JPH0315735A - Trouble diagnostic method for production line - Google Patents

Abstract

PURPOSE:To specify an operation block including the cause of abnormality by comparing the measured operation time of each operation block with a reference operation time. CONSTITUTION:The counted value of a step counter Cs which counts the number indicating the execution order of each operation step is incremented when internal coils Msi and Mi are turned on together. Consequently, the counted value of the counter Cs is monitored to detect the position which is executed at present of a program. That is, monitor and trouble diagnosis of the operation state of a built-in device are performed through only the counter Cs. Consequently, the change of a sequence program which normally operates the built-in device has not an influence upon the trouble diagnostic program, and the labor for the system change is reduced.

Description

[Detailed description of the invention] [Industrial application field] The present invention relates to a production line failure diagnosis method.

[Prior art] A program is created that specifies the order in which each output element (such as an actuator) that makes up the operating system of the equipment to be controlled is to perform the operations, and each step of the control is sequentially performed according to this program. The so-called sequence program control in which the program is performed is generally well known. In addition, in this sequence program control, various methods have been devised for diagnosing equipment failure by monitoring whether the control is being performed normally.
No. 8906 discloses that the operation patterns of each component of the sequence control circuit are sequentially stored in advance when the equipment is operated normally, and when the equipment is actually operated, the operation pattern of each of the above-mentioned components is stored in advance. A so-called teaching playback type operation abnormality detection device has been proposed, which sequentially checks whether the information matches the stored information and points out an abnormality when there is a mismatch.

[Problems to be Solved by the Invention] However, in the above teaching play pack type fault diagnosis method, even if the actual operation of the equipment is normal, the operating pattern may not match the normal pattern stored in the fault diagnosis device. If so, it is diagnosed as abnormal. That is, usually
Actual equipment has a variety of normal patterns, but the number of normal patterns that can be stored in a fault diagnosis device is limited (usually one pattern). If the pattern is different from the pattern specified, an abnormality is pointed out. Therefore, there is a problem that false detections increase.

In addition, in conventional fault diagnosis methods, a sequence circuit for detecting one abnormality is usually created for one actuator, and fault diagnosis is performed for each actuator, and equipment fault diagnosis is performed based on this. I try to do this. For this reason, the control section for controlling the operation includes an abnormality detection circuit with a capacity equal to or greater than the control section, which not only increases the size of the entire circuit but also makes it complex.

Furthermore, when changes occur to equipment, the fault diagnosis program must also be changed at the same time. Furthermore, even if an abnormality occurs in an actuator that does not affect the operation of the entire equipment, such as a slight delay in the operation of an individual actuator due to changes over time, it is pointed out as an abnormality in the equipment, which increases the number of false positives. Furthermore, there is a problem in that it is not possible to detect an abnormality in the equipment that is not accompanied by an abnormality in the actuator, such as an abnormality in the cycle time of the equipment caused by the operator.

This invention was made in view of the above problems, and when detecting the presence or absence of an abnormality in a production line and the location of the abnormality,
To be able to detect abnormalities in equipment that are not accompanied by abnormalities in actuators (output elements), and to prevent false detections caused by abnormalities in individual output elements that do not affect the operation of the equipment as a whole. The purpose is to provide a method for diagnosing production line failures.

[Means for Solving the Problems] Therefore, the first invention of the present application is a series of operations in which the various operations to be performed by equipment on a production line are performed independently from start to finish under normal conditions. is divided into a plurality of motion blocks with a unit of motion as a motion block, and each of the plurality of motion blocks is divided into a plurality of motion steps. In the above-mentioned equipment, which is sequence-controlled so as to be executed in a set order, the operation time from the start to the end of a series of operation steps is measured for each block, and this measured operation time is used as the reference operation time for the block. In addition to diagnosing the presence or absence of an abnormality in each of the blocks by comparing with This is what I did.

