JP4183685B2 - Assembly production system and method - Google Patents

Description

  The present invention relates to an assembly production system and method for assembling a plurality of small parts to a main part to complete a product.

  As a so-called cell production method of assembly work, a carriage is arranged so as to be movable on an annular conveyance path, one worker, a plurality of parts and necessary tools are placed on the carriage at a predetermined starting point, and this carriage is a predetermined end point. There is known a production method in which an operator assembles parts on a carriage until a predetermined product is completed (for example, see Patent Document 1).

  Also, a production method is known in which a work cart is moved along a production line that goes through each process, and a plurality of processes are performed on a single work cart to produce a product (for example, Patent Document 2). reference).

JP 2004-230485 A JP 2003-251575 A

However, in the production method disclosed in Patent Document 1, an operator rides on a cart to perform assembly work, so that the cart is large and a large-scale installation space such as a cart or a carriage transport path. There is a problem of needing.
Also, in the production method disclosed in Patent Document 2, since the worker rides on the work cart to perform the assembly work, the work cart becomes large and the work cart and the transport path of the work cart are large. There is a problem of requiring a large installation space.

  The present invention has been made in view of such problems of the prior art, and an object of the present invention is to provide an assembly production system and method that can easily cope with fluctuations in the number of production. Is.

In order to solve the above-mentioned problem, the invention according to claim 1 is an assembly production system for assembling a plurality of small parts to a main part to complete a product, wherein a plurality of overhead conveying units are connected in series in a loop shape and an overhead conveyor. And a plurality of hangers provided with jigs for placing main parts on the overhead conveyor and parts shelves of a plurality of types of sub-parts. the overhead conveying unit are connected with a predetermined frictional force generated possible driving force conveyed to the belt that circulates driven Rutotomoni, by releasing the clamping of the clamp fitting, suspender, frame, swing prevention mechanism, Osamu ingredients, can be divided into six two parts shelves until the hanger is conveyed to the end point from the start point During one in which the worker is assembling the sub-component in the main component while walking to follow the hanger to complete the product.

  According to a second aspect of the present invention, in the assembly production system according to the first aspect, the overhead transport unit includes a unique drive source, and the transport speed is variable.

The invention according to claim 3 is an assembly production method for completing a product by assembling a plurality of small parts to a main part, and placing the main part on an overhead conveyor configured in a loop shape with the start point and end point being close to each other A plurality of hangers provided with a jig to be used and parts shelves of multiple types of sub-parts are suspended, and these hangers are connected with a predetermined frictional force that generates a driving force that can be transported to the belt that drives the circulation of the overhead conveyor is Rutotomoni, by releasing the clamping of the clamp fitting, suspender, frame, swing prevention mechanism, the jig, can be divided into six two parts shelves, said plurality of hangers in the end point from the start point Until it is transported, a plurality of workers follow the respective hangers and walk to complete the product by assembling the sub-parts to the main part. Is Umono.

According to the first aspect of the present invention, since the same work that is completed in the loop is performed by a plurality of workers, it is not necessary to change the work contents of the workers even if the number of productions fluctuates. become. In addition, since the worker follows the hanger provided with the jig for placing the main parts and the parts shelf for the small parts, the small parts can be taken out at the shortest distance. In addition, since the start point for starting the work and the end point for finishing the work are close to each other, it is possible to return to the next work start point at the same time as the work is finished, so that the worker simply returns to the work start point without working. The walking distance can be reduced. Furthermore, the hanger is connected to the belt that circulates and drives the overhead conveying unit with a predetermined frictional force that generates a driving force that can be conveyed. When force is applied, the belt slips, so there is no damage to objects or hangers. In addition, since the hanger can be divided into six, a large storage space is not required even when waiting for an increase in the number of production or when the hanger is removed from the overhead conveyor due to a decrease in the number of production. On the other hand, a hanger can be easily assembled by using a clamp metal fitting for a hanging part, a frame, a shaking prevention mechanism, a jig, and a parts shelf.

