JP4598097B2 - Assembly system and assembly method - Google Patents

Description

  The present invention relates to an assembly system. More specifically, the present invention relates to an assembly system for assembling a plurality of types of automobile parts each composed of a main body and parts attached to the main body.

  Conventionally, in the manufacturing process of automobiles, automobile parts such as doors, instrument panels, and bumpers are assembled on separate lines. However, in recent years, in order to reduce the size of manufacturing equipment, it is required to reduce the number of lines and assemble different types of automobile parts on one line.

Therefore, it is conceivable to manually assemble different types of automobile parts, but there is a problem that the work of the operator becomes complicated and the cycle time is prolonged.
In order to solve this problem, for example, a plurality of trays are provided by dividing the inside of the stocker, different types of parts are stored in these trays, and parts to be assembled to this work according to the type of work to be transported Has been proposed (see Patent Document 1).
Thereby, since the operator only needs to take out a part from the tray in the part taking-out position and assemble it to the workpiece, the cycle time can be prevented from prolonging.
JP 2001-353627 A

  However, in this method, since the types of parts to be attached increase, it is necessary to arrange many parts around the worker, and there is a problem that the equipment space increases.

  An object of the present invention is to provide an assembly system capable of assembling different types of automobile parts in one line while reducing equipment space.

The assembly system of the present invention (for example, an assembly system 1 described later) is an assembly for assembling a plurality of types of automobile parts each composed of a main body (for example, main bodies 71 to 74 described later) and components attached to the main body. A plurality of first pallets (for example, a main body pallet 25 and a second component pallet 27 described later) on which the main bodies and parts of the plurality of types of automobile parts are placed; A plurality of second pallets (for example, a component pallet 30 described later) on which the respective parts of the automobile parts are placed, and a transport device (for example, a traveling unit 26 described later) and the first pallet and the second pallet are conveyed. the belt conveyor 40), a plurality of main line worker is placed (e.g., the first main line 51 to be described later, the second Meinra Down 52, and a third main line 53), a pair of main successive lines among the plurality of main lines (e.g., by an offset from the first main line 51 to be described later second main line 52), the pair The main line is provided between a downstream end of an upstream main line (for example, a first main line 51 described later) and an upstream end of a downstream main line (for example, a second main line 52 described later). And a bypass line (for example, a later-described bypass line 80) in which a robot (for example, RB1 to RB5 described later) is disposed, and a control device (for example, a later-described control device 60) for controlling these, controller has less of and between the bypass line between the upstream end of the main line of the downstream end and the downstream side of the main line of the upstream Also transport path setting means for setting a conveying path of the conveying device by one (e.g., conveyance route setting means 61 to be described later) and, by driving the transport device, along the conveying path which is set by the transport path setting means The first pallet and the second pallet are synchronously transported by a transport device driving means (for example, a transport device driving means 62 described later) and a robot in the bypass line to drive the first pallet and the second pallet from the first pallet. Robot drive means (for example, robot drive means 63 described later) is provided which takes out the parts and attaches them to the main body placed on the first pallet.

According to this invention, first, the transport path of the transport device is set. Next, the main bodies of different types of automobile parts are placed on the first pallet, and the parts attached to the main bodies are placed on the first pallet and the second pallet. Then, the first pallet and the second pallet are conveyed synchronously, and parts are taken out from the first pallet and attached to the main body placed on the first pallet by the robot of the bypass line. On the other hand, on the main line, an operator takes out a part from the second pallet and attaches it to the main body placed on the first pallet. Therefore, different types of automobile parts can be assembled in one line by an operator and a robot while reducing the equipment space.
In addition, since the worker is placed on the main line and the robot is placed on the bypass line offset from the main line, the area where the worker is placed can be separated from the area where the robot is placed. Can be secured.

In this case, it is preferable that the conveyance path setting unit of the control unit excludes the bypass line from the conveyance path in a predetermined case.

