JP2939300B2 - How to recover from a production line failure - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for controlling a sequence of operations of a facility in a production line. The present invention relates to a method for recovering from a failure in a production line, which is used to return the equipment to a state where sequence control of its operation is properly performed when the cause is eliminated.

2. Description of the Related 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 the sequence control unit performs operations to be sequentially performed by each facility. It is known to perform the following sequence control. When such sequence control is performed, a sequence control program is loaded into a computer built in the sequence control unit, and the sequence control unit executes each step of operation control for each of various facilities installed on the production line. , According to the sequence control program.

When performing sequence control on the operation of various facilities installed in such a production line, a failure diagnosis for monitoring the control state and detecting a failure in each facility is performed in parallel with the sequence control. Often it is. The fault diagnosis related to the sequence control may take various forms. For example, Japanese Patent Application Laid-Open No. 60-238906 discloses a sequence control under a condition in which equipment can be operated normally. The operation state of the component of the circuit unit is set as a reference state, and the operation state of the component of the sequence control circuit unit during the actual operation of the equipment is sequentially compared with the reference state,
Performing an abnormality detection based on the difference has been proposed as one of the failure diagnoses related to the sequence control.

(Problems to be Solved by the Invention) As described above, when the sequence control for the operation of various facilities installed on the production line is performed with the failure diagnosis, the failure diagnosis detects the failure of the equipment. In such a case, it is desirable to eliminate the cause of the detected failure and quickly return the equipment to a state in which the sequence control of the operation is properly performed by an easy operation. Therefore, it is hard to say that the return of the equipment to the sequence control state after the failure of the equipment is detected has been performed as desired in terms of easiness and speed of operation.

In view of such a point, the present invention classifies various operations to be performed into a plurality of operation blocks as a maximum unit of a series of operations that are independently performed from start to end under a normal state as an operation block. And, under the condition that each of the plurality of operation blocks is divided into a plurality of operation steps, 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 sequence control of the operation of the equipment is performed properly and promptly with easy operation. It is an object of the present invention to provide a method for restoring a failure in a production line, which can be restored to a normal state.

(Means and Actions for Solving the Problems) In order to achieve the above object, the method for recovering from a failure in a production line according to the present invention is configured such that various operations to be performed by equipment on the production line start under a normal state. The largest unit of a series of operations that will be performed independently from 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 in equipment that is controlled in sequence to sequentially execute a plurality of operation steps in each of the operation blocks in a preset order, and when an operation element that caused the failure is repaired,
An operation block that has been stopped at an intermediate operation step without reaching the recoverable operation step is specified as a failure operation block, and each of the operation steps from the intermediate operation step to the return operation step in the failure operation block is identified. Identifying the operating elements to be activated in order to sequentially proceed for each of the operation steps from the intermediate operation step to the resumable operation step, and obtaining data on the operation elements to be operated to activate the specified operation element, By comparing the obtained data with a preset operation element data map, the operation element to be operated is displayed on the operation element display means as being operable by touching the operation element display means. State and none, operated by touching the operation element display Each time the operation element corresponding to the operated element is actuated, the operation step is advanced to the next, and each of the operation steps from the middle operation step to the recoverable operation step in the failure operation block is sequentially advanced, and the failure operation is performed. The block does not reach the resettable operation step, and thereafter, the sequence control for the equipment is restarted.

By doing so, when a failure occurs in equipment that is sequence-controlled to sequentially execute a plurality of operation steps in each of the plurality of operation blocks in a preset order, the failure may be a cause of the failure. After the restored operating element is restored, the display of the operating element to be operated on the operating element display means is performed based on the preset operating element data map, so that a complicated display program or the like can be realized. It will be done easily and accurately without being required, and by an easy operation of operating the operation element displayed on the operation element display means only by touching the operation element display means,
It is possible to quickly return the equipment to a state where sequence control of its operation is properly performed, and as a result,
Damage due to stagnation of the production line can be reduced.

(Embodiment) Prior to the description of the method for recovering from a production line failure according to the present invention, an example of a vehicle assembly line to which the method for recovering from a production line failure according to the present invention is applied will be described with reference to FIGS. 2 and 3. Will be described with reference to FIG.

