JP2771013B2 - production management system - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION "Industrial application field" The present invention is used, for example, in an automobile production line or the like that mixes and produces different types of machines, and distributes information of processing contents using a network, and The present invention relates to a production management system that instructs processing such as welding for each model for each unit and executes the processing.

2. Description of the Related Art In a production line or the like, a processing machine is arranged at a predetermined position and performs various processes on a workpiece moving along the line. By the way, when different types of vehicles and the like are produced on the same line as in the case of an automobile production line, each processing machine must perform processing according to the types of vehicles and the like. Further, it is necessary to perform a process of converting the processing order information into a model pattern for performing a process corresponding to the type of the machine of each processing machine. Furthermore, since the information on the processing order is mixed and complicated, it is necessary to perform processing for organizing and collecting the information into the information of each processing machine.

For this reason, as shown in FIG. 6, the operator in the conventional machining process first organizes and summarizes the information of the machining order into order data of each machining process, as shown in FIG. After converting the data into a model pattern, the model pattern is input to the processing machine, and the work is set on the processing machine based on the ranking data. These are the first and second conversion processes by a person. The ranking data is based on the model (year, manufacturing factory, 2
Doors, 4 doors, etc.), derivation (grade), options (presence / absence of sunroof, etc.), rod numbers (numbers assigned for each predetermined number), numerical values for the predetermined number, etc., are arranged according to the processing order. It is a thing. On the other hand, the processing machine is arranged in the area of the production line, and when a model pattern is input by an operator, a code for determining an operation is created using a conversion table stored therein, and according to the code, Perform processing. This is the third conversion processing by (M / C). The code includes the number and operation pattern of the processing jig, the job number (operation pattern, welding condition number, etc.) of the robot, and the like.

For example, in a processing step of welding a side panel to a floor panel, information of a processing order is converted into order data of the processing step, and further converted into a model pattern,
Input to the processing machine. After that, based on the ranking data, take out the side panel suitable for the model, derivation, etc. from the mounting place and set it on the jig, while the processing machine creates the code for deciding the operation based on the model pattern Weld necessary parts to the floor panel and assemble the floor panel and side panel.

In addition, the work of converting the order information into the model pattern in which the order data is aggregated into the processing process unit is changed when the model change of the vehicle type or the like occurs. Provide education. Further, when the processing information is changed due to an order from a user, reprocessing, or the like, the changed order information is transmitted to the processing step each time.

[Problems to be Solved by the Invention] However, in such a conventional production line, in each processing machine arranged in the line area, an operator (person) collects and converts the processing order information. As a result, human errors occur, the efficiency of production management is low, and the number of man-hours is increased despite the automation line.

In addition, the work of the aggregation and conversion of the ranking information changes depending on the model change of the vehicle type, etc.However, in the case of a car line that produces a different model, the model change of the vehicle type is complicated, so every change is required. The number of man-hours for training the operators to be performed increases, and the efficiency of production management decreases. Further, the order information is changed by an order received from a user, reworked, or the like. However, the order information has been frequently changed due to factors such as a reduction in manufacturing lead time in recent years. At this time, every time a change is made, it is necessary to transmit the contents of the change of the order information to each process, so that the flow of the entire production management is not smooth and the efficiency is reduced.

Therefore, the present invention can reduce the man-hours of the operator, and can realize the construction of an efficient automated line system even when there is a change in the conversion work and a change in the processing order, and can improve the efficiency of production management. It aims to provide a production management system.

[Means for Solving the Problems] In order to achieve the above object, the production management system according to the present invention, as shown in FIG. A production line b that conveys between processing steps in a predetermined order for each predetermined number
For the workpiece a on the production line b, a processing order is set and stored for each of a predetermined number of units, for each model, for each derivation, and the like, and information of the processing order is distributed using a network. A controller c and the processing order
A conversion file is created that is classified into machine type derivation sections and the like for each processing step, a middle controller b that distributes the conversion file to a higher controller c, information on the processing order from the higher controller c, and a conversion file. Receives and converts the information of the processing order into processing instruction information for each processing step based on the conversion file, and a lower controller e for giving a processing instruction and a lower controller e arranged in the area of the production line b, and Processing execution means f for executing a predetermined processing corresponding to each model derivation in a line order on a predetermined number of workpieces a based on the processing instruction.

In a preferred embodiment, the middle controller d has a function of complementing the functions of the upper controller c and the lower controller e. , E are the lower controller e and the machining execution means f
In this case, the processing instruction information based on a predetermined number is distributed by batch communication.