When there is no problem in the operation of the robot, the transfer path of the transfer device is set including the bypass line. Thereby, each pallet is conveyed along the bypass line where a robot is arrange | positioned, and an automotive part is assembled with the robot of a bypass line.
Here, for example, when a failure occurs in the operation of the robot arranged in the bypass line, the bypass line is excluded from the transfer path of the transfer device. Thereby, since each pallet is not conveyed along this bypass line, the robot in which the malfunction has occurred can be maintained without stopping the assembly work of the automobile parts.

In this case, the conveying device drive means of said control means, in certain cases, the out of the bypass line of the robot to pass through at least one, it is preferable to transport the first palette.

  For example, when a malfunction occurs in the operation of the robot, each pallet is transported so as to pass through the robot in which the malfunction has occurred. As a result, it is possible to maintain the robot in which the malfunction occurred without stopping the assembly work of the automobile parts.

  According to the present invention, first, the transport path of the transport device is set. Next, the main bodies of different types of automobile parts are placed on the first pallet, and the parts attached to the main bodies are placed on the first pallet and the second pallet. Then, the first pallet and the second pallet are conveyed synchronously, and parts are taken out from the first pallet and attached to the main body placed on the first pallet by the robot of the bypass line. On the other hand, on the main line, an operator takes out a part from the second pallet and attaches it to the main body placed on the first pallet. Therefore, different types of automobile parts can be assembled in one line by an operator and a robot while reducing the equipment space. In addition, since the worker is placed on the main line and the robot is placed on the bypass line offset from the main line, the area where the worker is placed can be separated from the area where the robot is placed. Can be secured.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a diagram showing a schematic configuration of an assembly system 1 according to an embodiment of the present invention.
The assembly system 1 assembles a plurality of types of automobile parts each composed of a main body and parts attached to the main body.
The automobile parts are, for example, left and right doors, instrument panels, front bumpers, and rear bumpers.

This assembly system 1 is disposed so as to be surrounded by three body transport paths 11A, 11B, and 11C through which a vehicle body 10 is transported.
The assembly system 1 includes a plurality of traveling carts 20, a plurality of component pallets 30 as second pallets, a belt conveyor 40 as a second conveying device that conveys the component pallets 30, and the belt conveyor 40. A main line 50 that is provided sandwiched between the operator, a bypass line 80 that is offset from the main line 50 and where the robot RB is arranged, and a control that controls the traveling carriage 20, the belt conveyor 40, and the robot RB. Device 60.

The belt conveyor 40 extends from the first carry-in port 41 to the first carry-out port 42 in a substantially U shape. When the component pallet 30 is supplied to the first carry-in port 41, the belt conveyor 40 conveys the component pallet 30 and discharges it from the first carry-out port 42.
The belt conveyor 40 includes an outer belt conveyor 40A and an inner belt conveyor 40B arranged side by side inside the outer belt conveyor 40A.
In FIG. 1, in order to facilitate understanding of the configuration of the assembly system 1, the body conveyance paths 11 </ b> A to 11 </ b> C are arranged close to the carry-in port 41 and the carry-out ports 42 and 43. The transport paths 11 </ b> A to 11 </ b> C are arranged far away from the carry-in port 41 and the carry-out ports 42 and 43.

  A second carry-out port 43 is provided in the middle of the outer belt conveyor 40 </ b> A, and a second carry-in port 44 is provided between the second carry-out port 43 and the first carry-out port 42. .

The main line 50 includes an outer main line 50 </ b> A provided outside the belt conveyor 40 and an inner main line 50 </ b> B provided inside the belt conveyor 40.
That is, the outer main line 50A is disposed along the outer belt conveyor 40A, and the inner main line 50B is disposed along the inner belt conveyor 40B.

  Six workers PA1 to PA6 are arranged in order from the first carry-in port 41 side between the first carry-in port 41 and the second carry-out port 43 of the outer main line 50A. Further, eleven workers PA7 to PA17 are arranged in order from the second carry-in port 44 side between the second carry-in port 44 and the first carry-out port 42 of the outer main line 50A.

