying out such a recovery method is applied. A schematic side view and a schematic plan view showing an example, FIG. 4 is an operation block flowchart used for explaining sequence control for sequence control target equipment, and FIG. 5 is used for sequence control for sequence control target equipment by a sequence control unit. FIG. 6 is a ladder diagram showing an example of a sequence control program executed by the system shown in FIG. FIG. 7 is a schematic perspective view showing a part of the CRT operation panel device, FIG. 7 is a schematic plan view used for explaining the CRT operation panel device in the failure diagnosis / recovery system shown in FIG. 1, FIG. 8 and FIG. 6 is a flowchart provided for explaining an example of a method for recovering from a production line failure according to the present invention. In the figure, 16 is a transfer device, 17 is a pallet transfer device, 19 is a positioning device, 40 is a docking device, 45 is a slide device, 48
A and 48B are robots, 50 is equipment subject to sequence control, 51
Is a sequence controller, 52 is a failure diagnosis / recovery controller, 53
Is a CRT operation panel device, 51A, 65, 74 and 75 are transmission / reception interfaces, 61 and 71 are bus lines, 62 and 72 are central processing units (CPU), 63 and 73 are memories, and 64 and 76 are input / output interfaces (I / O interface), 66 and 77
Is a hard disk drive, 67 and 78 are cathode ray tubes (CRT), 6
8 and 79 are keyboards.

Claims (6)

(57) [Claims] 1. A variety of operations to be performed by equipment on a production line are divided into a plurality of operation blocks, each of which is a maximum unit of a series of operations that are independently performed under normal conditions from start to finish. In addition, each of the plurality of operation blocks is divided into a plurality of operation steps, and sequence control is performed on the equipment to sequentially execute the plurality of operation steps in each of the plurality of operation blocks in a preset order. And, when a failure occurs in the equipment, the one of the plurality of operation blocks that is stopped in an intermediate operation step without reaching the recoverable operation step is specified, and further the specified operation is performed. Operate in order to sequentially advance each of the operation steps from the middle operation step to the recoverable operation step in the block. Identifies the actuating element to be a method of recovery at the production line fault, characterized in that forming a state in which the operation block specified above has reached the restoration operable steps by actuating the identified actuating element. 2. A plurality of operation blocks, which have been stopped in an intermediate operation step without reaching a recoverable operation step, are specified after the operation element causing the failure is repaired. 2. The method for recovering from a production line failure according to claim 1, further comprising restarting the sequence control for the equipment after the specified operation block has reached the recoverable operation step. 3. A series of operations in which an operation to be performed by each piece of equipment in a production line provided with a plurality of pieces of equipment is performed independently from the operation of another piece of equipment under normal conditions from the start to the end. Is divided into a plurality of operation blocks as an operation block, and each of the plurality of operation blocks is divided into a plurality of operation steps, and the plurality of operation steps in each of the plurality of operation blocks are set in a preset order. When a failure occurs in the equipment under the sequence control for the equipment to be sequentially executed in step S1, the operation is stopped at an intermediate operation step without reaching the recoverable operation step of the plurality of operation blocks. Of the specified operation block, and the operation from the intermediate operation step to the recoverable operation step in the specified operation block. Characterized in that an actuating element to be actuated for advancing each of the steps is specified, and by actuating the specified actuating element, the specified operation block is brought into a state in which the resumable operation step is reached. How to recover from a production line failure. 4. The various operations to be performed by the equipment on the production line are divided into a plurality of operation blocks as an operation block, which is a maximum unit of a series of operations that are independently performed from the start to the end under normal conditions. In addition, each of the plurality of operation blocks is divided into a plurality of operation steps, and sequence control is performed on the equipment to sequentially execute the plurality of operation steps in each of the plurality of operation blocks in a preset order. And, when a failure occurs in the equipment, a failure operation block that identifies one of the plurality of operation blocks that has been stopped at an intermediate operation step without reaching the recoverable operation step as a failure operation block Identifying means and actions from the intermediate operation step to the recoverable operation step in the failure operation block Actuating element specifying means for specifying an operating element to be operated in order to sequentially proceed each of the operation steps, and operating element specifying for specifying an operating element to be operated for operating the operating element specified by the operating element specifying means Means, and each of the operation steps from the intermediate operation step to the recoverable operation step in accordance with the operation on the operation element specified by the operation element specifying means,
A production line failure recovery device comprising: an operation step advancing means for bringing the failure operation block into a state where the operation step capable of recovering has been reached. 5. The production line fault recovery device according to claim 4, further comprising operation element display means for displaying the operation element identified by the operation element identification means in an operable state. 6. The restarting means for restarting the sequence control for the equipment after the failed operation block has reached the recoverable operation step by the operation step advancing means. 5. The production line failure recovery device described in 5.