JP2750591B2 - Sheet metal production equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial application field) The present invention relates to an electric means, a mechanical means, a chemical means, etc., from a member mainly made of an iron plate or the like to a finished product. Processing of a plurality of processes, or, sheet metal products subjected to other processing, or a part of a semi-finished product production equipment, which is installed between the arrangement of processing equipment required for each of the steps and each of the steps Storage and relay facilities and equipment, especially those that correspond to FSM.

(Prior Art) In the case of so-called "multi-type small-quantity production" in which a certain product group is manufactured in small quantities over many types within a limited time limit, processing equipment in each processing step is increased according to the number of types of products. It is not economical, and in practice, it is best to combine as many of the products as possible into a single lot as much as possible within the time limit In general, a method is employed in which the production is performed by a limited number of processing equipment as much as possible, and the operation rate of the processing equipment is not reduced by bringing the production rate close to “small-scale mass production”.

(Problems to be Solved by the Invention) However, it is basically difficult to establish a “small-scale and large-scale production” system by the above-mentioned method. In the case of "", unintended stagnation of processed or unprocessed component products at the entrance and exit of each of the above-mentioned processing steps is unavoidable, and the rectification of the stagnation efficiently according to the production plan is fundamental. There was no method and no means.

Therefore, the present invention fundamentally states that the order of each type of product of all types of ordered products is grouped as much as possible within the allowable period and the number of products manufactured in one lot is increased as much as possible. Stop relying on simple palliative means,
Arrangement of each processing equipment and waiting for processing of products generated at each node in a series of processing steps of the product so that it can respond to "many kinds of small-quantity production" with the number of orders equal to the number of orders of customers Storage means and its arrangement, etc., are organically coupled, and the processing equipment waits for product members, and the traffic of product members stays, etc.
Another object of the present invention is to prevent the process from being disrupted due to stagnation and to provide one important means for implementing FMS.

(Means for Solving the Problems) The technical means for solving the above problems is to provide the sheet metal production facility with first and second three-dimensional warehouses for storing baskets for storing sheet metal parts separated from each other, A first transport path for transporting the basket from one of the first and second three-dimensional warehouses is laid between the first and second three-dimensional warehouses; A welding machine and a coating facility are disposed facing the periphery except for the first transport path, and a bending machine is disposed facing the periphery except the first transport path of the second three-dimensional warehouse. A second transport path for transporting the basket is laid on the second three-dimensional warehouse in a direction in which the first transport path extends, and a cutting machine is provided beside or at the end of the second transport path. , And the configuration.

(Operation) According to the above configuration, the member processed by the cutting machine arranged at the end of the second transport path or at the side is stored in a predetermined basket waiting on the second transport path. Then, it is forwarded on the second transport path, approaches the second three-dimensional warehouse, and is transferred to a predetermined shelf of the second three-dimensional warehouse and stored therein while being put in the basket.

The basket contains all the sheet metal members necessary to form one product of one kind, and some of the members need to be bent. It is pulled out from a predetermined shelf of the warehouse and is brought close to the bending machine. The section of the bending machine is located close to the second three-dimensional warehouse for convenience of this process, and when a predetermined member is subjected to a predetermined bending process, the member is restored to its original state. And stored in a predetermined shelf of the second three-dimensional warehouse.

Next, the basket is mounted on a carriage waiting at the end of the first transport path, forwarded to the first three-dimensional warehouse, temporarily stored as described above, and then close to the first three-dimensional warehouse. It is turned to a welding machine in the welding section in which it is placed, and the stored members are taken out, combined, welded, assembled, stored again in the original basket, and stored in the first three-dimensional warehouse in a predetermined manner. Stored and stored on shelves. Then, the basket is forwarded to a painting section, subjected to a predetermined base treatment, coated and finished, and stored again in the original basket and stored in a predetermined shelf of the first three-dimensional warehouse. And kept waiting for shipment.

As described above, the members housed in the basket are:
After completion of one processing step in a processing section arranged close to each three-dimensional warehouse, it is forwarded to the second three-dimensional warehouse and / or the first three-dimensional warehouse according to the status of waiting for members in the next process or waiting for processing. It is stored or arranged, arranged and indirectly sent from the previous process to the next process. In any case, it is systematically sent between each process or stored in a planned manner to control the process.

(Embodiment) The configuration and operation of an embodiment of a sheet metal production facility according to the present invention will be described below with reference to the drawings.