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

The pedestal 12 at the positioning station ST1
It is supposed to travel back and forth along 8,
Although not shown in the drawing, the positioning station ST1 is disposed in relation to the pedestal 12 and moves the pedestal 12 in a direction perpendicular to the rail 18 (vehicle width direction) and in a direction along the rail 18 (front-back direction). Moving means (BF) for positioning the body 11 placed on the cradle 12 in the vehicle width direction at the front, positioning means (BR) for positioning the rear part in the vehicle width direction, And, positioning means (TL) for positioning in the front-rear direction is provided, and furthermore, it engages 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 receiving table 12 are provided. The positioning device 19 in the positioning station ST1 is configured by these positioning means and the lifting reference pins.

The transfer device 16 is composed of a guide rail 20 that is arranged over the positioning station ST1 and the docking station ST2 and that is bridged therebetween, and a carrier 21 that moves along the guide rail 20. A lifting hanger frame 22 is attached to the carrier 21, and the body 11 is supported by the lifting hanger frame 22. Further, the pallet transport device 17 includes a pair of guide portions 24L and 24R provided with a large number of support rollers 23 each receiving the lower surface of the pallet 13, and a pair of transport rails 25L extending parallel to the guide portions 24L and 24R, respectively. And 25R, each with 13 pallets
Pallet locking portions 26 for locking the transport rails 25
Pallet carrier that moves along L and 25R
A linear motor mechanism (not shown) for driving the pallet transport tables 27L and 27R and the pallet transport tables 27L and 27R is provided.

The docking station ST2 includes struts in the front suspension assembly and struts 15 in the rear suspension assembly 15 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, each supporting A, and taking an assembled posture, and a pair of left and right rear clamp arms 31L and 31R are provided. Left and right front clamp arms 30L and 30R are attached to mounting plate portions 32L and 32R, respectively.
It is mounted to be able to move forward and backward in the direction perpendicular to the transfer rails 25L and 25R, and has a left and right rear clamp arm.
31L and 31R are attached to the mounting plate portions 33L and 33R, respectively, so as to be able to advance and retreat in a direction orthogonal to the transport rails 25L and 25R, the left and right front clamp arms 30L and 30R oppose each other, and Each of the left and right rear clamp arms 31L and 31R has an engaging portion that engages with a strut in the front suspension assembly or a strut 15A in the rear suspension assembly 15. Then, the mounting plate 32L is moved by the arm slide 34L to the fixed base 35L with respect to the transfer rail 25L.
L and 25R, and the mounting plate 32R is movable by the arm slide 34R with respect to the fixed base 35R in the direction along the transfer rails 25L and 25R.
33L is fixed to the fixed base 37L by the arm slide 36L.
It can be moved in the direction along the transfer rails 25L and 25R, and the mounting plate 33R is fixed to the base by the arm slide 36R.
With respect to 37R, it is movable in a direction along the transfer rails 25L and 25R. Therefore, the left and right front clamp arms 30
L and 30R will be able to move back and forth and left and right under the condition that their tips are engaged with struts in the front suspension assembly, and the left and right rear clap arms 31L and 31R Under the condition that the part is engaged with the strut 15A in the rear suspension assembly 15, it is possible to move forward and backward and left and right, the left and right front clamp arms 30L and 30R, the arm slides 34L and 34R, the left and right rear clamp arms 31L. And 31R, and the arm slides 36L and 36R constitute a docking device 40.

Further, in the docking station ST2, a pair of slide rails 41L and 41R, which are installed so as to extend in parallel with the transport rails 25L and 25R, respectively, and the slide rail 41L.
And movable member 42, which is supposed to slide along 41R,
A slide device including a motor 43 for driving a movable member 42 and the like
A movable member 42 of the slide device 45 is provided with an engagement means 46 which engages with a movable engine support member (not shown) provided on the pallet 13.
Is provided. Further, two lifting pallet reference pins for positioning the pallet 13 at a predetermined position.
47 are also provided. The slide device 45 has a body supported by the lifting 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
It is moved back and forth while engaging with the movable engine support member on the pallet 13 positioned by 47, thereby moving the engine 14 back and forth with respect to the body 11 to avoid interference between the body 11 and the engine 14. To be.

In the fastening station ST3, a robot 48A that is to perform screw fastening work for fastening the engine 14 and the front suspension assembly combined with the body 11 to the body 11, and a rear suspension assembly 15 combined with the body 11 A robot 48B, which is to perform a screw tightening operation for fastening, is installed. Further, also at the fastening station ST3, two lifting / lowering pallet reference pins, which are 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 transport device 17, and the robots 48A and 48B in the fastening station ST3 are provided. The sequence control unit connected thereto is a facility (sequence control target facility) that performs sequence control on the operation based on a sequence control program.