  The inner main line 50B is provided on the downstream side of the first main line 51 provided on the upstream side, the second main line 52 provided on the downstream side of the first main line 51, and the second main line 52. A third main line 53.

  In the first main line 51, three workers PB1 to PB3 are arranged in order from the upstream side. In the second main line 52, eight workers PB4 to PB11 are arranged in order from the upstream side. On the third main line 53, one worker PB12 is arranged.

The bypass line 80 includes a first bypass line 81 provided between the first main line 51 and the second main line 52 and a second bypass line provided between the second main line 52 and the third main line 53. 82.
In the first bypass line 81, four robots RB1 to RB4 are arranged in order from the upstream side. One robot RB5 is arranged in the second bypass line 82.

FIG. 2 is a perspective view of the traveling carriage 20.
Each traveling carriage 20 has a main body pallet 25 as a first pallet on which main bodies 71 to 74 of a plurality of types of automobile parts are placed, and a second pallet as a first pallet provided on the main body pallet 25. A pallet and a travel device 26 as a first transport device that transports the main body pallet 25 and the second component pallet 27 are provided.

On the second parts pallet 27, parts to be attached to the main bodies 71 to 74 of the respective automobile parts are placed according to the types of the automobile parts of the traveling carriages 21 to 24 supplied to the first carry-in port 41. .
Each traveling device 26 travels on a predetermined route in accordance with a command from the control device 60.

  Among the traveling carts 20, a vehicle having a rear bumper main body 71 mounted on the main body pallet 25 as a main body of the automobile part is mounted on the traveling cart 21, a vehicle having a front bumper main body 72 mounted on the traveling cart 22, and an instrument panel. The one on which the main body 73 is placed is referred to as the traveling carriage 23 and the one on which the left and right door main bodies 74 are placed is referred to as the traveling carriage 24.

  Returning to FIG. 1, the traveling carts 21 and 22 are supplied to the outer main line 50 </ b> A side of the first carry-in port 41. The traveling carriages 21 and 22 travel along the outer main line 50 </ b> A and reach the second carry-out port 43.

  The traveling carriage 23 is supplied to the second carry-in port 44. The traveling carriage 23 travels along the outer main line 50 </ b> A and reaches the first carry-out port 42.

The traveling carriage 24 is supplied to the inner main line 50B side of the first carry-in port 41 through the body conveyance path 11C.
The traveling carriage 24 includes a first main line 51 of the inner main line 50B, a first bypass line 81 of the bypass line 80, a second main line 52 of the inner main line 50B, a second bypass line 82 of the bypass line 80, and an inner side. Travel along the third main line 53 of the main line 50B. Thereafter, the traveling carriage 24 is carried out from the first carry-out port 42 and reaches the body conveyance path 11C.

The parts pallet 30 has a box shape with the upper side opened, and the parts pallet 30 has each car part according to the type of car parts of the traveling carriages 21 to 24 supplied to the first carry-in port 41. Parts to be attached to the main bodies 71 to 74 are placed.
The component pallet 30 is composed of an outer component pallet 30A supplied to the outer belt conveyor 40A and an inner component pallet 30B supplied to the inner belt conveyor 40B.

FIG. 3 is a block diagram illustrating a configuration of the control device 60.
The control device 60 includes a conveyance path setting unit 61, a conveyance device driving unit 62, and a robot driving unit 63.

The conveyance path setting means 61 sets the conveyance path of the traveling device 26 of the traveling carriage 20 by at least one of the main line 50 and the bypass line 80.
Specifically, the transport path setting means 61 includes the outer main line 50A, the first main line 51 of the inner main line 50B, the second main line 52 and the third main line 53, and the first bypass line of the bypass line 80. The conveyance path is set by appropriately selecting from 81 and the second bypass line 82.

