JP3252358B2 - Method of recovering system abnormality in FMS - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial application field) In the present invention, a central processing unit controls an automatic warehouse that stores a plurality of pallets of a plurality of numerically controlled machine tools, a workpiece transfer device, and a plurality of numerically controlled machine tools in common. The present invention relates to a method for recovering a system abnormality in a managed FMS (Flexible Manufacturing System).

(Prior Art) FIG. 11 is a schematic configuration diagram showing an example of a general FMS. A predetermined pallet transported from an automatic warehouse 11 is loaded on a work transport device 12 and transported to a side of a handling station 13. By the operation of the handling station 13, a part as a work is mounted on a pallet loaded on the work transfer device 12 and a predetermined numerically controlled machine tool 14 is mounted.
It is transported to APC (auto pallet changer) 16.
The pallet on the APC 16 is transferred to the numerically controlled machine tool 14 by the operation of the APC 16 in accordance with a command from the numerical control device 15, and the pallet on the numerically controlled machine tool 14 is
Passed to. Then, the work transfer device 12 loads the pallets from the APC 16 and transfers the pallets to the side of the handling station 13, and the parts attached to the pallets loaded on the work transfer device 12 are collected by the operation of the handling station 13. The contents of the work performed at the handling station 13 are displayed on a display device 17, and the above-described operations are managed by a central processing unit 18.

As shown in FIG. 12, the FMS data having such a configuration includes production plan data 31 (see FIG. 5) for registering a part number to be input to the system and the number of processed parts, and a processing step and processing for each part number. Processing process data 32 (see Fig. 6) for registering the processing program name, pallet used, jig, processing time, and processing machine for each process, and state for each part number and processing number (number No.) Processing progress data 33 (see FIG. 8) for recording (during processing, completion of processing, etc.), and an instruction to input a part registered in the production plan data 31 and an instruction to collect the processed part are given to the operator. Work order data for
34 (see FIG. 10), and machining schedule data 35 (see FIG. 9) for recording, by a part number and a process number, that the numerical control machine tool into which the component is put is waiting to be machined.
And information on parts (part number, process number, status of material / finished product, etc.) attached to pallets stored in automatic warehouses or numerically controlled machine tools. It is managed separately and set each time the pallet is moved by the work transfer device, and the status of the pallet (part number, process number, material / finished product status, etc.) in the automatic warehouse or numerically controlled machine tool is always the actual It is composed of inventory data 36 (see FIG. 7) which is matched with the status, and these data are created or updated according to a flowchart shown in FIG.

When the registration of the production plan data 31 and the machining process data 32 is completed, the operator instructs the central processing unit 18 to start a system operation (step S41). Accordingly, the central processing unit 18 checks the part number registered in the production plan data 31 (step S42), and determines whether or not the processing progress data 33 for the part number has been created and processed (step S42). S43) If processing has been completed, it is determined whether or not there is a next part number (step S46). If there is a next part number, the process returns to step S43 and repeats the above operation. On the other hand, if the processing has not been completed, the processing progress data 33 for the part number is created, and a set request (a state in which the operator is instructing the system to insert parts into the system) is set for the processing progress for the number of processed parts (step S44) Then, the work instruction data 34 is created, and the part number and the number of inserts for which the input instruction is issued are set (step S45).
When the investigation on all the part numbers registered in the production plan data 31 is completed (step S46), the central processing unit 18
Determines whether there is an input instruction in the work instruction data 34 (step S47), and if there is an input instruction, instructs the worker to insert components using the display device 17 (step S48). The operator sees the input instruction, inputs components into the system at the handling station 13, and notifies the central processing unit 18 that the input has been completed. Upon receiving the notification of the completion of the input (step S49), the central processing unit 18 creates the processing schedule data 35 for the component whose input has been completed, and at the same time updates the processing progress which has been a set request to the completion of the setting (step S50). ), Set the part number, process number, and status (material) in the inventory data of the pallet that has been input. Then, the central processing unit 18 determines whether or not the processing schedule data 35 has been created (step S51). The pallet of the number and the process number is conveyed to the APC 16 and a start signal is notified to the numerical controller 15. Numerical control unit 15
The APC 16 and the numerically controlled machine tool 14 are controlled to start machining.