The operation performed by each of these sequence control target facilities is divided into operation blocks defined as a maximum unit of a series of operations that can be independently performed from the start to the end, and B0 to B0 are as follows. 12 operation blocks of B11 are obtained.

B0: Operation block for positioning the body 11 on the receiving table 12 by the positioning device 19 (receiving table positioning operation block).

B1: 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
Clamps the struts of the front suspension assembly with 0L and 30R, and the left and right rear clamp arms 31L
Strut 1 of rear suspension assembly 15 by 31R and 31R
Operation block for preparing to clamp 5A (Strut clamp preparation operation block).

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

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

B5: An operation block for returning the cradle 12 to the original position by the positioning device 19 (a cradle original position return operation block).

B6: On the body 11 supported by the lifting hanger frame 22 in the transfer device 16, the engine 14 disposed on the pallet 13 and disposed on the pallet 13 and clamped by the left and right front clamp arms 30L and 30R. An operation block (engine / suspension docking operation block) combining the struts of the front suspension assembly and the struts 15A of the rear suspension assembly 15 clamped by the left and right rear clamp arms 31L and 31R.

B7: An 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 the 0L and 30R and the 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 to the fastening station ST3 ( Linear motor propulsion block).

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

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

These operation blocks B0 to B11 are represented in a time-series relationship with each other by the operation block flowchart shown in FIG.

Each of the above-described operation blocks B0 to B11 is divided into a plurality of operation steps, each of which includes an output operation.For example, for the cradle positioning operation block B0, the ten operations of B0S0 to B0S9 are performed as follows. It is divided into steps.

B0S0: Operation step for confirming various conditions (condition confirmation operation step).

B0S1: An operation step (BF positioning operation step) in which the cradle 12 is moved by the positioning means BF, and the front portion of the body 11 is positioned in the vehicle width direction.

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 receiving table 12 is moved by the positioning means TL, and positioning is performed in the direction along the rails 18 of the body 11 (front-back direction).

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

B0S5: Operation step in which the elevation reference pin FR engages the front right side of the body 11 (FR engagement operation step).

B0S6: Operation step in which the elevation reference pin RL engages the rear left side of the body 11 (RL engagement operation step).

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

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

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

Next, an example of a return direction at the time of a production line failure according to the present invention, which is applied to a vehicle assembly line in which the above-described sequence control target equipment is installed, will be described.

FIG. 1 shows a failure diagnosis / recovery system in which an example of a method for recovering from a production line failure according to the present invention is implemented, together with equipment to be sequence-controlled and a sequence control unit connected thereto. The sequence control target equipment 50 includes, as described above, the positioning device 19, the transfer device 16, the docking device 40,
Slide device 45, pallet transfer device 17, and robot 4
8A and 48B, which are subject to sequence control by the sequence control unit 51.

Equipment 50 subject to sequence control by sequence controller 51
The sequence control for the operation of
It is performed based on a sequence control program loaded in 51, such a sequence control program
For example, a ladder program as shown in FIG. 5 is created for the operation block B0, and a ladder program similar to that shown in FIG. 5 is created for each of the operation blocks B1 to B11. Ladder programs for each of the blocks B0 to B11 are obtained by being sequentially connected, and accordingly, the sequence control unit
The sequence control target equipment 50 in which the sequence control of the operation is performed by 51 is to sequentially execute a plurality of operation steps in each of the operation blocks B1 to B11 according to the sequence control ladder program created as described above. You.

In the ladder program as shown in FIG. 5, SRT indicates a start condition, STP indicates a stop condition, and ILC0 to ILC9.
Represents an interlock condition, MA is an output contact device relating to a start condition SRT, MS is an output contact device relating to a stop condition STP, X0 to X9 are confirmation contact devices, and XA to X13 are A manual contact device, XI is an interlock release contact device, and Y0 to Y9 are output coil devices.

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 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 playing a disk, and a keyboard 68 for inputting data and control codes are provided.
Further, the CRT operation panel device 53 includes a CPU 72, a memory 73, transmission / reception interfaces 74 and 7 connected through a bus line 71.
5, has an I / O interface 76, and further has a heart disk device 77 as an auxiliary memory connected to the I / O interface 76, and a CRT 78 for disc play.
And a keyboard 79 for inputting data and control codes, and a touch panel 80 connected to the transmission / reception interface 74. As shown in FIG. 6, the touch panel 80 is attached to the outer surface of the face plate portion of the CRT 78. I have. The transmission / reception interface 65 provided in the failure diagnosis / recovery control device 52 and the sequence control unit
The transmission / reception interface 51A provided in the CRT operation panel device 53 and the transmission / reception interface 51A provided in the sequence control unit 51 are interconnected with each other. A transmission / reception interface 65 provided on the control device 52 and a transmission / reception interface 75 provided on the CRT operation panel device 53 are interconnected.