[Operation] In the present invention, the processing order is set and stored for each predetermined number of models and for each derivation of the workpiece a by the higher-order controller c for the workpiece a, and this information is stored in a plurality of lower-orders using a network. Distributed to the controller e. In addition, a conversion file is created in the middle controller d that is classified into machine type derivation sections for each machining process, and the conversion file is distributed to the upper controller c. Further, the conversion file is distributed from the higher-level controller c to the lower-level controller e. Then, the processing instruction for the processing order for each different model is analyzed by the lower controller e, and the processing execution means f
, And predetermined processing corresponding to each model, each derivation, and the like is executed.

Therefore, the processing order data and the conversion file for the workpiece a are collectively managed by the upper controller c, and the man-hour for inputting or changing the processing order and the conversion file is reduced, and the efficiency of production management is improved.

Hereinafter, the present invention will be described with reference to the drawings.

2 to 5 are diagrams showing an embodiment of the production management system according to the present invention.

First, the configuration will be described. FIG. 2 is a schematic configuration diagram showing a network in a welding section of an automobile production line to which the present invention is applied. In this figure, 1 is a host computer (upper controller) as a processing order file computer, 2C, 2D, and 2E are derived centralized maintenance computers (middle controller), 2A and 2B are line area computers (lower controller), Reference numerals 3 and 3A denote networks. For example, the network 3 has a total of 44 nodes as nodes, and the personal computer network 3A has a total of 6 communication terminals. Reference numerals 4A to 4X denote terminal sequencers (processing execution means), each of which is constituted by a welding robot that executes welding processing. Reference numeral 5 denotes a production line, which places each body (workpiece) 6 including a different model on a transporting trolley (not shown) and transports it by a predetermined number in a predetermined order from a loading section to a sending section.

The host computer 1 receives, for example, weekly processing order data from the external computer 1A, checks a joint of the processing order data, stores the data, and distributes the processing order data to the line area computers 2A and 2B. That is, for each body 6 on the production line 5, the processing order is set and stored for each model derivation, for example, every predetermined number, and the information of the processing order is distributed using the personal computer network 3A. Each body 6 is arranged on the production line 5 in a predetermined number in a predetermined order.
For example, an external computer 1A determined on a weekly basis
To the host computer 1 in advance. Further, the information of the host computer 1 is transferred in a constantly communicating state to 2E, one of the derivative centralized maintenance computers, through the personal computer network 3A to back up the data. In other words, one of the derived aggregation maintenance computers, 2E, stores data,
It has an alternative function. Further, the switching to the alternative machine is performed by the switching device 10. Further, the derivative aggregation maintenance computers 2C, 2D, and 2E create a conversion file that divides the information of the processing order into a model derivation section for each processing step of the production line 5, and communicates the conversion file to the host computer 1. Further, the converted file delivered to the host computer 1 is backed up at the same level by 2E, which is one of the derivative aggregation maintenance computers in a constantly communicating state. That is, the host computer 1 stores data as a function of a file server, and 2E, which is one of the derivative centralized maintenance computers, stores data of the host computer 1 at the same level as an alternative function. Further, 2C and 2D of the derivative aggregation maintenance computers have a function of converting processing order information into processing instruction information, which will be described later, as an alternative function to the line area computers 2A and 2B. That is, in the derivative centralized maintenance computers 2C and 2D, the line area computers 2A and 2B
After the processing order information is distributed from the host computer 1, the function as a line area computer is satisfied. The host computer 1 has a disk drive device 11, a printer 12,
It has a keyboard 13 and a CRT display 14,
This is the same for the other derivative aggregation maintenance computer 2E (however, the other is not shown).

The information from the derivative aggregation maintenance computers 2C and 2D is stored once in the host computer 1 and then input to the line area computers 2A and 2B via the network 3A. Receiving the conversion file, converting the processing order information into processing instruction information for each processing step based on the conversion file, and transmitting a processing instruction corresponding to the processing content for each different model, each different derivation, etc. to each body 6 via a network. 3
To the sequencers 4A to 4X via. The derivative centralized maintenance computer 2C has a disk drive device 21, a printer 22, a keyboard 23 and a CRT display 24 as accessories, which are other derivative centralized maintenance computers 2D and line area computers 2A,
The same applies to 2B (others are not shown). Reference numeral 25 denotes a transceiver of the personal computer network 3A, and the other transceivers are omitted from the coding in order to avoid complication.