Then, the central processing unit 18 updates the processing progress, which has been set so far, during the processing (step S52). When the machining by the numerically controlled machine tool 14 is completed, the numerical controller 15 informs the central processing unit 18 that the machining has been completed (OK machining completed or NG
When the central processing unit 18 recognizes this as the completion of the OK processing (step S53), the processing progress which has been being processed is updated to the OK completed product (step S54),
The status of the pallet inventory data is set to OK completed product, and when it is recognized that NG has been completed (step S55), the machining progress that has been processed so far is updated to NG completed product (step S55).
S56), the status of the inventory data of the pallet is set to NG finished product. The central processing unit 18 examines the processing process data 32 in the case of an OK completed product to determine whether or not there is a next process (step
S57) If there is no next process or if the processing progress is an NG completed product, work instruction data 34 is created and a collection instruction for the part is set (step S58). If there is a next process, the next process for the part is performed The processing schedule data 35 is created, the processing progress of the next process is updated to the completion of setting (preparation completed) (step S59), and the status of the inventory data of the pallet is set to a semi-finished product. Next, the central processing unit 18 determines whether or not there is an instruction to collect the finished product (step S60). If there is an instruction to collect the finished product, the central processing unit 18 instructs the worker to use the display device 17 to collect the parts. (Step S61). The worker sees the collection instruction and collects the parts at the handling station 13, and when the collection is completed, notifies the central processing unit 18 that the collection is completed. Upon receiving the notice of the completion of the collection (step S62), the central processing unit 18 updates the processing progress to the completion of the collection (step S63), deletes the inventory data of the pallet, and sets the pallet to an empty (clear) state. Central processing unit 18
Determines that the production plan for the part number has been completed only after the parts having the part number registered in the production plan data 31 are input and the collection is completed. In this way, the central processing unit 18 determines whether or not the production plans for all the part numbers registered in the production plan data 31 have been completed (step S6).
4) If the production plans for all the part numbers have not been completed, the process returns to step S42 to repeat the above-described operations, and if the production plans for all the part numbers have been completed, all the processes are completed.

As described above, the numerical control machine tool 14 has been systematized for the purpose of improving productivity and reducing downtime, and various functions have been developed and put into practical use. Among them, countermeasures against the downtime of the central processing unit 18 that controls and manages the system are the most serious problems. That is, if the central processing unit 18 goes down due to an abnormality such as an instantaneous power failure or power failure, the production of the entire system will be stopped, which will also affect the productivity of the entire factory. Therefore, when the central processing unit 18 goes down, a function that can quickly return to the central processing unit 18 is required.

FIG. 14 is a block diagram showing an example of a function of a central processing unit for realizing a method for recovering a system abnormality in the conventional FMS. In the system initialization unit 6, the processing progress data 33 which the central processing unit 18 had before the down was performed. Then, the work instruction data 34 and the processing schedule data 35 are initialized. Then, in order to restart the system operation, the inventory data 36 in which the operator resets the state of all pallets to be used to the initial state (the first state in which no parts are placed) is the inventory data editing unit 1 The production plan data 31 after the restart of the system operation edited by the operator is re-registered in the production plan data editing unit 7, and the system operation is restarted by the system start processing unit 5 according to an instruction from the operator. It is to be started.

An operation example of such a configuration will be described with reference to a flowchart shown in FIG. First, the operator turns on the power of the central processing unit 18 and issues a system initialization command to the system initialization unit 6 (step
S71). As a result, the system initializer 6 deletes all the machining progress data 33, the work instruction data 34, and the machining schedule data 35 (Steps S72, S73, S74). Therefore, various data 33, 34, and 35 that the central processing unit 18 had before the down were initialized, and the central processing unit 18 was initialized.
18 will return to the initial state. Next, the worker checks the state of the pallets in the automatic warehouse 11 and the numerically controlled machine tool 14, and checks which part has been processed and to which process (step S75). The operator determines which part and which process to start from the inspected pallet state. In other words, if the state of the pallet is the material, a production plan from the first process is necessary, if it is a semi-finished product, a production plan from the next process is necessary, and if it is an OK finished product or NG finished product, it will be produced. You need to delete the plan. Thus, the production plan data 31 after the restart is determined (step S7
6) Of the inventory data 36 held by the inventory data editing unit 1,
The state of the pallet used in the production plan data 31 is reset to the initial state (the first state where no parts are placed) and registered again (step S77). Finally, the operator re-registers the production plan data 31 in the production plan data editing section 7 (step S78). Thereafter, when the worker issues a system start request to the system start processing unit 5 (step S79), the system is restarted according to the processing example shown in FIG.