The failure diagnosis / recovery control device 52 receives program processing data indicating the progress status of 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. According to the loaded failure diagnosis program, for example, the sequence controller 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 Investigate the operating element that caused the failure in the target equipment 50, perform a failure diagnosis that prompts the repair of the operating element, and after repairing the operating element that caused the failure, perform the sequence control target equipment 50. A return control is performed to return the sequence control of the operation to a state where the sequence control unit 51 performs the sequence control. The hard disk device 66 stores data representing each step ladder element in the sequence control ladder program loaded into the sequence control unit 51 in a state that is individually read out. The hard disk device 66 stores the sequence control ladder program. It is supposed to build a database for

In addition, the CRT operation panel device 53 has a touch panel 80 attached to the outer surface of the face plate portion of the CRT 78, which is entirely formed of a transparent body, and according to the contact position when a finger or the like is brought into contact with the surface. An output signal is generated, and as shown in FIG.
A plurality of operation panels, each having a display element DE and an operation element SE such as a switch, are arrayed on the face plate portion of FIG. 8 to be selectively displayed. Then, by touching the position corresponding to the selected one of the operation elements displayed on the face plate portion of the CRT 78 on the surface of the touch panel 80 with a finger or the like, an output signal obtained from the touch panel 80 at that time is displayed. The operation input corresponding to the operation of the selected one of the operation elements corresponding to the contact portion on the touch panel 80 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 preset as an operation panel data map and stored in the hard disk device 77.

Such an operation panel data map is set such that the one corresponding to the operation panel shown in FIG. 7 is as shown in Table-A below.

In the above Table-A, the column of “display section” indicates the number assigned to the display section in the face plate portion of the CRT 78, the column of “name” indicates the display items in each display section, and the “operation element” and The column of “display element” indicates a device related to a display item in each display section, and the column of “attribute” indicates a type of a switch when a device related to a display item in each display section is a switch.
The column of “color” indicates a display color in each display section.

Then, when the display on the face plate portion of the CRT 78 based on the operation panel data map is performed, the display section number in the operation panel data map is selected according to the result of the failure diagnosis in the failure diagnosis / return control device 52, As shown by the hatched portion in FIG. 7, the display is performed in the display section provided with the selected display section number on the face plate section of the CRT 78. Note that the hatched portion in FIG. 7 indicates a display state when the display section numbers “3” and “14” in Table-A are selected.

Further, an operation input supplied through the transmission / reception interface 74 when a finger or the like is brought into contact with the touch panel 80 is supplied to the CPU 72, and supplied from the transmission / reception interface 75 to the sequence control unit 51 through the transmission / reception interface 51A. Accordingly, a state in which operation control of the operation elements in the sequence control target facility 50 is performed can be taken.

As described above, when the operation panel input section is formed by the CRT 78 and the touch panel 80, every time an operation element on the operation panel selected on the face plate section of the CRT 78 is displayed, the operation panel input section is formed on the face plate section of the CRT 78. The position of each operation element on the displayed operation panel and the touch panel 80
The correspondence relationship with the position on the top is set.

With the failure diagnosis / recovery system having such a configuration, when a failure occurs in the sequence control target equipment 50, an example of a method for recovering from a production line failure according to the present invention is performed. In the following, the process is the eighth
This will be described along the flowchart shown in the figure.

First, based on the failure diagnosis by the failure diagnosis / recovery control device 52, it is determined whether or not a failure has occurred in the sequence control target facility 50 (step P1). Then, when a failure occurs in the sequence control target equipment 50, a failure analysis is performed (step P2), and as a result, a failure occurs among a plurality of operation blocks shown in the operation block flowchart of FIG. Related, i.e., a faulty operation block is specified, and further, a faulty one of a plurality of operation steps in the specified operation block,
That is, a failure operation step is identified, and a failure operation element that caused the failure is identified (step P3).