The transport device driving unit 62 causes the travel device 26 of the travel cart 20 to travel along the transport route set by the transport route setting unit 61.
Here, the conveying device driving means 62 drives the outer belt conveyor 40A, and synchronizes the outer parts pallet 30A with the traveling carriages 21 to 23 supplied to the outer main line 50A side of the first carry-in port 41. Transport. Further, the conveying device driving means 62 drives the inner belt conveyor 40B, and conveys the inner component pallet 30B in synchronization with the traveling carriage 24 supplied to the inner main line 50B side of the first carry-in port 41.

  The robot driving means 63 drives the robots RB <b> 1 to RB <b> 5 of the bypass line 80 to take out parts from the second parts pallet 27 of the traveling carriage 20 and attach them to the main body placed on the main body pallet 25.

The operation of the above assembly system 1 is as follows.
The traveling carriage 24 reaches the first carry-in port 41 through the body conveyance path 11C. Here, in the body conveyance path 11 </ b> C, the door body 74 is removed from the body 10 and placed on the traveling carriage 24.

  Next, the traveling carriage 24 includes a first main line 51 of the inner main line 50B, a first bypass line 81 of the bypass line 80, a second main line 52 of the inner main line 50B, a bypass line 80, a second bypass line 82, and Travel along the third main line 53 of the inner main line 50B.

In the first main line 51 of the inner main line 50B, parts are attached to the main body 74 of the door placed on the traveling carriage 24 by three workers PB1 to PB3.
In the first bypass line 81 of the bypass line 80, parts are attached to the main body 74 of the door placed on the traveling carriage 24 by the three robots RB1 to RB4.
In the second main line 52 of the inner main line 50B, the eight workers PB4 to PB11 attach components to the door main body 74 placed on the traveling carriage 24.
In the second bypass line 82 of the bypass line 80, parts are attached to the main body 74 of the door placed on the traveling carriage 24 by one robot RB5.
In the second main line 52 of the inner main line 50B, a part is attached to the main body 74 of the door placed on the traveling carriage 24 by one worker PB12.

  Thereafter, the traveling carriage 24 is carried out from the first carry-out port 42 and reaches the body conveyance path 11C. The door placed on the traveling carriage 24 is attached to the body 10 again in the body conveyance path 11C.

The traveling carriages 21 and 22 are supplied to the first carry-in port 41 and travel along the outer main line 50A.
In the outer main line 50A, components are attached to the main body 71 of the rear bumper and the main body 72 of the front bumper placed on the traveling carriages 21 and 22 by six workers PA1 to PA6.
Thereafter, the traveling carriages 21 and 22 are unloaded from the second carry-out port 43, and the rear bumper and the front bumper placed on the traveling carriages 21 and 22 are attached to the body 10 in the body conveyance path 11B.

The traveling carriage 23 is supplied to the second carry-in entrance 44 and travels along the outer main line 50A.
In the outer main line 50 </ b> A, eleven workers PA <b> 7 to PA <b> 17 attach components to the instrument panel main body 73 placed on the traveling carriage 23.
Thereafter, the traveling carriage 23 is carried out from the first carry-out port 42, and the instrument panel placed on the traveling carriage 23 is attached to the body 10 in the body conveyance path 11A.

Moreover, in the assembly system 1, when trouble occurs in all the robots constituting the bypass line, the following measures are taken.
For example, as shown in FIG. 4, when a failure occurs in the robot RB5 of the second bypass line 82, the operation of the robot RB5 is stopped. Then, the control device 60 changes the traveling route of the traveling carriage 24 as follows.
That is, the travel route of the travel vehicle 24 is set so that the second bypass line 82 is excluded from the travel route of the travel vehicle 24 and heads for the third main line 53 next to the second main line 52.
Furthermore, a worker PB13 is newly arranged between the second main line 52 and the third main line 53, and the worker PB13 performs the assembling work performed by the robot RB5.

Moreover, in the assembly system 1, when a malfunction occurs in a part of the robots constituting the bypass line, the following measures are taken.
For example, as shown in FIG. 5, when a failure occurs in the robot RB3 of the first bypass line 81, the operation of the robot RB3 is first stopped.

