JP3278233B2 - Casting management method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a casting management method.

[0002]

2. Description of the Related Art Conventionally, for example, a casting method of an aluminum product mainly occupies a sand mold, a mold, and a die cast, but each production line has different management contents such as setup and machine adjustment. Problems at the production site are also different. Therefore, the conventional management often depends on the intuition of workers at the site. For this reason, conventionally, material management and sales management, that is, management of factory entrances and exits, can be accurately grasped, but production management in the factory during that time is left to the on-site workers, and the situation can be accurately determined. I couldn't figure out.

[0003]

However, if all the work standards of thousands of parts rely solely on the experience and intuition of the operator, the quality, delivery time, cost, productivity, and other aspects are not enough. There are many problems to look at. In particular, it cannot cope with variant production.

The present invention has been made in view of such a point, and manages a production line through a network using part number information for each part in a part number information database.
It is an object of the present invention to provide a casting management method that can cope with a variety of variable production.

[0005]

According to the first aspect of the present invention,
A work standard related to at least a product number and a pouring amount is registered in a product number information database as product number information for each different product , and a production line is controlled through a network by the work standard registered in the product number information database, and obtained from the production line. the line operation information and feedback through the network, Lai was feedback
This is a casting management method that displays operating information .

[0006] The invention according to claim 2 is provided for each different product.
Part number information is related to at least the part number and pouring volume
Register the work standard in the part number information database, and
Network based on the work standards registered in the
Control the production line through the
Feed the obtained line operation information through the network
Responds to feedback on line operation information
Instructions to output to production line equipment
is there.

[0007] The invention according to claim 3 is provided for each different product.
Part number information is related to at least the part number and pouring volume
Register the work standard in the part number information database, and
Network based on the work standards registered in the
Control the production line through the
Feed the obtained line operation information through the network
In the line operation information
If there is a production line stop,
Casting management that acquires and displays at least one of the failure locations
Is the way.

[0008] The invention according to claim 4 is for each different product
Part number information is related to at least the part number and pouring volume
Register the work standard in the part number information database, and
Network based on the work standards registered in the
Control the production line through the
Feed the obtained line operation information through the network
Based on the line operation information
Is a casting management method that creates operation records for production lines.
You.

[0009] The invention according to claim 5 is provided for each different product.
Part number information is related to at least the part number and pouring volume
Register the work standard in the part number information database, and
In controlling the production line based on the work standard registered in the information database, the load of the production line is grasped by accumulating the individual part number information, and this load is adjusted to be within the capacity of the production line. Create a sequential plan
And production through the network according to this order plan
This is a casting management method that instructs a work standard to the line and controls the production line .

[0010] The invention according to claim 6 is provided for each different product.
Part number information is related to at least the part number and pouring volume
Register the work standard in the part number information database, and
Network based on the work standards registered in the
Control the production line through the
This is a casting management method in which the obtained line operation information is fed back to a part number information database through a network to improve the work standard of the database.

The invention according to claim 7 is the casting management method according to any one of claims 1 to 6 , wherein a plurality of production lines are installed.

[0012]

[Action] first aspect of the present invention, since an instruction at least part and casting concrete work standard production line across the network part information database registered working standards related to hot water as part information for each different product, different It can cope with varieties and varieties production where the pouring amount needs to be controlled for each product . Also obtained from the production line
Feedback of line operation information through the network
And display the line operation information that has been fed back.
And easily monitor the work progress of each product in real time.
Process management for products produced in different quantities and quantities.
I can.

The invention according to claim 2 provides feedback.
To the production line equipment
Output, so that the production line
Need to change line operation status
It can respond to the production of varieties and variables with certainty.

The invention according to claim 3 provides feedback.
When the production line is stopped in the line operation information
Is to determine at least one of
Since it is acquired and displayed, even if the production line is stopped,
Whether the cause of the line stoppage is a production line failure or not
If it is a production line failure, also know the location of the failure.
Variant that tends to stop the line due to
Suitable for mass production.