Next, after the failure diagnosis / recovery control device 52 makes a recommendation about the restoration of the failed operation element, the restoration of the failed operation element is waited for (Step P4). When the malfunctioning element is repaired, all of the plurality of operation blocks shown in the operation block flowchart of FIG.
It is determined whether or not the control has reached the resumable operation step, which is the final operation step in each case, and the sequence control unit 51 is in a state where restart of the sequence control is enabled ( Step P5) If the restart is enabled, the sequence control by the sequence control unit 51 is immediately restarted (Step P5).
P6). On the other hand, when the control is not in a state where all of the plurality of operation blocks have reached the returnable operation step and the restart cannot be performed, the recovery control in the failure diagnosis / recovery control device 52 is performed. Switching to the operation mode is performed, an undetermined operation block in a state where control has not reached the resumable operation step of the plurality of operation blocks is specified, and furthermore, a plurality of operation steps in the uncompleted operation block are identified. The control stop operation step in which the control is stopped is specified (step P7).

Subsequently, data representing a step ladder element corresponding to the specified control stop operation step is read from the hard disk device 66, and a state is displayed on the CRT 67 based on the read data, and control is stopped on the face plate portion of the CRT 67. A step ladder element corresponding to the operation step is displayed (Step P8). Next, the step ladder element displayed on the face plate portion of the CRT 67 is referred to, the analysis is performed, and the operation element causing the control stop operation step is specified (step P9), and the operation element is specified. An operation element to be operated is searched for to manually operate the operated operation element (step P1).
0). That is, an operation element to be operated to be brought into a state where the operation proceeds from the control stop operation step to the next operation step is specified, and an operation element to be operated to operate the operation element to be operated Is sought out. Then, operation element data, which is data relating to the searched operation element, is formed.

The operation element data thus obtained is transmitted from the transmission / reception interface 65 of the failure diagnosis / recovery control device 52 and supplied to the CRT operation panel device 53 through the transmission / reception interface 75 (step P11). Failure diagnosis /
In the CRT operation panel device 53 to which the operation element data is supplied from the return control device 52, the operation element data is compared with the operation panel data map stored in the hard disk device 77, for example, as shown in the above-mentioned Table-A. Then, the display section number relating to the operation element data in the operation panel data map is selected, and the operation panel data relating to each of the selected display section numbers is read and supplied to the CRT 78, and the selection in the face plate portion of the CRT 78 is performed. In the display section with the displayed display section number, the display element and the operation element represented by the read operation panel data, or only the operation element are displayed. And touch panel 80
The finger or the like is brought into contact with a position corresponding to the display section of the operation element represented by the operation element data in the face plate portion of the CRT 78 on the surface of
An operation input indicating that the operation element represented by the operation element data has been operated is supplied from the touch panel 80 through the transmission / reception interface 74. Then, the operation input is supplied from the transmission / reception interface 75 to the CRT operation panel device 53 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 operation element to be operated in the sequence control target facility 50 is operated, and data indicating that the operation element to be operated is operated is data. From the transmission / reception interface 51A provided in the sequence control unit 51, the failure diagnosis / recovery control device 5
2 is supplied through the transmission / reception interface 65 (step P13).

In the failure diagnosis / recovery control device 52 supplied with data indicating that the operation element to be activated from the sequence control section 51 has been activated, the control stop operation step proceeds by one step from the next step to the next operation step. The control to be performed is performed (step P14), and it is determined whether the next operation step that has been advanced is a resettable operation step (step P15). As a result, if the proceeded next operation step is not the resumable operation step, the operation step is set as the specified control stop operation step, and the hard disk device described above is again executed.
Data representing a step ladder element corresponding to the control stop operation step specified from 66 is read out, and a state based on the data is displayed on the CRT 67.
Each operation after the operation in which the step ladder element corresponding to the control stop operation step is displayed on the face plate portion of the RT 67 is sequentially performed, and such an operation state is repeated until the return possibility step is reached. Then, when the resumability step is reached, all of the plurality of operation blocks shown in the operation block flowchart of FIG. It is determined whether or not the sequence control can be restarted by the above-described operation, 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 return control are performed by the system will be described with reference to the flowchart shown in FIG.

First, under the condition that occurrence of a failure in the sequence-controlled equipment 50 is not detected by the failure diagnosis by the failure-diagnosis / recovery control device 52, display data representing an operating portion of the sequence-controlled equipment 50 is read from the hard disk device 77. As a result, a state in which a display based thereon is made on the CRT 78 is taken, and the CRT 78 performs an operation monitor display (step Q1). Under the circumstances, it is determined whether or not operation element data representing an operation element to be operated to operate the operation element to be operated as described above is supplied from the failure diagnosis / recovery control device 52. Are repeated until it is determined that the operation element data has been supplied (step Q2).