FIG. 1 shows an FM using the sheet metal production equipment according to the present invention.
FIG. 2 shows a plan view of the main structure of S in FIG.

The first and second three-dimensional warehouses 1 and 2 store one by one a basket 3 corresponding to a member to be processed or assembled or a basket for storing parts or assembled products. Many shelves of shelves stacked in the vertical direction on the Y coordinate are lined up in the horizontal direction on the X coordinate.
Items arranged so as to be addressable by XY codes are arranged in two rows, and the first three-dimensional warehouse 1 brings the two rows of shelves 1a and 1b into close contact with each other, and has The stacker cleaners 4 and 5 for loading and unloading the baskets 3 are respectively arranged from and run on any of the shelves of the three-dimensional warehouse or to any of the shelves of the three-dimensional warehouse. The two-dimensional warehouse 2 has a stacker cleaner 6 for moving the basket 3 in and out.
They are spaced apart so that they can travel between the rows of shelves 2a and 2b.

The stacker cleaners 4, 5, and 6 are each installed on a truck that runs on a monorail laid on the floor by a command of a central control unit (hereinafter referred to as a CPU).
An elevator that carries the basket 3 and moves up and down in response to a command from the CPU is provided.

The first transport path 7 includes a cart 8 on which the basket 3 is mounted and transported, two rails laid on the same plane on the floor on which the cart 8 travels, and a cart 8 mounted below the floor and controlled by the CPU. And a chain-type drive device for towing and traveling. In the embodiment, two sets are installed.

The roller conveyor 9 corresponding to the second transport path has two rows of feed roller devices that are driven in conjunction with each other by a command from the CPU, and transports the basket 3 placed on the rollers. In the embodiment, two sets are installed and three baskets 3 are mounted respectively. And said 2
A roller conveyor 10 having the same function and the same structure for connecting the two and transporting the basket 3 mutually is provided between the roller conveyors 9 of the set.

Automatic welding processing section RW by welding robot 11 equivalent to welding machine, and painting finishing section equivalent to painting equipment
The PF is disposed facing one side of the upper shelf 1a on the drawing of the first three-dimensional warehouse 1, and a dedicated jig for storing a dedicated jig for welding in the automatic welding section RW. Two welding robots 11 equipped with a three-dimensional warehouse 12 are illustrated, and two sets of closed-loop monorails are provided in the paint finishing section PF.
13 and 14 and a base treatment room 141, a base treatment curing room 142, a primary coating room 143, a primary curing room 144, and a repair room 14 provided respectively along the monorail 14.
5, secondary coating room 146, and baking finish room 14
7 is equipped as shown.

A bending section B by the brake press group 15 corresponding to the bending machine is installed facing one side of the lower shelf 2b on the drawing of the second three-dimensional warehouse 2, and a routine is provided on one side of the upper shelf 2a. A multi-purpose machining section M for performing machining that does not belong to any of the above-mentioned machining that is not a work is arranged.

The cutting section CT by the laser cutting machine group 16 corresponding to the cutting machine corresponds to the roller conveyor 9 corresponding to the second conveying path.
In the cutting section CT, a dispenser 161 that stores and supplies a plate material as a raw material and the plate material are transported to the laser cutting machine group 16 and placed in a predetermined position, and the cutting process is performed again. An autoloader 163 for transporting the sheet material to the sorting station 162 and a scrap conveyor 164 for processing the remaining material after the cutting process are provided, and the sheet metal production facility is configured. Next, the operation of the above-described configuration will be described, and a series of steps of the sheet metal production facility will be described as an aid for understanding the effect.

Compartment CT is 4 ^- × 8 ^- a compartment cut out products members of various shapes from the material iron plate, the dispenser 161 iron plate plate Atsubetsu a material, which is stored the required amount of current for each material, manufacturing instructions The plate material specified by the autoloader 163 operated according to the command of the CPU input is pulled out and placed on the specified laser cutting machine 16, and then the CP
According to the work instruction called in accordance with the production instruction from U, a predetermined cutting processing program nested in advance is selected, and the laser cutting machine 16 is instructed to perform the cutting processing.