Further, the second invention of the present application is such that various operations to be performed by equipment on a production line are divided into a plurality of operation groups, which are units of a series of operations that are performed independently from start to finish under normal conditions. A sequence for sequentially executing a plurality of action blocks in each of the plurality of action groups in a preset order, with the plurality of action groups being divided into action groups and each of the plurality of action groups being divided into a plurality of action blocks. In the controlled production line, the operation time from the start to the end of a series of operation blocks is measured for each group, and this measured operation time is compared with the reference operation time for the group to determine the operation time for each group. In addition to diagnosing the presence or absence of abnormalities,
A storage means is provided for storing the completion of operation of each block for each group, and a failure group and a failure block are specified from the contents of the storage means.

[Effects of the Invention] According to the first invention of the present application, by comparing the measured operation time and the reference operation time for each operation block, the operation block including the cause of the abnormality can be identified,
Furthermore, it is possible to identify the operational step that caused the failure from the storage contents of the storage means that stores the completion of each operational step in the block. In addition, when diagnosing the presence or absence of an abnormality in each motion block, the motion time from the start to the end of a series of motion steps within each motion block is measured, and this measured motion time is combined with the reference motion time of the motion block. This method effectively prevents false positives caused by abnormalities that do not affect the operation of the block as a whole, among individual operation abnormalities or differences in operation patterns within the operation block. In addition, even if there is no abnormality in the individual operations in the operation book a, but an abnormality occurs in the operation of the block as a whole, this abnormality can be reliably detected. As a result, it is possible to quickly and accurately diagnose the presence or absence of an abnormality in the production line and detect the abnormal location.

Further, according to the second invention of the present application, by comparing the measured operation time and the reference operation time for each operation group, it is possible to specify the operation group that includes the cause of the abnormality, and furthermore, by comparing the measured operation time and the reference operation time for each operation group, The action block that caused the failure can be identified from the storage contents of the storage means that stores the completion of the action of each action block. In addition, the presence or absence of an abnormality in each movement group is diagnosed by comparing the measured movement time from the start to the end of a series of movement blocks within each movement group with the reference movement time of the movement group. , when diagnosing the presence or absence of an abnormality for each operation group, the same effects as the first invention can be achieved. As a result, it is possible to quickly and accurately diagnose the presence or absence of an abnormality in the production line and detect the abnormal location.

[Embodiments] Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings, regarding a case in which an embodiment of the present invention is applied to an assembly device for assembling suspension parts such as a suspension and an engine to a vehicle body on an automobile assembly line.

As shown in FIG. IO, the assembly apparatus according to this embodiment is located at a positioning station S.1 which receives the vehicle body W brought in from the previous process and sets it in a positioning state. Docking station S!, which combines the vehicle body W with undercarriage parts such as the engine 2 and front and rear suspensions 3 (only the rear side is shown in Figure 1O) set at a predetermined position on the pallet P! and a screw fastening station S3 for fastening and fixing the engine 2, suspension 3, etc. to the vehicle body W after being docked. Further, between the positioning station S and the docking station S, there is provided a bowhead type transfer device Qt for suspending and transporting the vehicle body W, and on the other hand, the docking station S and the screw fastening station A pallet conveying device Q, which conveys the pallet P, is provided between the pallet S3 and the pallet S3.

The positioning station S1 is provided with a relay movable base 12 that travels back and forth along the rails 11 in order to carry the vehicle body W supplied from the previous process to the starting end of the transfer device Q. The movable base l2 is provided with a plurality of vehicle body holders l3 that support the lower end of the vehicle body W so as to be movable up and down. a longitudinal positioning means for positioning the vehicle body receivers 13, . . . A positioning device Q1 composed of a reference pin or the like is provided.

The transfer device Q, also includes a positioning station S,
A guide rail 16 extends between both stations above the Tomo Tocking Station S.
and a carrier 17 that reciprocates in a suspended state along the guide rail l6, and the carrier 17 is
As shown in FIG.
It is equipped with These vehicle body holding arms 19..., 19
are designed to be swung by, for example, an air cylinder (not shown), and each has an engagement pin 19a that engages with the vehicle body W at its tip.