(Problems to be Solved by the Invention) In the above-mentioned conventional method for recovering a system abnormality in the FMS, when the central processing unit goes down, the state of the pallets in the automatic warehouse and the numerically controlled machine tool is investigated to reconstruct the production plan data. , Reset the pallet used in the production plan to the initial state (the state where no parts are placed), re-register the inventory data, and re-register the production plan data. Since the restart cannot be performed, the burden on the operator is large, and it takes a long time to restart the system operation, which has a disadvantage that the productivity of the entire factory is greatly affected. In addition, there is a problem in that the system operation may not be performed properly even if the system is restarted because the operation depends on the operator.

The present invention has been made in view of the above-mentioned circumstances, and an object of the present invention is to shorten the return time when the central processing unit goes down and to reduce the burden on the operator to ensure the restart of the system operation. It is an object of the present invention to provide a method for recovering a system abnormality in an FMS that can be performed in a different manner.

(Means for Solving the Problems) The present invention relates to an FMS in which a central processing unit centrally manages a plurality of numerically controlled machine tools, a workpiece transfer device, and an automatic warehouse for commonly storing pallets of the plurality of numerically controlled machine tools. The present invention relates to a method for resetting when a system abnormality has occurred, and an object of the present invention is to process each part mounted on a pallet that has been reset when an operator instructs the central processing unit to restart the system operation. Based on the inventory data indicating the status, the machining progress data for recording the progress of the machining process for each part is automatically reset, and the parts waiting in the automatic warehouse are automatically selected from the inventory data. And register as machining schedule data for recording that each of the plurality of numerically controlled machine tools is waiting for machining, and machining for each part of the machining progress data. Register the data of parts that need to be newly introduced into the system from the progress and the parts that can be collected from the system as work instruction data, and operate the system using the stock data, processing progress data, processing schedule data, and work instruction data. Is achieved by resuming.

(Operation) In the present invention, machining progress data and machining schedule data are automatically created and edited based on inventory data set by an operator, and parts input / recovery instruction data is created based on the automatically created machining progress data. The system can automatically restart system operation from a state where the operator only needs to set inventory data to restore the system even if the central processing unit goes down due to an instantaneous power outage, power outage, etc. Therefore, it is possible to minimize and reliably recover the system stop time.

(Embodiment) FIG. 1 is a block diagram showing an example of a function of a central processing unit for realizing a system abnormality recovery method in an FMS according to the present invention. Inventory data with reset status
36 is re-registered in the inventory data editing unit 1. The re-registered stock data 36 is sent to the machining progress data automatic editing unit 2 and the machining schedule data automatic editing unit 3, and the machining progress data 33 and the machining schedule data 35 are automatically edited based on the stock data 36 and re-registered. Is done. The re-registered processing progress data 33 is sent to the work instruction data automatic editing unit 4, and the work instruction data 34 is automatically edited based on the processing progress data 33 and re-registered. Then, the system operation is restarted by the system start processing unit 5 in response to a command from the operator.

In such a configuration, an example of the operation will be described with reference to the flowcharts of FIGS. Here, after the central processing unit 18 goes down due to an instantaneous power failure, a power failure, or the like during the system operation with the production plan data 31 shown in FIG. 5 and the machining process data 32 shown in FIG.
It is assumed that the stock data 36 shown in FIG. 7 is re-registered, and that the work progress data 33, the work schedule data 35, and the work instruction data 34 including the input / recovery work instruction are created based on the stock data 36. Will be described.