The invention according to claim 4 provides feedback.
A production line operation record based on the updated line operation information
Makes it easier to manage line operations in variant and variable production.
On-site operation daily reports, production results
Abolish tallying, etc. to reduce burden and achieve paperlessness
You.

According to the fifth aspect of the invention, when controlling the production line, the load amount of the production line is grasped by accumulating the individual product number information, and the load amount is controlled within the capacity of the production line. create a sequence plan while adjusting, production lines
Control the production line used for variant and variable production.
Even in your application, efficiently running the productivity can be improved.

The invention according to claim 6 is obtained from a production line.
Part number information through the network the resulting line operation information
Feedback to the database to create the database
Industry standards are improved.
Quality can be stabilized and improved.
Can handle production.

According to the seventh aspect of the present invention, small lot production is possible by managing the production time information of a plurality of production lines through the network, and it is possible to cope with a variable quantity production using a plurality of production lines.

[0019]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to embodiments shown in the drawings.

FIG. 2 shows an outline of a production line network system of a casting factory for aluminum casting, in which a manufacturing office 11, a sand mold line production site 12, and a continuous gravitational casting (GRAVITY DIE CASTING) method using a mold. Casting line (hereinafter referred to as GD line) production site 13 and die casting line (hereinafter referred to as DC line) production site 14
And a maintenance office 15 and a core production site 16 with a core molding machine
, Heat treatment site 17, finishing site 18, machining site 19
A network terminal device (personal computer, hereinafter abbreviated as a personal computer) is installed at each of the product storage site 20 and each of these sites and the manufacturing office 11 are connected to a local area network (hereinafter, referred to as a network). LAN 21). It is also connected to a value-added information network (VAN) 22 to take in external information.

Then, in the manufacturing office 11, various part number information 23 relating to the production process such as part number, unit weight, casting line, pouring material, additive, customer, etc. is registered in a database by a LAN terminal device (personal computer). I do.

This database, together with the part number information 23, receives order information (collects and manages orders from customers according to delivery dates) and production plan information (forms a production plan while observing the line load based on the order information). , Line load information (change the load status of each casting line and core according to the production plan), sequence planning and production results (manage the status of work-in-progress and products based on production results and shipping status),
Operation monitor (files information on line operation such as start and end time of production line, person in charge, operation results, line stop reason, etc.), equipment management information (maintenance and maintenance of equipment related to production in the factory) Manage the situation).

The work standard of the product number information 23 is directly instructed from the manufacturing office 11 to the machines such as the line production sites 12, 13, and 14 as control conditions through the LAN 21. Further, a mold system sequence plan 24 or a sand mold system sequence plan 25 is created from the order information and the line load information, and the machines at the line production sites 12, 13, 14 and the like are operated in accordance with the sequence plans 24, 25. In addition, information from order receipt to shipment (production lot completion status, etc.) is displayed in real time on the display of a personal computer, and production point-of-view information is managed while visually observing the progress of each site.

Each automated line production site 12, 13, 14
And the like, directly obtain a work standard from the product number information database through the network 21 and the line control controller, and operate according to the sequence plans 24 and 25. Also,
Production results and operation rates at each line production site 12, 13, 14, etc. are automatically totaled and recorded by LAN terminal equipment (PC). At this time, the order plans 24 and 25 are automatically applied at the same time. In addition, the actual production lines of manual lines and outsourced products are indicated by the site staff using the mouse to indicate the digested lots in the detailed plan column displayed on the PC display. This is used as a daily report to eliminate paper from the site.

In the heat treatment site 17, the finishing site 18 and the machining site 19, when the movement between the processes is automatic, the product position is inputted from the line conveyor to the personal computer and is automatically stored. In the case of manual lines or outsourced products, the site staff uses the mouse to indicate on the display of the personal computer according to the movement of the production lot. This is used for daily operation reports and outsourcing data.

At the product storage site 20 as well, the lot allocated to the storage of the product in lots (which is also the data of the receipt of the product inventory and the production completion) and the shipment is indicated by a mouse in the detailed plan column displayed on the display of the personal computer. Use it to instruct (take in shipping data).