  According to the second aspect of the present invention, since the transport speed can be adjusted for each overhead transport unit, it is necessary to change the transport speed for some reason without changing the transport speed of the entire overhead conveyor. The conveyance speed can be adjusted.

According to the invention according to claim 3, the plurality of workers assemble the accessory parts to the main parts while walking following each hanger until the plurality of hangers are conveyed from the start point to the end point. Since the work to complete the product is repeated, the man-hour reduction immediately leads to a reduction in personnel. In addition, the hanger is connected to the belt that circulates and drives the overhead conveyor with a predetermined frictional force that generates a driving force that can be transported. If it is applied, the belt will slip, so that objects and hangers will not be damaged. In addition, since the hanger can be divided into six, a large storage space is not required even when waiting for an increase in the number of production or when the hanger is removed from the overhead conveyor due to a decrease in the number of production. On the other hand, a hanger can be easily assembled by using a clamp metal fitting for a hanging part, a frame, a shaking prevention mechanism, a jig, and a parts shelf.

  Embodiments of the present invention will be described below with reference to the accompanying drawings. Here, FIG. 1 is a basic configuration diagram of an assembly production system according to the present invention, FIG. 2 is an explanatory diagram of a working state, FIG. 3 is a schematic explanatory diagram of a connection state of an overhead transport unit and a hanger, and FIG. 5 is a front view of the hanger, and FIG. 6 is a schematic layout explanatory diagram of an engine assembly line to which the assembly production system according to the present invention is applied.

  As shown in FIG. 1, the assembly production system according to the present invention comprises an overhead conveyor 2 in which a plurality of overhead conveyance units 1 are connected in series to form a loop, and a start point 2a and an end point 2b of the overhead conveyor 2 are formed. Are in close proximity. A plurality of hangers 3 are suspended at substantially equal intervals on the overhead conveyor 2, and an operator 4 is attached to each hanger 3. In the present embodiment, eight workers 4 are organized.

  As shown in FIG. 2, the worker 4 follows the hanger 3 until the hanger 3 on which the main component 5 and the accessory component 6 are placed is transported from the start point 2 a to the end point 2 b of the overhead conveyor 2. A small part 6 is assembled to the main part 5 placed on the hanger 3 while walking to complete a predetermined product.

  As shown in FIG. 3, the overhead transport unit 1 circulates and drives a belt 10 that is endless and has a predetermined length by a unique drive source (electric motor) 11, and the hanger 3 is predetermined by the driving force of the belt 10. It is a belt type conveyance conveyor which conveys only this distance. Since the overhead transport unit 1 has its own drive source (electric motor) 11, the transport speed can be set for each overhead transport unit 1 by an operation panel (not shown) installed on the line side. it can.

  Further, the overhead conveying unit 1 and the hanger 3 are not firmly connected, but a predetermined frictional force that generates a driving force capable of conveying at least the hanger 3 on which the main component 5 or the small component 6 is placed. Are connected to each other and transport the hanger 3. Therefore, when an object or the like comes into contact with the moving hanger 3 and an unnecessary force is applied to the hanger 3, the belt 10 slips, so that the object or the hanger 3 is not damaged. In addition, the interval between the overhead conveyance units 1 connected in series is an interval at which the hanger 3 can be smoothly conveyed.

  As shown in FIGS. 4 and 5, the hanger 3 includes a hanging portion 30 that moves in the direction of the arrow and engages the overhead conveyor 2, and a hanger body 31 that is suspended from the hanging portion 30.

  The hanging portion 30 is connected to the guide portions 32 and 32 that are disposed in the front and rear and engage with the guide rail 20 that is installed along the overhead conveyor 2, the connection bar 33 that connects the guide portions 32 and 32, and the connection portion 33. It consists of a hanger support part 34 fixed to the center part of the bar 33. Moreover, the guide parts 32 and 32 are provided with a roller 32a that is rotatable on the guide rail 20 so as to be able to move smoothly along the guide rail 20, and sandwich the guide rail 20 from the left and right directions.

