JP6599416B2 - Manufacturing line monitoring device, manufacturing line monitoring program, manufacturing line monitoring method, manufacturing line monitoring system - Google Patents

Description

  Embodiments described herein relate generally to a technique for monitoring a production line.

  Conventionally, as a maintenance of the production line, measures have been taken to prevent failure during operation by periodic overhaul by preventive maintenance. According to such maintenance, for example, a drive motor in the production line is equipped with a thermometer or an ammeter, and an operator at the site visually confirms whether or not there is any abnormality in the production line. Further, when a failure occurs, the production line is stopped, and the failed part is repaired or replaced.

  Moreover, patent document 1 is disclosed as a related technique.

JP2012-160056

  However, in order to reduce manufacturing costs, the number of maintenance personnel tends to be reduced, and therefore preventive maintenance to detect abnormalities in the production line in advance becomes difficult. In this case, the production line is stopped. In other words, preventive maintenance is desirable as maintenance of the production line, but there is a problem that it requires a large cost.

  Embodiments of the present invention have been made to solve the above-described problems, and an object thereof is to provide a technique for performing preventive maintenance at a lower cost.

  In order to solve the above-described problem, an embodiment of the present invention includes a receiving unit that receives sensor data indicating a measured value by a sensor provided in the vicinity of a manufacturing apparatus constituting a manufacturing line, and a measured value indicated by the sensor data. A sensor determination unit that determines whether or not a first sensor threshold value indicating a predetermined range that is set in advance is exceeded, and when the sensor determination unit determines that the measurement value exceeds the first sensor threshold value, the client terminal And a notification unit that transmits a sensor abnormality notification that indicates to the user of the client terminal that the manufacturing apparatus is not operating normally.

It is the schematic which shows the whole structure of the manufacturing line monitoring system which concerns on this Embodiment. It is a block diagram which shows the hardware constitutions of a gateway terminal, a server apparatus, and a client terminal. It is a block diagram which shows the function structure of a gateway terminal and a server apparatus. It is a flowchart which shows operation | movement of a notification process.

  Embodiments of the present invention will be described below with reference to the drawings. First, the overall configuration of the production line monitoring system according to the present embodiment will be described with reference to FIG. FIG. 1 is a schematic diagram of a production line monitoring system according to the present embodiment.

As shown in FIG. 1, the production line monitoring system according to the present embodiment includes a production line 9, an inspection device 50, a production line PLC (Programmable Logic Controller) 60, a data collection PLC 70, as configurations installed at the production site. The gateway terminal 80 is provided, and the server apparatus 10 and the client terminal 20 are provided as a configuration installed in a remote place. In addition, the server apparatus 10 and the client terminal 20 shall be installed in a mutually different place.

  In the present embodiment, the production line 9 has a plurality of production apparatuses and produces films using these apparatuses, and the production process includes at least a heater 90 that dissolves film raw materials in the production process. In addition, the inspection process illuminates a plurality of transport rolls 91 for transporting a film continuously manufactured by the manufacturing process as a workpiece, a camera 92 for imaging the back surface of the workpiece, and an imaging range by the camera 92 An illumination 93, a camera 94 that images the surface of the workpiece, and an illumination 95 that illuminates the imaging range of the camera 94 are provided. The captured images captured by the cameras 92 and 94 are used for workpiece inspection by the inspection apparatus 50, and defect evaluation based on the inspection result by the inspection apparatus 50 is performed in the evaluation process. According to this defect evaluation, it is determined as a non-defective product or a defective product at every predetermined position interval in the workpiece conveyance direction. Further, a temperature sensor 90 a for measuring the temperature is provided in the vicinity of the heater 90, a vibration sensor 91 a for measuring the vibration is provided in the vicinity of the driving unit of the transport roll 91, and the illuminance is set in the vicinity of the illumination 93. An illuminance sensor 93a for measurement is provided. The temperature sensor 90 a outputs the temperature of the heater 90, the vibration sensor 91 a outputs acceleration, speed, and displacement as vibration of the transport roll 91, and the illuminance sensor 93 a outputs the illuminance of the illumination 93.