FIG. 3 shows a manufacturing office 11 and production sites 12, 13, and
Shows online network with 14, manufacturing office 11
, Sand mold line production site 12, maintenance office 15, GD
Terminal equipment (PC) 31 of the LAN 21 is installed at the production site 13 of the line, the core production site 16 and the production site 14 of the DC line, respectively, and the manufacturing office 11 and the production sites 12, 13,
14 are connected by a LAN 21. 32 indicates a lamp port, 33 indicates a communication cable, 34 indicates an optical terminal, and 35 indicates an optical cable.

In the manufacturing office 11, input number means such as a keyboard 36 or a mouse 37 of the personal computer 31 is used to create a part number information database (registration and change of work standards, cycle times, etc.), and to create a sequence plan. . In addition, management of work progress status (management of production lot digestion status, etc.), quality management (instruction of work standards, acquisition of defect information for production lots, etc.), line operation management (production results, line stop causes,
Various kinds of information relating to line failure status, operation rate calculation, etc.) are displayed on the display 38 of the personal computer 31, and the records are output from the printer.

At the sand mold line production site 12, the LAN 21
Information such as work standards (pour material, sand, mold, storage address of mold plate 42 to be fitted to master plate 41, size, type, required core, etc.), production sequence plan, etc. The sand casting line 44 as a production line is operated by the line control controller 43. The production results of the sand casting line 44 are automatically totaled by the personal computer 31 directly connected to the line control controller 43, and the operation time, the actual number of frames, the operation rate and the like are automatically recorded. At this time, the order plan is also cleared. The line stop reason and the waiting time are also displayed on the personal computer 31.
By using these production results and line stoppages as daily operation reports, paper can be eliminated from the site. Further, the line failure status such as the line failure location, the number of times, and the time is also specified, and these are monitored. The above information is provided to the LAN 21.

At the sand line production site 12, the LAN 21
If there is a molding machine or a grooming line that is not connected to the computer, the on-site person indicates the digested lot with the mouse 37 in the detailed plan column displayed on the display 38 of the personal computer 31 so that the keyboard 36 is Try to capture data without using it.

In the maintenance office 15, each line production site
Search the failure history automatically created for each production line from the failure location, number of times, and time of individual equipment obtained from 12, 13, and 14, maintain the equipment, and manage spare parts.

At the GD line production site 13, the LAN 21
Information such as the work standard (pour amount by type, mold temperature control, tilting speed, suction time, solidification time, etc.), production sequence plan, etc., is obtained through the line control controller 46 and continuously cast as a production line. The GD line 47 is automatically controlled. The production results of the GD line 47 are automatically recorded as described above, and the sequence plan is automatically deleted. In addition, the cause of the line stop, the location of the failure, and the like are specified, and these pieces of information are provided to the LAN 21.

At the core production site 16, a work standard and a production sequence plan instructed through the LAN 21 are obtained by a terminal device (the personal computer 31), and the core molding machine 48 is operated. When the core molding machine 48 is operated manually or in the case of an outsourced core, the lot that has been digested at the site is indicated by using the mouse 37 in the detailed plan column displayed on the display 38 of the personal computer 31.

At the DC line production site 14, in the case of each DC line 51 of 330 to 2000 tons as a production line, L
Directly instruct work standards (injection speed, boost time, release material blow, die height adjustment, mold opening time, water cooling time, etc.) to each DC line 51 from the personal computer 31a that has acquired information from the AN 21 via the line control controller 52. Then, each DC line 51 is automatically controlled. Then, the operation status of each DC line 51 obtained through the line control controller 52 is provided to the LAN 21 from the personal computer 31a to automatically obtain production results, automate operation records, erase sequence plans,
The reason for stopping the line, the failure location, etc. are specified.

A 2500 tDC line as a production line equipped with a dedicated microcomputer 53 for controlling a die casting machine.
In the case of 54, instructions to the die-casting machine body (injection speed, boost time, mold clamping force, casting pressure, biscuit thickness, etc.)
And the status of the machine itself (measuring value of mold clamping force, die height position, etc.) are performed through its dedicated microcomputer 53, and the instructions to peripheral devices (product take-out device, etc.) and the status of the line are understood.
This is performed by the controller 55 connected to the personal computer 31b.