The autoloader 163 has a function as a conveying means for transporting the iron plate from the dispenser 161 to the laser cutting machine 16 and a function as a positioner for accurately placing the iron plate at a predetermined position on a processing table of the laser cutting machine 16. The laser cutting machine 16 has a laser nozzle for freely moving in the X and Y-axis directions at predetermined intervals on the iron plate and cutting it into an arbitrary shape, and cuts the iron plate into a predetermined shape. Then, the product material cut and processed in this section CT and formed into members of various shapes is not completely separated from the base material but is connected at a very small part, and is transported to the sorting station 162 by the autoloader 163, and is manually processed. It is completely separated from the base material by a hammer, hand plasma, etc., separated, the shape is identified by an image sensor or an operator (not shown), and operation of a sorting robot according to a predetermined sorting program, or extraction by the operator Then, they are sequentially loaded in the basket 3 waiting on the roller conveyor 9, while the remaining scraped base material is dropped on the scrap conveyor 164 passing on the floor, collected in the scrap container 165, and carried out of the factory. Is done.

While the sheet metal members are stored in the basket 3 one by one, the terminal of the CPU is operated by a command from the CPU.
The work instruction sheet 301 (see FIG. 3) is issued to the 17 printers, and the pockets 302 provided in the respective baskets 3 are inserted, and are used for the subsequent processing of the members and the process management. When the sorting and loading work is completed, the bar code 303 on the work instruction sheet 301 is read by the terminal device 17 and "end of sorting work" is input to the CPU, registered, and used for later process management. Next, the basket 3 approaches the second three-dimensional warehouse 2 by the operation of the roller conveyor 9 according to the movement command of the CPU and moves to the predetermined position 20.
Stop at 1.

The roller conveyor 9 as the second transport path has a side surface shown in FIG. 4A and a front surface shown in FIG.
Is a normal roller conveyor provided with a large number of rollers 402 that are rotated in conjunction with each other by a driving device 401 that is operated in accordance with a command from the apparatus, and transports the basket 3 by rolling of the rollers. Also, the roller conveyor 10 is completely the same except that the length is different, and therefore the description is omitted.

The basket 3 stopped at the predetermined position 201 is loaded with the basket 3 of the stacker cleaner 6 according to the transfer instruction of the CPU (see FIG. 5), and is once scooped up by a fork 502 mounted on the elevator 501, and then retracted. Then, it is mounted on the elevator 501, then transported to the position of the shelf addressed by the XY code, and placed and stored on a predetermined shelf in the reverse order.

The stacker cleans 6, 5, and 4 are driven up and down by a winch 504 through a single wire 505 so that the basket 3 can move up and down inside the frame 503 of the upright frame structure, and to the shelf of the basket 3, Alternatively, it is mainly composed of an elevator 501 equipped with a fork 502 for a transfer operation from a shelf and a loading / unloading operation, and a carriage 508 mounted and fixed with the frame 503 and self-propelled on a monorail 507 by a traveling motor 506, and a movement command from the CPU. Is temporarily received by the controller 509 and the winch 504 and / or the traveling motor 506 are driven to load the basket 3 and to reciprocate for a predetermined stroke. Reference numeral 510 denotes a guide rail mounted on the factory building 511 and supporting the top side of the frame 503.

Next, the basket 3 is again operated by the stacker cleaner 6 in accordance with the above-mentioned manufacturing instruction.
Is pulled out of the shelf 2b of the three-dimensional warehouse 2 for bending by the brake press group 15 in the section B, and undergoes a predetermined processing, or other required predetermined in the M section for multipurpose work according to the work instruction sheet 301. Undergo processing or inspection.

Here, at the start and end of the work in each process, the CPU reads the barcode 303 on the work instruction sheet 301 by the terminal of the CPU installed in each process section, so that the CPU can check the status of each basket. All data can be ascertained and data used for later process management is accumulated.

Next, the basket 3 is mounted on the carriage 8 waiting at the end 202 of the first transport path 7 by the stacker cleaner 6, transported to the AD section on the transport path 7, temporarily stopped at 203, and then stopped at the rotating magazine type. The necessary parts other than the sheet metal members stored in the accessory stocker 18 such as door handles, hinges, window glass, sash, etc., procured from outside the company are replenished and loaded. In this AD section, the terminal 19 reads the barcode 303 on the work instruction sheet 301 stored in the pocket 302 provided in the basket 3, and the terminal 19 reads the above-described accessory to be refilled and loaded. The list is displayed, and when loading is completed, the barcode 303 on the work instruction sheet 301 is read again by the terminal 19, and “end of accessory replenishment” is input to the CPU, registered, and used for later process management. .