When the operation element data is supplied, the operation element data is collated with the operation panel data map stored in the hard disk device 77, for example, as shown in Table-A described above, and the operation element data in the operation panel data map is compared. The display section number relating to the data was selected, and the operation panel data relating to each of the selected display section numbers was read and supplied to the CRT 78, and the selected display section number in the face plate portion of the CRT 78 was added. In the display section, the read operation panel data is displayed in advance as display elements and operation elements, or only operation elements (steps Q3 and Q4). Under such circumstances, the coordinate reference for display on the face plate portion of the CRT 78 is matched with the coordinate reference on the touch panel 80 (step Q).
5) On the touch panel 80, the position corresponding to the display category of the operation element represented by the operation element data in the face plate portion of the CRT 78 is the operation element represented by the operation element data from the failure diagnosis / return control device 52. It is set to be a specific contact operation unit that generates an operation input that has been operated (step Q6).

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

(Effects of the Invention) As is clear from the above description, according to the method for recovering from a production line failure according to the present invention, various operations to be performed are performed independently from start to end under a normal state. A plurality of operation blocks in each of the plurality of operation blocks are divided into a plurality of operation blocks while each of the plurality of operation blocks is divided into a plurality of operation steps. In a facility on a production line that is to be sequentially controlled in a predetermined order, when a failure that stops the sequence control occurs, after removing the cause of the failure, the operation element The display of the operation element to be operated on the display means is performed based on a preset operation element data map. This makes it easy and accurate without requiring a complicated display program or the like, and operates the operation element displayed on the operation element display means by touching the operation element display means. With this simple operation, the equipment can be promptly returned to a state in which the sequence control of the operation is properly performed, and as a result, damage caused by stagnation of the production line can be reduced.

[Brief description of the drawings]

FIG. 1 is a block diagram showing a failure diagnosis / return system in which an example of a recovery method at the time of a production line failure according to the present invention is implemented, together with a sequence control target facility and a sequence control unit;
FIGS. 2 and 3 are a schematic side view and a schematic plan view showing an example of a vehicle assembly line to which the method for recovering from a production line failure according to the present invention is applied. FIG. FIG. 5 is an operation block flow chart provided for description. FIG. 5 is a ladder diagram showing an example of a sequence control program used for sequence control of a sequence control target facility by a sequence control unit.
The figure shows the fault diagnosis / recovery 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 for explaining the CRT operation panel device in the failure diagnosis / return system shown in FIG. 1, FIG. 8 and FIG.
FIG. 5 is a flowchart 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 transport 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 control unit, 52 is a failure diagnosis / recovery control device, 53
Is a CRT operation panel device, 62 and 72 are central processing units (CP
U), 63 and 73 are memories, 64 and 76 are input / output interfaces (I / O interfaces), 66 and 77 are hard disk drives, 67 and 78 are cathode ray tubes (CRT), 80 is a touch panel, DE is a display element, SE Is an operation element.

──────────────────────────────────────────────────続 き Continuation of front page (56) References JP-A-62-224893 (JP, A) JP-A-1-248206 (JP, A) JP-A-60-73706 (JP, A) JP-A-2- 253311 (JP, A) JP-A-2-275503 (JP, A) (58) Fields investigated (Int. Cl. ⁶ , DB name) G05B 19/02-19/05 G05B 23/02 301

Claims (1)

(57) [Claims] 1. A maximum unit of a series of operations, which are to be performed independently from start to finish under normal conditions, are divided into a plurality of operation blocks as operation blocks. The sequence control is performed to sequentially execute a plurality of operation steps in each of the plurality of operation blocks in a preset order, with each of the plurality of operation blocks being divided into a plurality of operation steps. When a failure occurs in the equipment and the operating element that caused the failure is repaired, the operation block that has been stopped in an intermediate operation step without reaching the resumable operation step is a failure operation block. And each of the operation steps from the halfway operation step to the recoverable operation step in the faulty operation block. An operation element to be operated to sequentially advance each of the operation elements is specified for each of the operation steps from the halfway operation step to the returnable operation step, and an operation element to be operated to operate the specified operation element By obtaining data on the operation element and comparing the data with a preset operation element data map, the operation element to be operated can be operated by touching the operation element display means on the operation element display means. The state in which the operation step is advanced to the next each time the operation element corresponding to the operation element operated by the contact with the operation element display means is operated, Each of the operation steps up to the above-mentioned resettable operation step is sequentially advanced, and State and without the work block has reached the restoration operable step before the method of the return time of the production line fault, characterized in that to achieve restart sequence control for the equipment.