FIG. 1 shows a production management system of a foundry.

First, as shown in Table 1 below, the production processes such as the product number, customer, manufacturing plant, casting line, single weight, pouring material, additives, pouring amount, solidification time, cooling time, etc. are involved. Various information (work standards) are collectively registered for each item in a file of the personal computer 31, and a part number information database is created (A).

[0038]

[Table 1]

Next, when the individual part number information is accumulated, the load on each production line such as the sand casting line 44, the GD line 47, the core molding machine 48, and the DC lines 51 and 54 is determined. While adjusting the load amount to be within the capacity of each production line (B), a large schedule plan for 10 days to 1 month is created (C), and a detailed order plan is performed by a method described later. (D), and then a production lot is selected from the planning menu, and a setup such as instructing a worker in accordance with the work zone is performed (E). By this setup, a lot to be produced at the present time in a corresponding production line from among a wide variety of products is determined, and specific conditions for each product number can be set (F).

After the product number is specified in this way, the pouring amount, solidification (mold opening) time, product cooling time, deburring method, determination of the mold cooling time table, pouring material and sand storage in the sand casting line 44 are determined. Various control conditions (work standard) such as the tilting speed and suction time in the GD line 47, the injection speed and the boosting time in the DC line 51, and the like to each production line through the LAN according to the detailed sequence plan. Directly instruct (G) and control the operation of each production line (H).

Then, line operation information is obtained from a controller for each production line or the like (I). For example, a computer directly connected to the line control controller automatically totals the production results and calculates the operating rate. If the production line is stopped, the cause of the line stoppage (waiting for hot water, setup, waiting for cooling) , Waiting for the core, failure of the production line, etc.), furthermore, the location of the failure is acquired and displayed by limit switches and various sensors attached to the production equipment, and the temperature of the mold is acquired by the radiation thermometer etc. To display.

The mold temperature detected during the operation of the line is fed back to instruct water-cooling and air-cooling conditions corresponding to the mold temperature to the cooling equipment of the production line (J).

The personal computer on the LAN counts the production results and simultaneously erases the detailed order plan created in D for each lot (K). Therefore, by looking at the display of the personal computer, it is possible to monitor the progress of the production line with respect to the detailed sequence plan (the progress of the production lot) in real time.

At the site, the product is checked for defects automatically or manually, and defect information for the lot is input (L).

Operation records (production results, production results, etc.), such as production line operation daily reports, automatically recorded through the operation information and product check
(M), and outputs and utilizes information on work standards, sequence plans, etc. (N). For example,
A defect countermeasure is performed based on the defect information obtained by the product check, and the defect countermeasure is fed back to the part number information database to improve a work standard of the database. The changed work standard (control condition) is directly instructed to the production line at G.

FIG. 4 schematically shows a GD line (continuous casting line) 47, which includes a tilting machine 61, a mold opening / closing machine 62, and an automatic pouring machine.
63, mold transfer devices 64, 65, etc. are arranged.

The dies (upper die and lower die) are transported from a section to a section b by a traverser (cart) (not shown).
It is separated by the mold switch 62. Only the lower mold is moved to the c section by the traverser and the core is set, while b
In the section, the product in the upper mold is dropped into the take-out device 66 and carried out to the product cooling conveyor 67.

The mold matched in the part b is fed to the mold feeder 68
Thus, the molten metal pumped out of the holding furnace 69 by the automatic pouring machine 63 is poured into the mold clamped at the d portion of the tilting machine 61 through the tub attached to the mold.
At this time, the mold is rotated by 90 ° by the tilting machine 61 and the molten metal is cast into the mold while the air in the mold is sucked and exhausted to the outside.

After the feeder effect is completed, the mold is released from the clamp and is carried out to the portion e of the mold conveying device 64, is conveyed to the portion f by the mold conveying device 64, and is further molded by the mold feeder 70. The mold is conveyed to the g portion of the conveying device 65, where the mold is cooled by the mold cooling means such as the water injection means 71, the air cooling fan 72, and the water spray nozzle 73, and then is carried out to the a section.

