JP3099617B2 - Production line layout creation device - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a production line layout creating apparatus for creating a layout of each process and equipment of a production line in a factory.

[0002]

2. Description of the Related Art In recent years, factory production lines have been increasingly automated, and factory automation (F)
As described in A), products are manufactured by arranging production equipment such as robots and automatic machines, and continuously sending works in each process. In such FA factory,
The layout of the processes and equipment that make up the production line is an important factor in improving product manufacturing efficiency and productivity, and the layout of each process and equipment, the arrangement of conveyor belts connecting them, and the factory The layout of the production line must be considered so as to efficiently use the limited space of the production line and not to reduce productivity.

Conventionally, in order to create a layout of this production line, a layout designer performs each process based on dimensions such as a space for installing equipment in a factory and the size of each equipment and a conveyor belt. The layout is created on the desk while considering the order and the connection between the facilities.

[0004]

However, as described above, the conventional production line layout is based on only data such as factory space and equipment size.
Since the layout is created in consideration of the order of each process, the layout designer must know all the information, such as the order of the processes and the connection of each facility, or design while obtaining the necessary information. This imposes a heavy burden on layout designers, and in the course of designing, searching for data and materials necessary for layout design, interrupts the thinking of layout design and induces design errors. There was fear.

Accordingly, an object of the present invention is to provide a production line layout creating apparatus for automatically creating a production line layout by automatically discriminating the order of processes, connections between processes, and equipment when creating a layout of a production line in a factory. To provide.

[0006]

According to the present invention, there is provided a production line layout for producing each step of a production line constituted by a plurality of steps and an arrangement of each equipment used in each step. a producing apparatus shown before climate <br/> extent a stylized and represents a layout diagram of the data, and stylized the equipment used in each step layout
Layout figure storage means for storing figure figure data;
An arrangement rule storage unit that stores the arrangement rules of the respective steps and the respective facilities; and a size of the respective facilities used in the respective steps, a movable range of the respective facilities, and a work range in which the work is performed in the respective steps. Attribute data storage means for storing the size, step contents input means for inputting each piece of equipment required for each step and a work to be performed in each step, and each of the steps inputted by the step contents input means Line model creation means for creating a production line model by detecting a connection between the steps from each facility required in the process and a work performed for each step, and a line model creation means. From the connection of each process of the production line model, the layout figure of each process and the
Place a layout diagram of equipment, wherein the attribute data the used in each step based on the size of the movable range and the work of the equipment, the arranged mutually adjacent step
Line layout creation means for creating a line layout by correcting the layout intervals of the layout figures, and whether or not the line layout created by the line layout creation means fits in the space where the production line is to be installed . Line layout for factory production line
Equipment in each process when placed in the installation space
Check for interference between the workpiece and structures and passages in the factory
If there is interference, move the line in the direction to eliminate the interference.
Navigate the entire layout and if there is still interference
Direction to eliminate interference for layout figure of process with interference
To the extent that no other interference occurs, and
If it does not disappear, the final layout will be regarded as interference.
And a line layout evaluation correcting means for outputting a figure .

Further, the present invention provides the production line layout creating apparatus, wherein a line layout data storage means for storing an existing production line layout;
The number of steps in the production line model created by the line model creation means and the way of connecting each step are the same
In, and a case retrieval means for retrieving from the production line layouts that the already stored the layout <br/> preparative production line same process more than half is in the line layout data storage means, And a production line layout creating apparatus.

[0008]

The present invention configured as described above operates as follows. Based on the information of the equipment required for each process of the production line and the work to be performed in each process input by the process content input means, the line model creation means detects the connection of each process and performs production. Create a model that understands the connection between the steps that make up the line.

The line layout creating means, based on the connection of each step of the line model, according to the layout rules stored in the layout rule storage means, layout graphics of the process in the layout graphic storage means and the layout of the equipment.
Place the figure, further more from the attribute data stored in the attribute data storing means on the size of the movable range and the work of the equipment used in each step, modifying the arrangement interval of the layout pattern of the adjacent steps to each other To create a line layout.

The line layout evaluation correcting means evaluates whether or not the line layout created by the line layout creating means fits in a space where the production line is installed, and arranges each process so as to fit in the space. To correct.

Thus, the layout of the production line can be automatically created.

Further, in the present invention, by further providing the case search means and the line layout storage means, the number of steps in the line model created by the line model creating means and the way of connecting each step are the same. And
Utilizing an existing production line layout by retrieving a production line layout in which at least half of the same processes are present from among the existing production line layouts stored in the line layout storage means. To shorten the production line layout creation time.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the accompanying drawings.