First, an operation example of the processing progress data automatic editing unit 2 shown in FIG. 2 will be described with reference to a flowchart. The processing progress data automatic editing unit 2 checks the stock data 36 and totals the pallets for each part number (step S1). In this example, PART-A is one material pallet and one OK finished product pallet, PART-B
Means one semi-finished product pallet and one NG finished product pallet, PA
RT-C counts as one semi-finished product pallet. Here, the raw material is input into the first processing step of the system (hereinafter, referred to as the first step), and the semi-finished product is machined in the system and then waiting for the next processing. A thing. Next, the processing progress data 33 created for each part number based on the totaled inventory data 36 is edited as shown in FIG. 8 (step S2).

Then, the processing progress data 33 of PART-A is examined to determine whether or not there is a processing progress of the final process that has not been completed. If there is a processing progress that is not completed, the processing progress of the number No. is initialized. (Step S3). This is the central processing unit 18.
This is because there may be a case where the processing has already been completed and the collection from the system has been completed before the pallet goes down (the pallet which has already been collected is not in the automatic warehouse 11). In this example, the processing progress of the PART-A is the completion of collection of the first PART-A ((a) in FIG. 8), but not the completion of recovery of the second and subsequent PART-A ((b) to (d) in FIG. 8). The second and subsequent machining progresses are initialized.

Next, it is determined whether or not the PART-A OK completed product is included in the stock data 36 (step S4). In this example, the PART-A OK completed product is present, and the process number of the OK completed product is “4”. Because there is
Set the machining progress of No. 2 to OK completion up to the 4th process (No. 8
Illustration (b). Then, it is determined whether or not the NG completed product of PART-A exists in the inventory data 36 (step S6).
Since there is no NG finished product of RT-A, the process proceeds to step S8, and it is further determined whether or not there is a semi-finished product of PART-A in the inventory data 36 (step S8). Since there is not, the process proceeds to step S10. Then, PART is added to the inventory data 36.
It is determined whether there is a material of -A (step S10). In this example, there is a material of PART-A, and since the process number of the material is "1", the setting is completed in the first process of the number No.3. Is set (the eighth illustration (C)). Since there is no PART-A pallet corresponding to the number No. 4 in the inventory data 36, the machining progress of the set request, which is a request for inputting a component not yet input to the system, in the first process of the number No. 4 is calculated. It is set (step S12, eighth illustration (d)). Then, it is determined whether or not the stock data 36 has the next part number (step
S13) In this example, since there is PART-B, the process returns to step S3.

In this example, the processing progress of PART-B is the completion of the collection of the first PART-B ((e) in FIG. 8), but the completion of the recovery of the second and subsequent PART-Bs ((f), (g) in FIG. 8). The second and subsequent machining progresses are initialized.

Next, it is determined whether or not the PART-B OK completed product is included in the stock data 36 (step S4). In this example, since there is no PART-B OK completed product, the process proceeds to step S6. And to inventory data 36
It is determined whether there is an NG finished product of PART-B (step S
6) In this example, there is an NG finished product of PART-B, and since the process number of the NG finished product is "3", the machining progress of the third and fourth processes of No. 2 is set to NG completed. (FIG. 8 (f)), the processing progress of the first step and the second step is set to OK completion (FIG. 8 (f)). The reason why the machining progress of the fourth process is also set to NG completion is that a component that is NG completed in the third process is not machined in the fourth process. Then, it is determined whether or not there is a semi-finished product of PART-B in the inventory data 36 (step S8). In this example, there is a semi-finished product of PART-B, and the process number of the semi-finished product is “2”. Therefore, the machining progress of the first process of No. 3 is set to OK completion (FIG. 8 (g)),
The processing progress of the second step is set to the completion of setting (eighth illustration (g)). Then, it is determined whether or not the stock data 36 includes the material of PART-B (step S10).
Since there is no material, the process proceeds to step S12, and since there is no remaining number, the process proceeds to step S13. And inventory data 3
It is determined whether the next part number exists in 6 (step S13),
In this example, since there is PART-C, the process returns to step S3. Then, similarly, the processing progress of PART-C is set to obtain the processing progress data 33 as shown in FIG. 8 (symbols in parentheses), and all the processing is ended.