A mold setting device 74 provided outside the continuous casting machine is for exchanging dies efficiently.
The prepared mold is made to stand by at the position h, and after the mold is carried out to the position i from the part e in the GD line (continuous casting line) 47, the mold setting device 74 is moved to move the mold set from the position h to the position i. The mold moved to the position is carried into the part e.

FIG. 5 is a block diagram for controlling the GD line 47. In FIG.
36, mouse 37, etc.), display means (CRT display 38)
Etc.), calculation and storage means (CPU, memory, etc.) of electromagnetic information equipment, information transmission means (communication cable 33, cable between personal computer and controller, etc.), control means (line control controller 46), mold temperature detection means ( A radiation thermometer, a temperature sensor, etc.), a pouring means (automatic pouring machine 63), and a mold cooling means (water pouring means 71, an air cooling fan 72, a water spray nozzle 73, etc.) are provided.

FIG. 6 schematically shows the DC lines 51 and 54.
Mainly a die casting machine body 81 equipped with a die 80, a mold storage area 82, a holding furnace 83 and an automatic water heater 84, a product removal device
85, a product transport conveyor 86, a product cooling device 87, a deburring device 88, and the like.

FIG. 7 is a block diagram for controlling the DC lines 51 and 54. Input means (keyboard, mouse, etc.), display means (CRT, etc.), calculation and Storage means (CPU, memory, etc.), information transmission means (optical cable 35, cable between personal computer and controller, etc.), control means (controllers 52, 55, dedicated microcomputer
53), mold temperature detection means (radiation thermometer, temperature sensor, etc.), mold cooling means (water injection means, water spray nozzles, etc.), hot water supply means (holding furnace 83, automatic water heater 84), product removal means (products) Take-out device 85), transfer means (product transfer conveyor 86, etc.), product cooling means (product cooling device 87), and deburring means (burr removing device 88) are provided.

FIG. 8 is a detailed sequence plan in the production line.
24 is a flowchart illustrating a method for creating 24 and 25. First,
By accumulating the individual part number information 23 stored in the database, the sand casting line 44, the GD line 47, the core molding machine
48, the load on each production line such as DC line 51, 54 etc. is determined, so that the load should be grasped and the load should not be concentrated on specific production equipment. Another leveling range is set (step 1).

Next, individual production lines (sand casting lines)
Leveling is performed for each casting line in consideration of the casting capacity and load of the 44, GD line 47 and DC lines 51 and 54) (step 2). In this case, it is determined whether or not the load is within the line casting capacity (step 3), and the sequence plans 24 and 25 are adjusted so that the load is within the casting capacity.

Next, in the melting furnace, since the amount of melting differs depending on the material of the molten metal, leveling is performed for each material in consideration of the melting capacity and the load amount for each material (step 4). In this case, it is determined whether or not the load is within the melting capacity of the melting furnace (step 5), and the sequence plan is adjusted so that the load is within the melting capacity.

Next, leveling is performed for each core production line while taking into consideration the core production capacity and load amount of the core production line (step 6). In this case, it is determined whether the load is within the core supply capacity of the core production line (step 7),
Adjust the sequencing to keep the load within core production capacity.

As described above, while adjusting the sequence plan so that the load amount falls within the capacity of each production line, the sequence plan for each casting line is created (step 8), and the melting amount sequence plan for each pouring material is created. (Step 9), and a core line-based sequence plan is created (Step 10).

[0059]

According to the first aspect of the present invention, different products are manufactured.
Since the work standard is directly instructed to the production line through the network from the part number information database where at least the part number and the work standard relating to the pouring amount are registered as the part number information for each product , it is necessary to control the pouring amount for each different product. Can respond to. In addition, line operation information obtained from the production line is fed through a network.
Back up and display the feedback line operation information
Therefore, the work progress status of each product is easy in real time
Can be easily monitored and the process control of products produced in different quantities and quantities is easy.
Can be done.

According to the second aspect of the present invention, the feedback
Of the production line
Outputs to the equipment, so the line on the production line
Can give appropriate instructions according to the situation and change the line operation status.
It can respond to the production of varieties and variables that need to be manufactured.