Here, assuming that the parts attached by the robots RB1 to RB4 are parts B1 to B4, in this state, since the robots RB1, RB2, and RB4 are operating, the body of the automobile parts on the traveling carriage 24 is the robot RB1, After the parts B1 and B2 are attached by RB2, the part B3 is not attached by the robot RB3, and the part B4 is attached by the robot RB4.
Therefore, when the part B4 can be attached after the part B3 is attached, the traveling carriage 24 is caused to travel so as to pass through the RB3 by the control device 60, and the operator manually operates at the position X in FIG. A part B3 is attached.

  However, the part B4 may not be attached after the part B3 is attached. For example, there is a case where a part of the part B4 is fitted to the part B3 or a part B3 is fastened with the part B4.

  In this case, the operation of the robots RB1 to RB4 is stopped and the first bypass line 81 from the travel route of the traveling carriage 24 is stopped by the control device 60 in the same manner as when all the robots constituting the bypass line have a problem. And the traveling route of the traveling carriage 24 is set so as to go to the second main line 52 next to the first main line 51. And a worker is newly arranged between the 1st main line 51 and the 2nd main line 52, and the operation which was being performed by robots RB1-RB5 by these workers is performed.

Alternatively, in addition to the robot RB3, the operation of the robot RB4 is stopped, and the control device 60 causes the traveling carriage 24 to travel so as to pass through the RB3 and RB4. Parts B3 and B4 are manually attached.
In addition, according to this method, even when the type of automobile parts to be manufactured is changed or the structure of the robots RB1 to RB5 is changed in accordance with the design change, Can be constructed.

  Here, the case where a failure has occurred in the robot RB3 of the first bypass line 81 has been described, but the same technique can also be adopted when a failure has occurred in other RB1, RB2, and RB4.

According to this embodiment, there are the following effects.
(1) First, the conveyance path of the traveling device 26 of the traveling carriage 20 is set by the conveyance path setting means 61. Next, the main bodies 71 to 74 of the automobile parts are placed on the main body pallet 25 of the traveling carriage 20, and the parts attached to the main bodies 71 to 74 are the second part pallet 27 and the parts pallet of the traveling carriage 20. 30. The traveling carriage 20 and the parts pallet 30 are conveyed synchronously, and the parts are taken out from the second parts pallet 27 of the traveling carriage 20 by the robots RB1 to RB5 of the bypass line 80. It is attached to the main bodies 71 to 74 placed on the pallet 25.

  Then, in the main line 50, the main body of the automobile parts is supplied by the traveling carriage 20 to the front side of each worker PA1 to PA17, PB1 to PB12, and on the back side of each worker PA1 to PA17, PB1 to PB12. The parts attached to the main body are supplied by the parts pallet 30. Therefore, the workers PA1 to PA17 and PB1 to PB12 take out the components from the rear-side component pallet 30 and attach them to the main bodies 71 to 74 mounted on the front-side main body pallet 25. Thereby, it is possible to assemble different types of automobile parts in one line while reducing equipment space.

  Further, since the workers PA1 to PA17 and PB1 to PB12 are arranged on the main line 50 and the robots RB1 to RB5 are arranged on the bypass line 80 offset from the main line 50, the area where the worker is arranged and the robot are arranged. The area to be arranged can be separated, and safety can be ensured.

  (2) For example, when a malfunction occurs in the operation of the robot RB5 arranged in the second bypass line 82, the second bypass line 82 is excluded from the travel route of the traveling device 26 of the traveling carriage 20. As a result, the main body pallet 25 is not transported along the second bypass line 82, so that the troubled robot RB5 can be maintained without stopping the assembly work of the automobile parts.

  (3) For example, when a malfunction occurs in the operation of the robot RB3 in the first bypass line 81, the traveling device 26 of the traveling carriage 20 is caused to travel so as to pass through the robot RB3 in which the malfunction occurs. As a result, it is possible to maintain the robot in which the malfunction occurred without stopping the assembly work of the automobile parts.