  The hanger body 31 includes a frame 35 in which a pipe material is formed in a substantially C shape, a shaking prevention mechanism 36 for preventing the frame 35 from shaking, a jig 37 for placing and positioning the main component 5, and a plurality of types of hanger bodies 31. It consists of two upper and lower parts shelves 38 and 39 for storing small parts 6. Reference numeral 40 denotes a reinforcing rib, and reference numeral 41 denotes a rubber cap that closes the cut opening of the pipe material.

  An upper end portion 35 a of the frame 35 is attached to the hanger support portion 34 via two clamp fittings 42 and 42. The position at which the upper end portion 35a of the frame 35 is attached to the hanger support 34 is adjusted in consideration of the balance state when the hanger body 31 is suspended by the hanger 30 and the attachment positions of the two clamp fittings 42 and 42 are adjusted. Can be set freely.

  The shake prevention mechanism 36 is attached to the upper end 35a of the frame 35 in the vicinity of the hanger support portion 34 in the left-right direction via the clamp fitting 43, and is attached to both ends of the shaft 44 so as to protrude upward and leftward and outward. The four spherical rollers 45 and two balancing rails 46 with which the four spherical rollers 45 are rotatably engaged. The two balance rails 46 are constructed along the guide rail 20.

  As described above, the four spherical rollers 45 are rotatably engaged with the two balance rails 46, thereby preventing the hanger 3 from moving forward and backward and without hindering smooth movement along the guide rail 20 of the hanger 3. The shaking to the left and right direction can be prevented.

  The jig 37 is attached to the lower end 35 b of the frame 35 via two clamp fittings 47, 47. The position where the jig 37 is attached to the frame 35 can be freely set by adjusting the attachment position of the two clamp fittings 47, 47 in consideration of the balance state when the hanger body 31 is suspended by the suspension part 30. be able to. The jig 37 is configured to be rotatable about a vertical axis orthogonal to the lower end portion 35b of the frame 35.

  The parts shelf 38 includes a pallet 48 partitioned so as to accommodate a plurality of types of small parts 6, a base plate 49 on which the pallet 48 is placed and fixed, a pallet support part 50 that supports the base plate 49, and a pallet support part 50. It consists of two clamp fittings 51, 51 fixed and slidably engaged with the frame 35, and a positioning stopper 52 for positioning the pallet 48 in a desired horizontal direction. Reference numeral 53 denotes a stopper fitting that prevents the parts shelf 38 from descending.

  The base plate 49 includes a plate 49 a for mounting and fixing the pallet 48, and a pipe material bar 49 b disposed on the back surface of the plate 49 a in the left-right direction, and the bar 49 b is fixed to the pallet support portion 50. The plate 49a on which the pallet 48 is placed and fixed is tilted with respect to the operator 4 and fixed to the bar 49b so that the small component 6 stored in the pallet 48 can be easily seen.

  The positioning stopper 52 is composed of a spring 52a that has been fitted and a stopper pin 52b that protrudes from the spring 52a. The stopper pin 52b is fitted into a hole 35d that is opened in the frame 35 by the spring 52a. The position in the direction can be fixed. A plurality of holes 35d are formed in the outer peripheral surface of the frame 35.

  The component shelf 38 configured in this manner is supported by the central portion 35c of the frame 35 and positioned at a position where the positioning stopper 52 functions in the horizontal direction. The parts shelf 39 has the same configuration as the parts shelf 38.