  The inspection device 50 inspects the workpiece and detects a defect based on the captured images captured by the cameras 92 and 94. Defects to be detected include pinholes, black spots, FE (Fish EYE), scratches, and the like, and the inspection apparatus 50 uses defect types and their numbers or sizes as inspection data for each workpiece. Output to the collection PLC 70. The inspection device 50 has a program installed on a PC (Personal Computer) for inspection, and a temperature sensor 50a for measuring temperature is provided in the vicinity of the heat discharge location in the casing. The temperature sensor 50a outputs the temperature of the inspection device 50.

  A production line PLC (Programmable Logic Controller) 60 is connected to each facility of the production line 9, receives various signals indicating the operation status, and outputs signal values to the data collection PLC 70 as production line data. Examples of the signal indicating the operation status include a failure signal indicating that the production line 9 has failed, an inverter control output of the driving unit, a transfer line speed indicating the work transfer speed, and an operating frequency of the manufacturing line 9.

  The data collection PLC 70 acquires inspection data output from the inspection device 50, manufacturing line data output from the manufacturing line PLC 60, values output from the various sensors 90a to 93a, 50a as sensor data, and acquired inspection data, The production line data and sensor data are output to the gateway terminal 80.

  The gateway terminal 80 receives the inspection data, the production line data, and the sensor data output from the data collection PLC 70, and transmits the received data to the server device 10 installed at a remote place via the network.

  The server device 10 accumulates the inspection data, the production line data, and the sensor data transmitted from the gateway terminal 80 and makes it possible to browse these various data from the client terminal 20. Further, the server device 10 makes a determination on various data based on an instruction from the client terminal 20, and notifies the client terminal 20 of a determination result as necessary.

  The client terminal 20 is a PC used by a person in charge of maintenance of the production line 9 installed at a location different from the installation location of the production line 9 and the installation location of the server device 10. The client terminal 20 can browse various data stored in the server device 10 by a browser, and gives an instruction regarding determination on various data by the server device 10 and receives a notification based on this determination.

  Next, the hardware configuration of the gateway terminal, server device, and client terminal will be described. FIG. 2 is a block diagram illustrating hardware configurations of the gateway terminal, the server device, and the client terminal.

  As shown in FIG. 2, the gateway terminal 80, the server device 10, and the client terminal 20 all include a CPU (Central Processing Unit) 11, a memory 12 that is a main storage device, a nonvolatile storage device 13, and other devices. An external I / F (interface) 14 is provided for performing communication with the device. The external I / Fs 14 of the gateway terminal 80, the server device 10, and the client terminal 20 are all connected to a network, and the gateway terminal 80 and the client terminal 20 are connected to the server device 10 so as to be able to transmit and receive data.

  Next, functional configurations of the gateway terminal and the server device will be described. FIG. 3 is a block diagram illustrating functional configurations of the gateway terminal and the server device.

As illustrated in FIG. 3 , the gateway terminal 80 includes an acquisition unit 801, a management unit 802, and a transmission unit 803 as functions. Each of these functions is realized in the gateway terminal 80 by loading a program stored in the storage device 13 into the memory 12 and the CPU 11 performing an operation on the loaded program.

  The acquisition unit 801 acquires inspection data, production line data, and sensor data. The management unit 802 associates various data acquired by the acquisition unit 801 with the date and time at the acquisition timing. The transmission unit 803 transmits various data associated with the date and time by the management unit 802 to the server device 10 via the network. The transmission of the various data is performed in a cycle having a length equal to or longer than the cycle in which the acquisition unit 801 acquires the various data, and the transmission unit 803 collects the various data acquired during the cycle to the server device 10. Send.

  In addition, the server device 10 includes a receiving unit 101, an accumulation unit 102, a setting unit 103, a defect determination unit 104, a sensor determination unit 105, a notification unit 106, and a conversion unit 107 as functions. Similar to the gateway terminal 80, each of these functions is executed by the server device 10 in which the production line monitoring program stored in the storage device 13 is loaded into the memory 12 and the CPU 11 is loaded with the production line monitoring program. This is realized.