FIG. 1 is a block diagram for explaining a production line layout creating apparatus according to an embodiment of the present invention.

This production line layout creating apparatus 1
A process table input unit 10 which is a process content input unit for inputting equipment necessary for each process of the production line and a work carried in each process, and linking each process from the equipment and work required for each process. A model creation unit 11 as a line model creation unit to be detected, and a case search / judgment unit 12 as a case search unit to search past cases and search for a line having the same line configuration as the production line model.
And a layout plan creating unit 13 that is a line layout creating unit that creates a line layout according to an arrangement rule based on a connection between the processes and the line layout of the searched case.
Check and evaluate each process for interference with surrounding structures,
Layout evaluation / correction unit 14 for correcting the layout
And a database 20 storing various data. In the database 20, a case database 21 serving as a line layout data storage unit storing a case of a production line layout that already exists.
(Hereinafter, database is abbreviated as DB), layout graphic DB 22 as layout graphic storage means storing graphic data in which each process and equipment is designed, and layout rule storage storing layout rules for each process and equipment. It comprises an arrangement rule DB 23 as a means and an attribute DB 24 storing the attributes of each facility. Further, a display unit 30 for displaying a process chart, a layout diagram, a progress of processing, and the like is connected to the apparatus.

In the production line layout creating apparatus 1 thus configured, the model creating unit 11 links the processes constituting the production line from the equipment and work required for each process input from the process chart input unit 10. A model of the production line is created, a case search / judgment unit 12 searches for the same case in the past, and if there is a past case in the layout plan creation unit 13, the Based on the case, and if there is no past case, a layout plan is created according to the placement rules. Then, the layout plan evaluation / correction unit 14
Due to the restrictions on the space that can accommodate the production line in the created layout plan, the layout of the production line is created by making timely corrections so that the facilities and peripheral structures do not interfere.

Hereinafter, the function and operation of each part of the apparatus will be described in detail.

First, in the process chart input section 10, the equipment used in each process constituting the production line and the work to be performed in the process are represented by a process number, a process name, and the like as shown in FIG. It is input as a process chart including equipment and loading parts that are used works. In the illustrated process chart, process names, equipment, loading parts, and the like are input using predetermined abbreviations or symbols. For example, the process number is # 0.
1, # 02..., And the process name of # 01 is “I
This is abbreviated as “NR-ASSY-Multi 1” so that the contents of the process can be understood from the process name. In the sub-assembly process of the inner panel, small parts (“loading parts” column) , The inner panel, the hinge-upper, the hinge-lower, etc.) are assembled with a multigun.

The equipment used in step # 01 is a multi-welder.
r), and a manual (1) indicating that a manual operation is performed is input. The work used in this step is input as a loading part. In addition, if it is known in advance that the equipment or work to be used is determined to be used to some extent based on the process content under the process name, simply enter the process name and it will automatically be used. You may make it input.

Next, the model creation unit 11 determines the connection of each process from the input process chart (see FIG. 2), and creates a model that abstracts the entire production line.

The connection of each process is determined from the work name in the loading part described in the process chart. For example, looking at the items of the loading parts in the process # 02, “# 01-OU TP UT”, “INR-WAI”
ST], it is understood that the work processed in the step # 01 is used in the step # 02, and that the step # 02 is located after the step # 01. Similarly, in step # 25, “# 01-OU TP UT”,
Since it is “OTR-WAIST”, step # 2
It can be seen that Step 5 is a step that follows Step # 02.

In step # 01 and step # 10,
Since there is no description of "-OUTPUT", it is determined that the process is located at the top. Further, when looking at step # 30, “# 20-OUTPUT” and “# 25-OUTPU”
T "indicates that the work from the process # 20 and the work from the process 25 come, and it is determined in the process # 30 that the process starting from the process # 01 and the process starting from # 10 are connected. You.

When the connection of each process is determined as described above, a model of the production line is created. In this model, for example, as shown in FIG. 3A, each step found from the above-described step connection is connected by a line. That is, step # 0
Steps # 02 and # 25 are continuous from 1 and steps # 10 to # 70 are continuous. Step # 25 is connected to step # 30. This model is not only a model in which each step of the entire production line is connected and abstracted as shown in FIG. 3A (referred to as an abstraction model), but also only a branch state thereof is simplified as shown in FIG. 3B. A simplified model (referred to as a simplified model) is also created. This simplified model is used to shorten the search time in case search described later.