  Further, the hanger 3 can be divided into six parts, that is, the hanging portion 30, the frame 35, the shaking prevention mechanism 36, the jig 37, and the component shelves 38 and 39 by releasing the clamp fittings 42, 43, 47, and 51. . Thus, since the hanger 3 can be divided into six, a large storage space is not required even when waiting for an increase in the number of production or when the hanger 3 is removed from the overhead conveyor 2 due to a decrease in the number of production. On the other hand, the hanger 3 can be easily assembled by using the clamp fittings 42, 43, 47, 51 for the hanging portion 30, the frame 35, the shaking prevention mechanism 36, the jig 37, and the component shelves 38, 39.

  Based on the engine assembly line to which the assembly production system according to the present invention configured as described above is applied, the operation of the assembly production system and the assembly production method according to the present invention will be described. As shown in FIG. 6, the engine assembly line includes a first zone A, a second zone B and a third zone C to which the assembly production system according to the present invention is applied.

  In the first zone A, the engine main component 5 is placed on a jig 37 provided mainly on the hanger 3, and the engine accessory 6 is placed on the two component shelves 38 and 39 provided on the hanger 3. The overhead conveyor 60 installed in the first zone A is a chain type conveyor.

  The hanger 3 paid out from the first zone A is put into the start point 2a of the overhead conveyor 2 installed in the second zone B. Then, the worker 4 who is in charge of the hanger 3 follows the moving speed of the hanger 3 and puts the small parts 6 taken out from the parts shelves 38 and 39 into the main parts 5 of the engine placed on the hanger 3 with a tool (not shown). ). In the second zone B, small parts 6 that are mainly engine framework parts are assembled.

  Then, when the predetermined assembling work of the accessory parts 6 to the main parts 5 by one worker 4 defined in the second zone B is completed, the hanger 3 reaches the end point 2b of the overhead conveyor 2. The hanger 3 is transported by a plurality of overhead transport units 1 connected in series from the start point 2 a to the end point 2 b of the overhead conveyor 2.

  Furthermore, the worker 4 who has finished the predetermined assembling work repeatedly performs the same assembling work on the hanger 3 that has been put into the starting point 2a of the overhead conveyor 2 at the end of the work. Here, the start point 2a of the overhead conveyor 2 that starts the work and the end point 2b of the overhead conveyor 2 that finishes the work are close to each other. Can start. Such an assembling work is performed by the worker 4 who constitutes the personnel of the second zone B with respect to the hanger 3 which is thrown into the second zone B one after another.

  Next, the hangers 3 that are successively dispensed from the end point 2b of the overhead conveyor 2 in the second zone B are put into the auxiliary assembly process Ba in which the chain-type overhead conveyor 61 is installed, and the small parts 6 that are the skeleton of the engine are assembled. Operations such as inspection and assembly correction are performed on the main parts 5 of the engine. When such work is finished, the hanger 3 is put into the third zone C configured similarly to the second zone B. The auxiliary assembly process Ba can also be used as a buffer process when adjusting the cycle time of the engine assembly line or when trouble occurs.

  When the hanger 3 is inserted into the start point 2a of the overhead conveyor 2 installed in the third zone C, the operator 4 in charge of the hanger 3 follows the moving speed of the hanger 3 as in the second zone B. The small parts 6 taken out from the parts shelves 38 and 39 are assembled to the main parts 5 of the engine by using a tool (not shown). In the third zone C, small parts 6 that are mainly appearance parts of the engine are assembled.

  Then, when the predetermined assembling operation of the accessory component 6 to the main component 5 by one worker 4 defined in the third zone C is completed, the hanger 3 reaches the end point 2b of the overhead conveyor 2. The hanger 3 is transported by a plurality of overhead transport units 1 connected in series from the start point 2 a to the end point 2 b of the overhead conveyor 2.