  The reception unit 101 receives various data transmitted by the transmission unit 803 of the gateway terminal 80. The accumulation unit 102 associates the various types of data received by the reception unit 101 with each other and accumulates the data in the storage device 13 of the server device 10 in chronological order. The setting unit 103 associates the defect type of the workpiece with a specific sensor related to the defect type based on an instruction from the client terminal 20, and sets a first defect threshold to be described later in the defect determination unit 104. Then, a first sensor threshold to be described later is set in the sensor determination unit 105. Here, the first defect threshold is set as a predetermined value, and the first sensor threshold is set as a value indicating either the upper limit and the lower limit, only the upper limit, or only the lower limit. This is referred to as a setting range. The defect determination unit 104 determines the inspection data based on the first defect threshold set by the setting unit 103 and the second defect threshold that is lower than the first defect threshold by a predetermined amount. The sensor determination unit 105 detects the first sensor threshold value set by the setting unit 103 and the second sensor threshold value that differs from the first sensor threshold value by a predetermined amount with respect to the upper limit or the lower limit within the setting range. Make a decision on the data. The notification unit 106 notifies the client terminal 20 of an abnormality or warning of the workpiece or sensor measurement target based on the determination by the sensor determination unit 105 or the defect determination unit 104 and the sensor determination unit 105. The conversion unit 107 converts various data stored in the storage unit 102 into a format that can be browsed by the client terminal 20 so that the person in charge of maintenance can easily grasp the status of the production line 9.

  Assume that the storage unit 102 associates various data with data having the longest output cycle by associating other data that is temporally within this cycle. For example, if the output from the inspection apparatus 50 is every 1 second, the output from the production line PLC 60 is every 0.2 seconds, and the output from various sensors is every 0.1 seconds, The production line data and the various sensor data of 10 are associated with each other.

  Regarding the notification by the notification unit 106, the abnormality notification regarding the workpiece indicates that the number and size of defects existing on the workpiece has already exceeded the allowable range, and the warning notification regarding the workpiece indicates the defect existing on the workpiece. The possibility that the number, size, etc. will exceed the allowable range in the future is shown. Further, the abnormality notification regarding the measurement target indicates that the measurement target of the sensor has not been normally operated, and the warning notification regarding the measurement target indicates the possibility that the measurement target of the sensor will not normally operate in the future. Specifically, these notifications are made when the notification unit 106 transmits an e-mail to the client terminal 20, and the type of notification and its specifics are determined depending on the title or text of the e-mail. It is assumed that the general situation is grasped by the person in charge of maintenance.

  Data conversion by the conversion unit 107 includes graphing of various data and conversion into HTML. According to the graphing, for the inspection data, production line data, and sensor data, a graph is generated in which the vertical axis represents the data value and the horizontal axis represents the time. As for this graph, in order to make it easy for maintenance personnel to grasp the relationship between inspection data, production line data, and sensor data, each type of data uses the same time scale. It is desirable that the data values of various data are in a uniform state. In addition, according to HTML conversion, various data graphs can be viewed from the browser of the client terminal 20 without introducing a specific application for browsing various data graphs.

  Also, the conversion unit 107 provides an interface for receiving an instruction from the client terminal 20 by using HTML. According to this interface, it is possible to select any one of a text box in which a value as a first defect threshold can be input as a setting item, and a lower limit and upper limit, only a lower limit, and only an upper limit as a first sensor threshold setting method. A radio box, one or two text boxes that can be input as a value for the first sensor threshold, displayed according to the selection of the radio box, are prepared for each defect type in the inspection data. A check box indicating a sensor type associated with at least one sensor. Similar to the check box indicating the sensor type, a check box indicating a type of operation status associated with at least one defect type may be further provided.

  Next, the operation of the notification process for notifying the client terminal based on the workpiece defect and the measured value by the sensor will be described. FIG. 4 is a flowchart showing the operation of the notification process. In this flowchart, the setting unit associates in advance a temperature sensor in the vicinity of the heater, which is one of the sensor types, with the FE, which is one of the defect types, and the first number of FEs. It is assumed that a defect threshold is set and a first sensor threshold having only a lower limit is set for a temperature sensor near the heater. In addition, this notification process is executed every time various data is received by the receiving unit.

  As shown in FIG. 4, first, the defect determination unit 104 refers to the inspection data and determines whether or not FE exists in the workpiece (S101).

  When FE exists (S101, YES), the defect determination unit 104 determines whether or not the number of FEs is larger than a second defect threshold value having a value lower than the first defect threshold value by a predetermined amount (S102). .

  When the number of FEs is larger than the second defect threshold (S102, YES), the sensor determination unit 105 determines whether the heater temperature measured by the temperature sensor 90a is smaller than the second sensor threshold (S103). Here, the second sensor threshold has a value different from the first sensor threshold by a predetermined amount within the range, and in the present embodiment in which only the lower limit is set, the second sensor threshold is larger than the first sensor threshold by a predetermined amount. Has a value.