The sequencers 4A to 4X are arranged in the area of the production line 5, and correspond to each model derivation in the order in which the predetermined number of the bodies 6 are arranged in accordance with the processing instructions from the line area computers 2A and 2B. A predetermined welding process is performed.

Here, the network of the processing instruction system can be easily understood as shown in FIG. In the figure, 1A is an external computer that performs information processing such as creation of weekly processing order data, 1 is a processing order file computer as the host computer 1, 2C, 2D, and 2E are derived aggregate maintenance computers, and 2A and 2B are line area computers. , 2G is a performance monitor display screen, 2H is a performance data collection controller, and 4A to 4X are M / C controllers as sequencers.

31 to 35 are performance monitor computers, which are arranged in, for example, an office, a maintenance department, a planning room, a retrieval room, and the like, and display processing results in real time. The performance monitor computer 31 has a main body 41, a printer 42, a keyboard 43, and a CRT display 44, and the same applies to other performance monitor computers (however, other symbols are omitted). 51 is a line server in the network 3 and 52 is a power supply device.

The information handled by the network 3 includes the following information.

Machining instruction Actual number of machines Line stop time Line tact: Machining time per unit number Flow between lines: Relationship between the cumulative number of own process and the cumulative number of next process.

Line automatic operation signal: Includes channel, manual, and abnormal signals.

Maintenance notification signal Construction notification signal Line status signal Next, the operation of this embodiment with the above configuration will be described.

In the production process for welding, first an external computer
For example, the processing contents (particularly, processing order) of the body 6 are determined and sent in units of one week from the host computer 1 to the host computer 1, and are loaded in the host computer 1 in advance. This information is set and supplemented for each body 6 on the production line 5 for each predetermined number of models and for each model, and is distributed to the line area computers 2A and 2B via the personal computer network 3A. The information includes, for example, the model of the body 6 (the model name of the body and 4 doors, 2
Doors, etc.), derivative information (destination country, destination: cold regions, etc.)
Etc. are included. Also, the setting of the model-specific derivative aggregation code for each line is based on the derivative aggregation maintenance computers 2C, 2D,
2E, in particular, information on the processing order is created as a conversion file for classifying the processing steps of the production line 5 into model-derived sections and the like. This conversion file is distributed to the host computer 1 and set as host computer 1 as setting data. Stored in the line area computer 2
A, delivered to 2B.

Next, the processing order information from the host computer 1 is analyzed by the line area computers 2A and 2B from the host computer 1 using the conversion file, and processing instructions corresponding to the processing contents of each body 6 for each different model, each derivative, each option, etc. Output to 4A ~ 4X. On the other hand, on the production line 5, each body 6 including a different model is placed on a transport trolley from its input section to the output section, and is transported between the processing steps in a predetermined order every predetermined number. . Then, based on the processing instruction, the sequencers 4A to 4X apply a predetermined welding to each of the predetermined number of bodies 6 placed on the production line 5 in the order in which they are arranged, corresponding to each model, each derivative, and the like. Processing is performed.

FIG. 4 shows a specific example of the welding process.
At 06, the rear frame, rear floor panel, front wheel house, front floor, rear floor, and front comp are assembled (component: COMP), and the rear floor is inspected at step 108. Unload each one. Process 11
In step 0, the assembled parts (rear floor, front floor, front comp) are transported, and in step 111, the floor comp is assembled. Next, in step 112, processing of sub-main general welding (SMGW) is performed. Prior to this step, download (DL) from the second floor to the first floor of the factory is executed in steps 114 to 118. That is, the roof is lowered from 2F to 1F in step 114, the left and right sides of the rear inner panel are lowered in steps 115 and 116, and the left and right sides of the side panel are lowered in steps 117 and 118, respectively. In steps 119 and 120, the right and left pillar inners are similarly lowered. Then
In step 121, additional welding is performed on the sub main general welding, and similarly, in step 122, additional welding is performed by the spot welding robot (SR). Then the process
At 123, final MIG welding is performed, and if necessary, a spot welding supplementary step (manual supplementary step at the time of robot trouble) is executed at step 124, and a door or the like is attached at step 125. In steps 126 to 132, the bonnet is assembled, the trunk is assembled, the left and right front doors and the left and right rear doors are assembled, and the left and right huenders are assembled. Will be

FIG. 5 shows the state of each line in the production line 5, and lines 203 to 212 are provided around the management office 201 and the maintenance section 202 for each welding process.
In the figure, the black portions are the locations where welding is performed automatically, the hatched portions are locations where welding is performed manually, and the white portions are locations where model change setup is performed. is there.

Considering the effect of this embodiment, the following is obtained.