Next, the case search / judgment unit 12 stores the case DB
A comparison is made between the existing model of the past production line layout in 21 and the model to search for the same one.

First, the data of the production line layout in the case DB 21 includes the detailed layout of the production line and the abstract model and the simplified model as one production line layout data. First, as shown in the flowchart of FIG. 4, the determination unit 12 first compares the number of processes in the production line and searches for cases having the same number of processes in the case (S2).
1) If there is a process having the same number of processes (S22), a process having the same simplified model structure is searched from the processes (S2).
3). Next, if any of the simplified models match (S24), each process is compared from among them (S25),
If the same process matches at least half (S26),
This is output as a layout example (S27). If there are finally a plurality of layout cases, all of them are output as layout cases. If there is no layout case, the absence of case is output (S28).

Next, the layout plan preparing section 13 prepares a layout plan in accordance with the layout case, the equipment arrangement rule, the layout figure, and the attribute data obtained by the above-described case search.

In preparing a layout plan, if the same or a similar layout plan is obtained in the case search, a layout plan is prepared based on the layout case. Of course, if all the steps of the layout example and all the steps of the production line to be created are the same, it is output as it is as the layout plan. Here, creation of a layout plan when there is no identical layout example will be described.

First, layout figures, arrangement rules, and attribute data will be described. Each of these data is stored in the database 20, and the layout graphic data is in the layout graphic DB 22, which is a pattern of each process and equipment. For example, as shown in FIG. A figure in which the type of equipment is designed is stored as data. Although FIG. 5 shows the description of the figure, the description may be a data comment as data, but may not be used for processing. The placement rules are located in the placement rule DB 23, and are rules for locating equipment.
For example, (a) an upstream process is arranged on the left and a downstream process is arranged on the right, (b) a related process is arranged within an arbitrarily determined radius, and (c) each process is Work space
The minimum interval (referred to as line pitch) required as a distance. The attribute data is stored in the attribute DB 24.
As shown, the size (dimension) and a movable range of the movable equipment such as a robot work is equipment and using et al., Which is disposed in each step, also the required distance range, etc. between each equipment and the work, respectively, above Are stored together with the abbreviations and symbols described in the process chart.

Using these data, the layout plan creating unit 13 uses the data in each process according to the connection of the processes in the process chart and the line abstraction model as shown in the flowchart of FIG. The equipment figure data is obtained from the layout figure DB 22 and the layout rule DB 2
3 is arranged according to the arrangement rule.

[0030] First, the layout diagram which is used to as the factory upstream steps to the left, arranged downstream of the step to the right (S3
1) An interval corresponding to a line pitch is provided between layout figures indicating respective steps (S32). Interference Ji E Kkushi equipment and work in the step of adjoining the like the size of the workpiece to be working in the movable range and the process of the movable equipment from the attribute data of the equipment used in the respective steps (S33), If there is interference (S34), the interference amount of the interfering part is determined from the equipment movable range and the size of the work in each process (S35),
The position of the layout figure indicating the process is corrected by the amount of interference (S36). When the interference disappears, it is output as a layout plan (S37).

Although the above description is for the case where there is no case, if there is a case where more than half of the steps match, the part of the matching step is used as it is and the step which does not match is used. As described above, by arranging the steps as described above and outputting as a layout plan, the time required for creating the layout plan can be reduced.

Next, the layout plan evaluation / correction unit 14
When the layout plan output by the layout plan creation unit 13 is arranged in the production line installation space of the factory, the interference between the facilities and works in the individual processes and the structures and passages in the factory is checked. Correct the position of each process.

First, as shown in the flowcharts of FIGS. 8 and 9, the center of gravity of the entire production line of the output layout plan is located at the center of gravity of the space in the factory where this production line is installed. (S41), it is checked whether or not the peripheral structure of the production line and the facilities and works in each process do not interfere (S42). If there is interference (S43), which process the interference position is in check the stores determined interference amount of the portion (S44). At this time, if there are a plurality of interference positions, the processing is performed for each of them.

Next, the interference position detected in the current interference check is compared with the one already stored as the interference position (S45). If it is detected that the interference positions are not the same (S46), a plurality of interference positions are detected. It is determined whether or not certain interference positions are at positions facing each other (S47). This is because, when shifting the line to be described later, since it is impossible to move the line when in the position where the interference position is opposed to each other, by which the intended to Ji E click, a facing position, the For example , layout layout of the process at the most upstream side
The arrangement position and the arrangement position of the layout graphic in the most downstream process are opposed to each other, and the right side of the line and the left side of the line are opposed to each other.