According to the third aspect of the present invention, the feedback
Of the production line in the line operation information
If at least one of the cause of the line
And display it, so even if the production line stops,
Whether or not the cause of the line stoppage is a failure of the production line
Understand, if the production line is faulty,
Changes that tend to stop the line due to
Applicable to seed variable production.

According to the fourth aspect of the present invention, the feedback
Operation record of production line based on checked line operation information
Line operation management in variant and variable production
Can be easily performed, and daily operation reports can be created
Elimination of tallying of production results, etc. to reduce burden and paperless
Can be achieved.

According to the fifth aspect of the invention, when controlling the production line, the load of the production line is grasped by accumulating the individual product number information, and this load falls within the capacity of the production line. Create a sequencing plan ,
Controls the production line, so it is used for variant and variable production
Even on a production line, it can operate efficiently and improve productivity.

According to the invention of claim 6 , the production line
Line operation information obtained from
Feedback to the number information database and the database
Work standards to improve
The quality of each product can be stabilized and improved.
Can handle variable production.

[0065] According to the invention of claim 7 Symbol placing by the production point of service of a plurality of production lines through the network is capable of small-lot production, it corresponds to the variant variable production using a plurality of production lines.

[Brief description of the drawings]

FIG. 1 is a schematic view showing an embodiment of a casting management method according to the present invention.

FIG. 2 is a schematic diagram showing a local area network of the casting management method.

FIG. 3 is a specific configuration example of the network.

FIG. 4 is a plan view showing a layout of a GD line for implementing the casting management method.

FIG. 5 is a block diagram for controlling a GD line.

FIG. 6 is a plan view showing a layout of a DC line for implementing the casting management method.

FIG. 7 is a block diagram for controlling a DC line according to the embodiment.

FIG. 8 is a flowchart showing an example of creating a detailed sequence plan in the casting management method.

[Explanation of symbols]

 21 LAN as a network 23 Part number information 44 Sand casting line as a production line 47 GD line as a production line 51, 54 DC line as a production line

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int.Cl. ⁷ , DB name) B22D 46/00 G06F 17/60

Claims (7)

(57) [Claims] At least a work standard relating to a product number and a pouring amount is registered in a product number information database as product number information for each different product , and a production line is controlled through a network according to the work standard registered in the product number information database. the line operation information <br/> report obtained from the production line and feedback through the network, feed
A casting management method characterized by displaying backed-up line operation information . 2. Part number information for each different product is small.
In addition, the work standard for the product number and pouring amount is
Database, and this part number information database
Production line through the network
Control the line operation information obtained from this production line.
Information through the network and feed
The production line sends instructions corresponding to the backed-up line operation information.
A casting control method, wherein the output is output to a facility. 3. The product number information for each different product is small.
In addition, the work standard for the product number and pouring amount is
Database, and this part number information database
Production line through the network
Control the line operation information obtained from this production line.
Information through the network and feed
In the backed-up line operation information, the production line
If at least
Casting management method characterized by acquiring and displaying one of them
Law. 4. The product number information for each different product is small.
In addition, the work standard for the product number and pouring amount is
Database, and this part number information database
Production line through the network
Control the line operation information obtained from this production line.
Information through the network and feed
Production line operation record based on backed up line operation information
A casting management method characterized by making a record. 5. The product number information for each different product is small.
Both the part number and related to the pouring amount of work standard part number information de
Database, and this part number information database
In controlling the production line according to the work standards
By accumulating the individual part number information, the load on the production line is grasped, and a sequence plan is created while adjusting this load to be within the capacity of the production line .
The work standard is instructed to the production line through the network
And, forming management method cast you and controlling the production line. 6. The product number information for each different product is small.
In addition, the work standard for the product number and pouring amount is
Database, and this part number information database
Production line through the network
Control the line operation information obtained from this production line.
Distribution and fed back to part information database through the network, granulation management method cast you, characterized in that to improve the working standard database. 7. The casting management method according to any one of claims 1 to 6 production line is characterized in that a plurality of installed.