  Note that the present invention is not limited to the above-described embodiment, and modifications, improvements, and the like within the scope in which the object of the present invention can be achieved are included in the present invention.

It is a figure showing a schematic structure of an assembly system concerning one embodiment of the present invention. It is a perspective view of the traveling cart of the assembly system according to the embodiment. It is a block diagram which shows the structure of the control apparatus of the assembly system which concerns on the said embodiment. It is a figure for demonstrating operation | movement when a malfunction arises in all the robots of the bypass line of the assembly system which concerns on the said embodiment. It is a figure for demonstrating operation | movement when a malfunction arises in the one part robot of the bypass line of the assembly system which concerns on the said embodiment.

Explanation of symbols

1 Assembly system 25 Main body pallet (first pallet)
26 Traveling part (conveying device)
27 Pallet for second part (first pallet)
30 Parts palette (second pallet)
40 Belt conveyor (conveyor)
DESCRIPTION OF SYMBOLS 50 Main line 60 Control apparatus 61 Feed path setting means 62 Feed apparatus drive means 63 Robot drive means 71 Rear bumper main body 72 Front bumper main body 73 Instrument panel main body 74 Left and right door main bodies 80 Bypass lines RB1 to RB5 Robot

Claims (4)

An assembly system for assembling a plurality of types of automobile parts each composed of a main body and parts attached to the main body,
A plurality of first pallets on which main bodies and parts of the plurality of types of automobile parts are placed;
A plurality of second pallets on which the respective parts of the plurality of types of automobile parts are placed;
A transport device for transporting the first pallet and the second pallet;
Multiple main lines where workers are placed;
Offset from a pair of continuous main lines of the plurality of main lines , and provided between the downstream end of the upstream main line and the upstream end of the downstream main line of the pair of main lines The bypass line where the robot is located,
A control device for controlling these,
The control device is configured to set a transfer route of the transfer device between a downstream end of the upstream main line and an upstream end of the downstream main line and at least one of the bypass lines. When,
By driving the conveying device, and along the conveying path which is set by the transport path setting means, conveying device driving means for transporting and synchronizing the first pallet and said second pallet,
An assembly system, comprising: a robot drive unit that drives the robot of the bypass line to take out the component from the first pallet and attach it to the main body placed on the first pallet. The assembly system according to claim 1,
The assembly system according to claim 1, wherein the transport path setting means of the control means excludes the bypass line from the transport path in a predetermined case. The assembly system according to claim 1,
Assembly system conveying device drive means, in certain cases, that to pass at least one of the robot of the bypass line, characterized by conveying the first pallet of the control means. An assembly method for assembling a plurality of types of automobile parts each composed of a main body and parts attached to the main body by an assembly system,
The assembly system includes:
A plurality of first pallets on which main bodies and parts of the plurality of types of automobile parts are placed;
A plurality of second pallets on which the respective parts of the plurality of types of automobile parts are placed;
A transport device for transporting the first pallet and the second pallet;
Multiple main lines where workers are placed;
Offset from a pair of continuous main lines of the plurality of main lines, and provided between the downstream end of the upstream main line and the upstream end of the downstream main line of the pair of main lines A bypass line on which the robot is disposed, and
When the robot arranged in the bypass line operates normally, a transfer route including the bypass line is set, and the first pallet and the second pallet are synchronously transferred along the set transfer route. Driving the robot of the bypass line, taking out the part from the first pallet and attaching it to the main body placed on the first pallet;
When a failure occurs in the robot arranged in the bypass line, a transfer path including a space between the downstream end of the upstream main line and the upstream end of the downstream main line is set, and the set transfer path The first pallet and the second pallet are synchronously transported along the line, and an operator is disposed between the downstream end of the upstream main line and the upstream end of the downstream main line, An assembly method, wherein an operator takes out the component from the first pallet and attaches the component to a main body placed on the first pallet.

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