Next, when it is detected that the interference position is not at the position facing the interference position (S47), a margin between the equipment or the work in the process at the position facing the interference position and the peripheral structure of the portion is determined (S47). (S48), the interference amount at the interference position is compared with the allowance at the position facing the interference position (S4).
9) If the interference amount is smaller than the margin amount (interference amount <margin amount) (S50), the entire line is shifted in the marginal direction by the interference amount (S51). In the storage of the interference position (S44), it is assumed that 0 has been cleared (no stored interference position) at the time of the first interference check.

The repeated interference Chi E click back to this after step 42 (S42). In the case where the interference portion is not eliminated by shifting the entire line, that is, in step 46 (S46), after the interference position is checked,
When it is detected that the interference has occurred at the same position as the already stored interference position, or Step 4
7 (S47) is a case where it is detected that a plurality of interference positions are at positions facing each other. In such a case, the interference is eliminated by shifting the layout figure of each process individually in the following step 52 (S52).

For this, first, a step having interference is shifted within a range of the constraint conditions of the step (S52), and interference with a peripheral structure is checked (S53). Here, the constraint conditions of the process means that the direction and amount of movement can be determined based on the size of the equipment in the process obtained from the attribute data of each process described above, the size of the work used in the process, the distance to the work, and the like. It is subject to restrictions, for example, from the attribute data of the process at the interference position, if the work space with the adjacent process can be narrower, how far it can be narrowed, and the distance between the belt conveyor and the equipment (work and The constraint condition is how close the object can be (or can be separated).

Next, the layout figure of the process at the interference position
Only shifted arrangement if there is interference, shifting the step adjacent to the interference position within the constraints of the process (S55), the interference check is performed (S56),
If there is still interference (S57), the process of the process adjacent to the process at the interference position is sequentially performed from the process adjacent to the process .
An interference check is performed by shifting the layout of the layout figure, and the process is performed up to the end step (S55 to S58). In the middle of the process, when the interference disappears, the layout is output as a layout diagram (S60). If it is detected that the process is shifted to the endmost step and the endmost step is reached (S60).
58), add a note "interference exists" and output the layout diagram at that time (S59).

The functions and operations of each unit have been described above. The functions and operations of each unit are specifically executed by computer hardware called a personal computer or a workstation as shown in FIG. A program for executing the functions of the respective units operates in the processing operation device 2, and the storage device 3 stores the program and a database 20, and necessary data and processing instructions are input by the input device 4. , Process charts and layout diagrams,
Output of the intermediate results is performed by the display device 5 or a printer (not shown).

Hereinafter, the flow of the entire layout creation will be described with reference to the overall flowchart shown in FIG.

First, a process chart as shown in FIG. 2 is input (S1). Based on the process chart, the model creation unit 11 converts the connection of each process into an abstract model of a production line, a simplified model. A generalized model is created (S2) (see FIG. 3).

Next, in the case search / judgment unit 12,
As shown in FIG. 4, a case search is performed (S
3) If there is a layout case where the simplified models match and more than half of the processes match (S4), the layout case is acquired (S5).

Next, the layout plan creating section 13
As shown in FIG. 7, a layout plan is created (S6).

Next, in the layout plan evaluation / correction unit 14, as shown in FIGS. 8 and 9, interference check and optimal placement due to the layout plan being placed in the production line installation space of the factory are performed. A layout diagram is created (S7).

Next, the layout designer checks whether or not there is an error in the output layout diagram.
If re-correction is necessary, the re-correction is performed (S8). This re-correction is performed so that the layout evaluation / correction can be performed artificially if necessary even when a layout drawing having no interference is output. No modifications need to be made.

Next, it is determined whether or not the layout has been completed (S9). If the layout cannot be performed due to interference even after the artificial re-correction is performed, a layout inability is output (S13). In addition, after the artificial re-correction (S8), the layout plan after the artificial re-correction may be automatically evaluated by the layout plan evaluation and correction unit 13.

When the layout is completed, a completed layout diagram is output (S10), and an abstract model and a simplified model of the completed layout are created (S11). Is stored in the case DB 21 (S12), and the processing ends.

FIG. 12 shows an example of a production line created by the production line layout creating apparatus according to the present embodiment as described above. This production line has processes # 10 to #
Process # 0 with up to 70 linearly arranged and involving artificial work
Nos. 1 to # 25 are installed close to the process # 30, and two of these lines are arranged.