(I) The processing order data and the conversion file for the body 6 are collectively managed by the host computer 1, which is a higher-level controller, and the order area data is analyzed in the line area computer. Unlike the analysis of the processing order data and the processing instruction data, the man-hour can be reduced for the analysis or the change of the processing order or the instruction data, and the efficiency of production management can be improved. That is, even if there is a change in the processing order or the conversion file, it is possible to realize an efficient automated line system. For example, the host computer 1 collectively stores data such as immediate responsiveness to the processing order when there is a change in the processing order and correspondence when there is a change in the displacement file. Is simple and the burden on the operator is reduced.

(II) Further, in the present embodiment, since the processing information is distributed using the networks 3 and 3A, it is possible to improve the reliability of the data receiving equipment, prevent loss of received data, and prevent doubles. In addition, there is flexibility in changing the processing order, always only the latest data is maintained, data reliability is ensured, and data maintenance is excellent. When the number of communication lines of the network 3 is set to an appropriate number, the load on the network 3 can be reduced.

(III) In this embodiment, the line area computer 2
Sequencer 4 by A and 2B (lower order controller)
Data distribution to A to 4X (processing execution means). Therefore, the line area computers 2A and 2B are controlled by a large number of the sequencers 4A to 4X (processing execution means).
By reducing the data processing burden on the (lower-order controller), the speed of data processing is increased,
A factory for operability in the sequencers 4A to 4X (processing execution means) is achieved.

(IV) The derivative centralized maintenance computers 2E and 2F have a function of substituting the host computer 1 as a file server and perform backup of data, so that the reliability of data is also secured from this aspect. If a certain amount of continuity of data communication with the terminal is ensured against the failure of the file server and the communication down, further reliability is maintained.

In the above embodiment, welding is performed as a process on a workpiece, but the present invention is not limited to this, and can be applied to other processes, such as assembly.
Further, the workpiece is not limited to the body of the vehicle, but may be another object.

[Effect] According to the present invention, since the processing order data and the conversion file for the workpiece are collectively managed by the upper controller, it is possible to reduce the man-hour for the change of the processing order and the conversion file. In addition, human errors can be prevented, and the efficiency of production management can be increased.

[Brief description of the drawings]

FIG. 1 is a basic conceptual diagram of the present invention, FIGS. 2 to 5 are diagrams showing an embodiment of a production management system according to the present invention, and FIG. 2 is a schematic diagram showing a network in a welding section of an automobile production line. FIG. 3 is a diagram showing a network of the machining instruction system, FIG. 4 is a diagram showing specific steps of the welding process, FIG. 5 is a diagram showing a state of each production line, FIG. It is a figure explaining the processing order of the conventional production management system. 1A ... external host computer 1 ... host computer (upper controller), 2C, 2D, 2E ... derived centralized maintenance computer (middle controller), 2A, 2B ... line area computer (lower controller), 3 ... Network, 3A ... PC network, 4A-4X ... Sequencer (machining execution means), 5 ... Production line, 6 ... Body (workpiece), 10 ... Switcher, 11, 21 ... Disk drive unit, 12, 22, 42… Printer, 13, 23, 43… Keyboard, 14, 24, 44… CRT display, 25… Transceiver, 31-35… Actual performance monitor computer, 41… , 51 ... line server, 52 ... power supply device.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁶ , DB name) G05B 15/02 G05B 19/418 G06F 17/60 B23Q 41/08

Claims (3)

(57) [Claims] 1. A production line for transporting workpieces including different types of machines from a feeding section to a delivery section in a predetermined order at a predetermined number of times between processing steps, and a predetermined number of workpieces on the production line. For each model,
For each derivation, etc., a processing order is set and stored, and a higher-level controller that distributes the processing order information using a network, and the processing order information is classified into a model derivation section for each processing step of a production line. A conversion file to be created, and a middle-level controller that distributes the conversion file to a higher-order controller; information of a processing order from the higher-order controller; and a conversion file, and the information of the processing order is based on the conversion file. A lower-level controller that converts the information into processing instruction information for each processing step and provides a processing instruction, and a predetermined number of workpieces arranged in the area of the production line based on the processing instruction from the lower-level controller. A production execution means for executing predetermined processing corresponding to each model derivation in a line order. 2. The production management system according to claim 1, wherein said middle controller has a function of complementing each function of said upper controller and lower controller. 3. The production management system according to claim 1, wherein the upper and lower controllers distribute machining instruction information based on a predetermined number of units to the lower controller and the machining execution means by batch communication. system.