When the heater temperature is lower than the second sensor threshold value (S103, YES) , the notification unit 106 notifies the client terminal 20 of an abnormality in the number of FEs as an abnormality notification related to a workpiece and a heater abnormality as an abnormality notification related to a measurement target ( S104).

  On the other hand, when the heater temperature is equal to or higher than the second sensor threshold (S103, NO), the defect determination unit 104 determines whether or not the number of FEs is larger than the first defect threshold (S105).

  When the number of FEs is larger than the first defect threshold (S105, YES), the notification unit 106 notifies the client terminal 20 of the FE number abnormality (S106).

  On the other hand, when the number of FEs is equal to or less than the first defect threshold value (S105, NO), the notification unit 106 notifies the client terminal 20 of an FE number warning as a warning notification related to the workpiece (S107).

  In step S102, when the number of FEs is equal to or smaller than the second defect threshold (S102, NO), the sensor determination unit 105 determines whether the heater temperature is lower than the first sensor threshold (S108).

  When the heater temperature is lower than the first sensor threshold value (S108, YES), the notification unit 106 notifies the client terminal 20 of the heater abnormality (S109).

  On the other hand, when the heater temperature is equal to or higher than the first sensor threshold (S108, NO), the sensor determination unit 105 determines whether the heater temperature is lower than the second sensor threshold (S110).

  When the heater temperature is lower than the second sensor threshold value (S110, YES), the notification unit 106 notifies the client terminal 20 of a heater warning as a warning notification regarding the measurement target (S111).

  On the other hand, when the heater temperature is equal to or higher than the second sensor threshold (S110, NO), the sensor determination unit 105 ends the notification process.

  In Step S101, when FE does not exist in a work (S101, NO), sensor judgment part 105 judges whether heater temperature is smaller than the 1st sensor threshold (S108).

  As described above, according to the notification process, the abnormality related to the workpiece based on the determination based on the first defect threshold and the warning related to the workpiece based on the determination based on the second defect threshold are notified, and the measurement target based on the determination based on the first sensor threshold is related. A warning regarding the measurement object based on the abnormality and the determination based on the second sensor threshold is notified. For both the notification regarding the workpiece and the notification regarding the measurement target, the maintenance person can grasp the possibility of the occurrence of an abnormality by making a determination based on a threshold different from the set threshold. In addition, when the defect type and the sensor type that are estimated to be highly correlated with each other are associated with each other and the determination criterion based on the second defect threshold is satisfied and the determination criterion based on the second sensor threshold is satisfied, By assuming that an abnormality has occurred in the measurement object and notifying that effect, the measurement value by the sensor is determined by the first sensor threshold before the number or size of defects reaches the first defect threshold. Before exceeding the range, the maintenance person can grasp that an abnormality has occurred in both.

  In the present embodiment, the production line monitoring program is described as being installed in advance in the server device as the above-described production line monitoring device. However, the production line monitoring program in the present invention is stored in a storage medium. Is also included. Here, the storage medium is a magnetic tape, magnetic disk (hard disk drive, etc.), optical disk (CD-ROM, DVD disk, etc.), magneto-optical disk (MO, etc.), flash memory, etc. Furthermore, it refers to all media that can be read and executed by a computer in the above-described server device, such as media that can be transmitted via a network.

  Although the embodiment of the present invention has been described, this embodiment is presented as an example and is not intended to limit the scope of the invention. These novel embodiments can be implemented in various other forms, and various omissions, replacements, and changes can be made without departing from the scope of the invention. These embodiments and modifications thereof are included in the scope and gist of the invention, and are included in the invention described in the claims and the equivalents thereof.