[0049]

As described above, the production line layout creating apparatus of the present invention converts graphic data, which is a diagram of each process and equipment used in each process, into a layout graphic as information necessary for creating a production line layout. In the storage means, the arrangement rule for each process and each equipment is stored in the allocation rule storage means, and the size of each equipment used in each process, the movable range of each equipment and the size of the work are stored in the attribute data storage means. , Respectively, based on the information of each process of the production line input by the process content input means, detects the connection of each process, creates a production line model, according to the stored arrangement rules, Connect graphic data of each process and equipment, and further
Since the process intervals adjacent to each other are determined from the attribute data such as the size of the work and the line layout is created, the layout of the production line can be automatically created. This eliminates the need to search for process and equipment materials for layout creation when creating line layouts, and allows line layouts to be created without interrupting the layout designer's thinking. The time required for layout creation can be shortened well.

Further, in the present invention, the provision of the case search means and the line layout storage means makes it possible to utilize the existing production line layout. When the layout is changed by remodeling the production line, the layout of the remodeled production line can be created in a short time. Further, by storing the modified rain layout in the line layout storage means, the accuracy of the stored production line layout is improved.

[Brief description of the drawings]

FIG. 1 is a block diagram for explaining a production line layout creating apparatus according to an embodiment of the present invention.

FIG. 2 is a drawing showing an example of a process chart.

FIG. 3 is a drawing showing an example of a line model.

FIG. 4 is a flowchart of a case search.

FIG. 5 is a drawing showing an example of graphic data.

FIG. 6 is a diagram illustrating an example of attribute data.

FIG. 7 is a flowchart of layout creation.

FIG. 8 is a flowchart of layout evaluation correction.

FIG. 9 is a flowchart of layout evaluation correction subsequent to FIG. 8;

FIG. 10 is a diagram showing a hardware configuration of the embodiment.

FIG. 11 is a flowchart illustrating an overall flow for creating a layout.

FIG. 12 is a drawing showing an example of a production line layout diagram.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Production line layout creation apparatus 10 ... Process table input part 11 ... Model creation part
12: case search / judgment unit; 13: layout plan creation unit
14 ... Layout plan evaluation / correction unit, 20
... Database department, 21 ... Case D
B, 22 ... layout figure DB, 23 ...
Placement rule DB, 24 ... attribute DB,
30 Display unit.

──────────────────────────────────────────────────続 き Continued on front page (58) Field surveyed (Int.Cl. ⁷ , DB name) G06F 17/50 636 G06F 17/60 108

Claims (2)

(57) [Claims] 1. A plurality of production lines layout creating apparatus for creating an arrangement of the equipment used in each step and each of said steps of configured production line by step, shows a higher pre climate and stylized Layout figure data,
And a diagram showing the equipment used in each process.
Layout figure storage means for storing layout figure data, arrangement rule storage means for storing the arrangement rules of the respective steps and the respective facilities, size of the respective facilities used in the respective steps, Attribute data storage means for storing the movable range and the size of the work on which the work is performed in each of the steps, and step contents input means for inputting each facility required for each of the steps and the work on which the work is performed in each of the steps And a line model for detecting a connection between the respective processes from a facility required for each of the processes and a work performed for each of the processes input by the process content input unit and creating a model of the production line. and creating means, according to the arrangement rule from consuming the steps of the model obtained the production line by the line model generating means Facilities in the steps layout diagram and steps
Ray Place a layout diagram, based on a size of the movable range and the work of the equipment used in each step of the attribute data, the arranged mutually adjacent step
A line layout creating means for creating a line layout by correcting the arrangement interval of the out figure, and whether the line layout created by the line layout creating means fits in the space where the production line is installed is created. Factory line layout
Individual process when placed in the production line installation space
Interference between equipment and workpieces in the factory and structures and passages in the factory
Check, if there is interference, the one that eliminates the interference
Move the entire line layout in the direction
If there is no interference,
Move in the direction in which other interference does not occur.
However, if the interference does not go away, the
And a line layout evaluation correcting means for outputting a simple layout figure . 2. A production line layout creating apparatus, comprising: line layout data storage means for storing an existing production line layout; and the number of steps and each step in a production line model created by the line model creation means. Are connected in the same way
And a case search means for searching a production line layout in which the same process is present in more than half of the existing production line layouts stored in the line layout data storage means. The production line layout creating apparatus according to claim 1.