Then, while riding on the cart 8, the basket 3 approaches the first three-dimensional warehouse 1 and stops at the predetermined position 204 in accordance with the movement command of the CPU.

The first transport path 7 has two rails 601 (see FIG. 6).
And a chain provided under the floor for pulling the cart 8 and a driving device thereof, which has (A) a side surface, (B) a front surface, and (C) a plane, and has a drive (not shown) according to a command from the CPU. Equipment driven towing chain
The basket 3 is attached to the cart 8 which is connected by inserting the connecting pins 604 into the connecting fittings 603 attached at a predetermined pitch to the 602.
Equipped with or with an empty load, tow.

The basket 3 stopped at the predetermined position 204 is mounted on the stacker 5 in the same manner as described above, and then another XY
It is transported to a predetermined shelf position of the three-dimensional warehouse 1 addressed by the code, placed and stored, taken out again, and forwarded to the next welding process. The basket 3 is sent in advance to the HW section via the shelf 1b of the three-dimensional warehouse 1 to receive manual welding of a predetermined portion, or if the work instruction 301 is only an instruction for automatic welding, the basket 3 is directly It is sent to the RW section via the shelf 1a of the warehouse 1 and receives a robot welding operation of a predetermined portion.

Between the shelves 1a and 1b of the three-dimensional warehouse 1, a basket 3 is directly connected from the stacker clean 4 side to the stacker clean 5 side.
A conveyor 205 similar to the conveyor 9 for receiving and transferring is provided.

In the RW section (see FIG. 7), around the welding robot 11, the shelf 1a of the three-dimensional warehouse 1, a work table 701, a stacker clean 702 for a special jig, a three-dimensional warehouse 12 for a special jig, and a work table 703 are arranged. In addition to the automatic welding by the welding robot 11 on the work table 701, each member was taken out from the basket 3 on the work table 703 and was selected from the dedicated jig three-dimensional warehouse 12 by the dedicated jig stacker 702. The combination work is performed using the special jig 704, and as soon as welding on the work table 701 is completed, a preparation work is performed so that the welding work can be started immediately.
As in the above-described steps, a series of these welding steps, that is, selection of a dedicated jig, calling of a welding program, and the like are all performed by the work instruction 301 via the terminal 20 of the CPU. Then, the basket 3 temporarily stored on the shelf 1a of the three-dimensional warehouse 1 is sent to the next paint finishing section PF again. In the section PF, the parts that have been prepared as products in the previous process are taken out of the basket 3 and inspected, tested, or prepared for the next painting, and reworked after finishing the painting, and for multipurpose use such as inspection. There are a monorail 13 and two sets of closed loop monorails for the painting finishing process itself, and the process can be performed via the monorail 13 or directly to the monorail 14 process as required.

In the painting finishing process itself, the part 21 is hung on a hanger 140 mounted on the monorail 14, and the base treatment chamber 1
In 41, a base treatment is performed by chemical means such as a phosphoric acid solution bath or a mechanical means such as disk sander polishing, and dried in a base treatment curing chamber 142.
Alternatively, the undercoat is sprayed in the primary coating chamber 143, and the undercoat is semi-solidified or solidified in the primary curing chamber 144.
At 145, the finished state of the undercoat is inspected, and a reworking operation is performed if necessary. Secondary coating room
In 146, a top coat spray is performed, and a baking finish room 147
Then, baking and drying by infrared rays or the like is performed, and a series of coating processes is completed.

In this way, all parts and materials for completing one product of a certain kind are put into the basket, and each basket is put in and taken out every time the process is performed, and finally, the painting, Finished products become finished products, and repetition of loading and unloading continues until just before shipping.However, it is not economical for the processing equipment provided in each process section to have a capacity corresponding to the peak workload in a short time. In general, since the capacity is set to be slightly lower than the steady amount, stagnation occurs between the respective steps of the basket 3 at the peak time. Therefore, the stored baskets are temporarily stored on the shelf of the three-dimensional warehouse addressed by the XY code, and the CPU is made to perform programmed stay management. The baskets stored in Iku) are taken out in order (or interrupt operation is possible in special cases).