9 Production line, 10 Server device, 20 Client terminal , 50 Inspection device, 80 Gateway terminal , 101 Receiving unit, 102 Storage unit, 103 Setting unit, 104 Defect determination unit, 105 Sensor determination unit, 106 Notification unit, 107 Conversion unit

Claims (4)

A production line monitoring device connected to a client terminal via a network,
Sensor data indicating a measurement value by a sensor provided in the vicinity of a manufacturing apparatus constituting the manufacturing line, and output from an inspection apparatus for inspecting a defect on a workpiece manufactured by the manufacturing line, and indicated by the defect type and the defect type A receiver for receiving defect data indicating the number or size of defects to be generated;
A sensor determination unit for determining whether or not a measurement value indicated by the sensor data exceeds a sensor threshold value indicating a predetermined range set in advance;
A defect determination unit that determines whether the number or size of defects indicated by the defect data is greater than a preset defect threshold;
By the defect determination unit, it is determined that the number or size of defects indicated by the previous Kiketsu Recessed type is larger than the defect threshold, and, by the sensor judgment section, associated in advance before Kiketsu Recessed type sensor If the measured value due is determined to exceed said sensor threshold, presenting that to the client terminal, and a work abnormality notification to present that an abnormality in the workpiece has occurred, the abnormality in the manufacturing apparatus has occurred A production line monitoring device comprising: a notification unit that transmits a production device abnormality notification. A production line monitoring system comprising a client terminal and a production line monitoring device connected to the client terminal via a network,
The client terminal is
A work abnormality that transmits instruction information indicating a predetermined defect type and a predetermined sensor corresponding to the predetermined defect type to the manufacturing line monitoring device and presents an abnormality in the work manufactured by the manufacturing line Receiving from the manufacturing line monitoring device a notification and a manufacturing device abnormality notification indicating that an abnormality has occurred in the manufacturing device constituting the manufacturing line;
The production line monitoring device is
Wherein the sensor data indicating a value measured by a sensor provided in the manufacturing apparatus vicinity is output from the inspection apparatus for inspection before the defects on verge over click, the number or size of defects indicated by the defect type and the defect type A receiving unit for receiving defect data indicating
A sensor determination unit for determining whether or not a measurement value indicated by the sensor data exceeds a sensor threshold value indicating a predetermined range set in advance;
A defect determination unit that determines whether the number or size of defects indicated by the defect data is greater than a preset defect threshold;
A setting unit that receives the instruction information from the client terminal and associates a predetermined defect type indicated by the defect data with a predetermined sensor indicated by the sensor data based on the instruction information;
The defect determination unit determines that the number or size of defects indicated by the predetermined defect type is greater than the defect threshold, and the sensor determination unit associates the defect type with the predetermined defect type. And a notification unit configured to transmit the work abnormality notification and the manufacturing apparatus abnormality notification to the client terminal when it is determined that a measured value by the obtained sensor exceeds the sensor threshold value. Production line monitoring system. A production line monitoring program executed by a computer connected to a client terminal via a network,
Sensor data indicating a measurement value by a sensor provided in the vicinity of a manufacturing apparatus constituting the manufacturing line, and output from an inspection apparatus for inspecting a defect on a workpiece manufactured by the manufacturing line, and indicated by the defect type and the defect type Receive defect data indicating the number or size of defects
Determining whether the measured value indicated by the sensor data exceeds a sensor threshold value indicating a predetermined range set in advance;
Determining whether the number or size of defects indicated by the defect data is greater than a preset defect threshold;
It is determined that the number or size of defects indicated by the previous Kiketsu Recessed type is larger than the defect threshold, and, it is determined that the previous Kiketsu Recessed measured by pre-sensor associated with the type exceeds the sensor threshold In this case, the computer transmits a work abnormality notification that indicates that an abnormality has occurred in the work and a manufacturing apparatus abnormality notification that indicates that an abnormality has occurred in the manufacturing apparatus to the client terminal. Production line monitoring program to be executed. A production line monitoring method executed by a computer connected to a client terminal via a network,
The computer is
Sensor data indicating a measurement value by a sensor provided in the vicinity of a manufacturing apparatus constituting the manufacturing line, and output from an inspection apparatus for inspecting a defect on a workpiece manufactured by the manufacturing line, and indicated by the defect type and the defect type Receive defect data indicating the number or size of defects
Determining whether the measured value indicated by the sensor data exceeds a sensor threshold value indicating a predetermined range set in advance;
Determining whether the number or size of defects indicated by the defect data is greater than a preset defect threshold;
It is determined that the number or size of defects indicated by the previous Kiketsu Recessed type is larger than the defect threshold, and, it is determined that the previous Kiketsu Recessed measured by pre-sensor associated with the type exceeds the sensor threshold A manufacturing line monitoring method for transmitting, to the client terminal, a work abnormality notification indicating that an abnormality has occurred in the work and a manufacturing apparatus abnormality notification indicating that an abnormality has occurred in the manufacturing apparatus. .

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