Next, a description will be given with reference to a flowchart showing an operation example of the processing schedule data automatic editing unit 3 in FIG. The processing schedule data automatic editing unit 3 initializes the processing schedule data 35 held by the central processing unit 18 before the down processing (step S14), and checks the stock data 36 for each part number (step S15). First, it is determined whether there is a semi-finished product of PART-A in the inventory data 36 (step S16). In this example, since there is no semi-finished product of PART-A, it is determined whether there is a material of PART-A. (Step S17). In this example, PART−
Since there is a material of A and the process number of the material is "1", the processing machine "1" of the first process is obtained from PART-A of the processing process data 32 (step S18), and the processing schedule data 35 of the first machine Then, the data of the process number "1" of PART-A is registered (step S19, ninth illustration (k)). Then, it is determined whether or not the stock data 36 has the next part number (step S2).
0) In this example, since there are PART-B and PART-C, step S
Return to 16. Then, similarly, the processing schedules of PART-B and PART-C are set to obtain the processing schedule data 35 as shown in FIG. 9, and all the processes are completed.

Finally, a description will be given with reference to a flowchart of FIG. 4 showing an operation example of the work instruction data automatic editing unit 4. The work instruction data automatic editing unit 4 checks the processing progress data 33 for each part number (step S21). First, PART- of machining progress data 33
The processing progress of the first process of No. 1 of A is taken out (step S22), and it is determined whether the first process is the process of the final progress (step S23). Here, the final progress step is the last step in which the processing progress is recorded. In this example, since the first process of PART-A No. 1 is not the process of the final progress, the process proceeds to step S28 to determine the presence or absence of the next process. In this example, since there is a next process for the number No. 1 of PART-A, the process returns to step S23 and the same operation as described above is repeated. Then, since the fourth process of PART-A number No. 1 is the process of the final progress, it is determined whether or not the processing progress of the fourth process is a set request (step S24). In this example, PAR
Since the machining progress of the fourth process of No. 1 of TA is not a set request, it is determined whether the machining progress of the fourth process is OK completion or NG completion (step S25). In this example, PART-A
Since the machining progress of the fourth process of No. 1 is neither OK completion nor NG completion, the process proceeds to step S29 to determine the presence or absence of the next number No. In this example, since the number of PART-A is No. 2, the operation returns to step S22 and the same operation as described above is repeated. Then, since the fourth step of the PART-A number No. 2 is the final progress step and the OK is completed, the part number “PART- A "
Then, the process number “4” is written (FIG. 10 (p)). At this time, if the same part number and process number already exist in the collection work instruction data, it is only necessary to count up the number of collections (step S27). Then, the process proceeds to step S29 to determine the presence or absence of the next number. In this example, the number of PART-A No.
Since there is No. 3 and No. 4, the process returns to step S22 and the same operation as described above is repeated. And the number 1 of PART-A No. 4
Since the process is the final progress step and is a set request, the part number “PART-A” and the process number “1” are written in the input work instruction data of the work instruction data 34 (FIG. 10 (n)). . At this time, if the same part number and process number already exist in the input work instruction data, it is only necessary to count up the input number (step S26). Then, since the next process and the next number No. have disappeared (steps S28 and S29),
It is determined whether or not there is a next part number (step S30). In this example, since there is PART-B and PART-C, the process returns to step S21 to repeat the same operation as described above. As a result, the part number “PART-B” and the process number “4”
Is written (10th illustration (q)), and the part number “PART-C” and the process number “1” are written in the input work instruction data (10th figure).
As shown (o), all the processes are completed.