  Furthermore, the worker 4 who has finished the predetermined assembling work repeatedly performs the same assembling work on the hanger 3 that has been put into the starting point 2a of the overhead conveyor 2 at the end of the work. Here, since the start point 2a of the overhead conveyor 2 that starts the work and the end point 2b of the overhead conveyor 2 that finishes the work are close to each other, the worker 4 can perform the next work almost simultaneously with the end of the work without mere return walking. Can start. Such an assembling work is performed by the worker 4 who constitutes the personnel of the third zone C with respect to the hanger 3 which is thrown into the third zone C one after another.

  Next, the hangers 3 that are successively paid out from the end point 2b of the overhead conveyor 2 in the third zone C are put into an intermediate inspection process Ca in which a chain-type overhead conveyor 62 is installed, and small parts 6 that are external parts of the engine are supplied. Operations such as intermediate inspection are performed on the main parts 5 of the assembled engine. When such work is completed, the engine is completed, and the completed engine is paid out to the inspection process. The intermediate inspection process Ca can also be used as a buffer process when adjusting the cycle time of the engine assembly line or when trouble occurs.

  In the second zone B and the third zone C, the hanger 3 held in the second zone B and the third zone C without changing the content of work performed by one worker 4 even if the production number varies. It is possible to cope with this by increasing / decreasing the number of processes, and it is not necessary to newly organize a process or perform a new work training accompanying the process. Also, reducing the number of hangers 3 by 1 will reduce the number of man-hours and reduce the number of personnel immediately.

  By applying the assembly production system or the assembly production method according to the present invention, it is possible to newly increase or decrease the number of hangers without changing the work content performed by one worker even if the number of production varies. It is possible to construct an assembly production line that does not require process organization or new work training accompanying the process organization.

Basic configuration diagram of an assembly production system according to the present invention Illustration of working condition Outline explanatory diagram of the connection state of overhead transport unit and hanger Hanger side view Hanger front view Outline layout explanatory diagram of engine assembly line to which assembly production system according to the present invention is applied

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... Overhead conveyance unit, 2 ... Overhead conveyor, 2a ... Start point, 2b ... End point, 3 ... Hanger, 4 ... Worker, 5 ... Main parts, 6 ... Small parts, 20 ... Guide rail, 30 ... Hanging part, 31 ... Hanger body, 32 ... guide portion, 35 ... frame, 36 ... anti-swing mechanism, 37 ... jig, 38, 39 ... parts shelf, 44 ... shaft, 45 ... spherical roller, 46 ... balance rail.

Claims (3)

An assembly production system that completes a product by assembling a plurality of small parts to main parts, and constructs an overhead conveyor by connecting a plurality of overhead conveyance units in series in a loop, and closes the start point and end point of this overhead conveyor A plurality of hangers provided with jigs for placing main parts on the overhead conveyor and parts shelves for a plurality of small parts, and these hangers can be transported to a belt that circulates and drives the overhead transport unit. is connected with a predetermined frictional force generated force Rutotomoni, by releasing the clamping of the clamp fitting, suspender, frame, swing prevention mechanism, the jig, can be divided into six two parts shelves Until the hanger is transported from the start point to the end point, an operator follows the hanger and walks. Assembly production system, characterized in that said to want the main parts by assembling small parts to complete the product. The assembly production system according to claim 1, wherein the overhead conveyance unit includes a unique drive source and the conveyance speed is variable. An assembly production method that completes a product by assembling a plurality of small parts to a main part, and includes a jig and a plurality of types of small parts for placing the main part on an overhead conveyor configured in a loop shape with the start point and end point close to each other. lower plurality hanging hangers provided with parts of the component shelf, these hangers are connected with a predetermined frictional force generated possible driving force conveyed to the belt circulating drive of the overhead conveyor Rutotomoni, tightening of the clamping bracket Can be divided into 6 parts of a hanging part, a frame, a shaking prevention mechanism, a jig, and two parts shelves, until the plurality of hangers are conveyed from the start point to the end point, An assembly life characterized in that a plurality of workers repeatedly perform the work of assembling the accessory parts to the main parts and completing a product while walking following each hanger. Method.