As described in detail above, a series of sheet metal production equipment that cuts out sheet materials, combines them, and also welds, assembles, and paints necessary accessories together to make a product When trying to obtain the same effects as low-mix, high-volume production in production, how to rectify the flow of semi-finished products that have to wait for processing between each process is a major issue. However, the problem was solved by providing a three-dimensional warehouse that can be temporarily stored for each process. The complexity of management work by handling many types of products in a short period of time is based on the fact that a work instruction sheet like a lost tag is attached to a basket in which each product is stored, thereby enabling each process to be started and ended. Inevitably, the information on the existence and status is inevitably aggregated in the CPU, and as a result, the central control unit determines which products are stored in which three-dimensional warehouses, in which shelves, and in what stage of processing. The effect that the CPU can always grasp the situation and respond to sudden changes in the delivery date of the demand destination during production, etc. It became possible to obtain.

Note that the work instruction may have a configuration in which information is written to an IC card or a memory chip instead of issuing a work instruction with a barcode.

(Effects of the Invention) By the above-described configuration and operation, even in the case of an order lot such as one production quantity for one order quantity for a wide variety of customers, semi-finished products are temporarily stored in a three-dimensional warehouse for each process, While looking at the operating state of the processing equipment, it is possible to arrange the traffic efficiently and send out the semi-finished product to the next process, and to make a little extra in anticipation of the troublesome setup change No more consideration. As a result, it is no longer necessary to have inventory that could be defective in the factory.

The delivery date can be uniquely determined from the kind and quantity of the ordered product, and the production plan can be easily drafted.

The material purchase amount was uniquely determined from the kind and quantity of the ordered product, and material management became easy.

Since only the ordered product needs to be produced, the delivery time can be shortened.

Since all processing equipment and warehouse equipment can always correspond to any type, even when mass-producing one type of product, production is promoted in parallel without biasing the load to the specific equipment, This has made it possible to shorten delivery times without lowering the operation rate of the equipment.

The basket into which all the parts and materials for completing one product across all varieties are put in one size, and the parts group cut out from the iron plate, which is the material, is immediately equivalent to one product. Each of them is stored in this basket, and there is no other storage space, so that there is no possibility of loss or the like, and it is not necessary to manage the stock of each part. Furthermore, it was possible to eliminate the occurrence of an unexpected situation such as interruption of a machining process caused by a shortage of parts or an apparent shortage of parts. Furthermore, in terms of layout, the system has a three-dimensional warehouse at the meeting point between the processes, and furthermore, the transport path is aligned. Therefore, when the production speed is required, by using the shelves near the transport path, it is possible to realize the production by the extremely short basket movement.

Also, you can return the empty basket straight to its original location,
When the same basket is repeatedly produced, the production efficiency can be increased.

This has the effect of providing one of the important means of FMS.

[Brief description of the drawings]

FIG. 1 is a perspective view of a sheet metal production facility showing an entire configuration of the present invention, FIG. 2 is a schematic plan view of a main part of FIG. 1, FIG. 3 is a simplified perspective view illustrating a basket and work instructions, FIG. 4 is a side view (A) of a conveyor which is a second transport path, similarly a front view (B), FIG. 5 is a side view (A) of a stacker clean, similarly a front view (B), and FIG. FIG. 7 is a side view (A), a front view (B), a plan view (C), and a simplified perspective view of a section RW of the welding machine. CPU / Central control unit, 1,2 / Three-dimensional warehouse 3.Basket 4,5,6 / Stack stacker 7.First transfer path, 8 / trolley 9.Roller conveyor (second transfer path) 11.Welding robot 15・ Brake press 16 ・ Laser cutting machine RW ・ Automatic welding section PF ・ Painting section B ・ Bending section, CT ・ Cutting section

 ────────────────────────────────────────────────── ─── Continuation of the front page Examiner Yasushi Nakamura (56) References JP-A-60-44256 (JP, A) JP-A-61-86164 (JP, A) JP-A-1-205830 (JP, A)

Claims (1)

(57) [Claims] A first and a second three-dimensional warehouse for storing baskets for storing sheet metal parts are provided apart from each other, and a first and a second three-dimensional warehouse for transporting the basket from one of the first and second three-dimensional warehouses to the other are provided. A first transport path is laid between the first and second three-dimensional warehouses, and a welding machine and a coating facility are arranged facing the periphery of the first three-dimensional warehouse except for the first transport path. A bending machine is arranged facing the periphery of the second three-dimensional warehouse except for the first transport path, and in a direction in which the first transport path extends with respect to the second three-dimensional warehouse, Sheet metal production equipment in which a second transport path for transporting baskets is laid, and a cutting machine is arranged beside or at the end of the second transport path.