As described above, the creation of the processing progress data 33, the processing schedule data 35, and the work instruction data 34 based on the stock data 36 set by the worker is completed, and thereafter, the start of the system is instructed by the worker, and FIG. The system operation is restarted according to the flowchart shown in FIG. That is,
It is determined whether or not the processing has been completed for each part number of the production plan data 31 shown in FIG. 5 (the processing progress data 33 has already been created), and the processing progress data of PART-A, PART-B and PART-C are determined.
Since 33 has already been created, machining progress data 33 and work instruction data 34 are created only for PART-D. Next, it is determined whether or not there is an input instruction. However, as shown in FIG. 10, the input work instruction data already contains the data of PART-A and PART-C. Process and
An input instruction for one step of PART-C is issued. And the ninth
Machine processing is performed according to the processing schedule data 35 shown in the figure, and the processing progress data 33 is updated during the processing. For example, when the part of PART-A in the processing schedule data 35 is processed, the processing progress of the first process of the number No. 3 of PART-A shown in FIG. Also the
For the worker by the collection work instruction data shown in Fig. 10
Recovery instructions for the four steps of PART-A and four steps of PART-B are issued. Thereafter, the operator performs the designated input and recovery work, and notifies the completion of the input to newly update the processing schedule data 35 and the processing progress data 33, and notifies the completion of the recovery to notify the completion of the processing. Is updated. For example, when one process of PART-A is input, data of one process of PART-A is created in the machining schedule data 35 of the first machine, and the number of PART-A No. 4 shown in FIG.
Of the first process is updated from the set request to the completion of the set.

As described above, the system can be restored from the processing progress data 33, the processing schedule data 35, and the work instruction data 34 created by automatic editing based on the stock data. In other words, it is possible to resume the parts that have been waiting for processing from the state of waiting for processing, the parts that have been completed processing from the collection of parts, and the parts that have not yet been put into the system from the part input. .

(Effects of the Invention) As described above, according to the method for recovering a system abnormality in the FMS of the present invention, even if the central processing unit goes down due to an instantaneous power failure, a power failure, etc., the operator only needs to set inventory data in a short time. In addition, the system can be reliably restored, and a system that does not reduce productivity can be constructed.

[Brief description of the drawings]

FIG. 1 is a block diagram showing an example of a function of a central processing unit for realizing a method for recovering a system abnormality in the FMS according to the present invention. FIGS. 2 to 4 are flow charts for explaining an example of the operation. FIG. 10 to FIG. 10 are diagrams showing examples of data used in the method of the present invention, FIG. 11 is a schematic configuration diagram showing an example of a general FMS, FIG. 12 is a diagram showing an example of data configuration used for FMS, FIG. Is a flowchart illustrating an example of an operation of creating and updating the data, FIG. 14 is a block diagram illustrating an example of a function of a central processing unit for realizing a conventional method of recovering a system error in the FMS, and FIG. 15 is an example of the operation 5 is a flowchart for explaining FIG. 1 ... stock data editing section, 2 ... processing progress data automatic editing section, 3 ... processing schedule data automatic editing section, 4 ...
Automatic work instruction data editing unit, 5 System start processing unit, 6 System initialization unit, 7 Production plan data editing unit, 11 Automatic warehouse, 12 Work transfer device, 13 Handling station , 14 ... Numerical control machine tool, 15 ... Numerical control device, 16 ... APC, 17 ... C
RT, 18 Central processing unit, 31 Production plan data, 32
... machining process data, 33 ... machining progress data, 34 ... work instruction data, 35 ... machining schedule data, 36 ... stock data.

Claims (1)

(57) [Claims] When a system error occurs in an FMS in which a central processing unit supervises and manages a plurality of numerically controlled machine tools, a workpiece transfer device, and an automatic warehouse for commonly storing pallets of the plurality of numerically controlled machine tools, Processing for recording the progress of the machining process for each component based on inventory data indicating the machining status of each component attached to the pallet reset when the operator instructs the central processing unit to restart the system operation. Automatically reset the progress data, automatically extract the parts waiting in the automatic warehouse from the inventory data, and record that each of the plurality of numerically controlled machine tools is waiting for processing Of the parts that need to be newly introduced into the system and the parts that can be collected from the system from the processing progress of each part in the processing progress data. The chromatography data was registered as work instruction data, the inventory data, the processing progress data, system error return method in FMS, characterized in that so as to resume the system operation by using the processing schedule data and work instruction data.