As shown in FIG. 12, the pallet conveying device Q, which connects the docking station S and the screw fastening station S, includes a large number of support rollers 22 that receive the left and right lower ends of the pallet P, and the left and right side ends of the pallet P. A pair of left and right guide portions 2l equipped with a large number of side rollers 23 that guide the pallet P, a conveyor rail 24 extending parallel to both guide portions 21 and 21, and a pallet locking portion 25a that locks the pallet P. and a pallet transport base 25 which is movably provided along the transport rails 24.

Although not specifically illustrated, the guide portion 21.
21 and the conveyor rail 24 are connected to the wood assembly device 1 and the engine 2.
After sequentially passing through the parts supply station (not shown) that supplies the suspension and suspension 3, etc., to the docking station S of this assembly device L and the screw fastening work station S3, the vehicle body W that has completed the fastening work is sent to the next process. It is formed in a loop shape that passes through a conveyance station (not shown) and then returns to the parts supplying machine (not shown).
are arranged so that each ring moves in a predetermined cycle.

2. The tocking station S is equipped with a damper unit 3a (see Figure 10, p, <0) that is in a floating state until it is attached to the vehicle body W when the suspension unit 3 is assembled to hold it in a predetermined posture for donking. In addition, front and rear clamp arms 26, which form a pair with the guide portions 21 and 21 of the pallet conveying device Q separated, are installed at locations corresponding to the mounting positions of the front and rear suspension yons 3.
., 26 are arranged. Each of these clamp arms 2
6 is provided with a claw portion 26a at its tip portion for clamping the damper unit 3a, and the guide portion 21.6 is provided with a claw portion 26a for clamping the damper unit 3a.
It is attached via a mounting plate 28 to each mounting base 27 provided on the left and right sides of the vehicle 21 so as to be movable forward and backward in the left and right direction (vehicle width direction). Each of the mounting plates 28 also has a
For example, arm slides 29 made up of air cylinders are attached to each arm, so that the damper unit 3a can be moved laterally and longitudinally in a clamped state. That is, the above-mentioned clamp arm 2
6..., 26 and Anim Slide 29. ...29 is,
It constitutes a part of a docking device Q for docking Ennon 2 and Zasubenshi 3 with the vehicle body W.

Further, the docking station S, includes a pair of left and right slide rails 3l arranged parallel to the guide portion 21, 21 of the pallet transport device Q, and the slide rails 3l.
A slide device Q4 is provided, which includes a movable body 32 that slides in the front-rear direction along 1.3+, and an electric motor 33 that drives the movable body 32. By moving the engine 2 on the pallet P back and forth with the device Q4, when docking,
Interference between the vehicle body W and the engine 2 can be avoided.

The screw fastening station S performs screw fastening work to fasten and secure the engine 2, suspension system 3, etc. to the vehicle body W. ! Several robots Q8 are arranged, and a plurality of pallet reference bins 38 for positioning and locking transported pallets P at predetermined positions are provided so as to be movable up and down. In addition, the above docking station S
, are also provided with a plurality of pallet reference pins 38 similar to those provided in the screw fastening station S3.

As shown in FIG. 13, the pallet includes a pair of vertical frames 41 extending in the front-rear direction, and the vertical frames 41.4.
It is formed in the shape of a ladder with multiple horizontal frames 42 provided across the pallet, and a plurality of engagement holes that engage with the pallet reference bins 38 are provided near the front and rear ends of the frame. 40 is provided, near the side end of the central part in the front-rear direction,
A locking portion 50 is provided to be locked to the locking portion 25a of the pallet conveyance base 25.

Further, at the front part of the pallet P, a front side support board 4 is provided which supports a front side base frame 5r on which the engine 2, front suspension system (not shown), etc. are mounted.
3f is provided, and at the rear thereof, a rear side support board 43r that supports the rear side base frame 5'' on which the rear suspension 3 and the like are mounted is provided.
As shown in FIG. 14, the base frames 5f, 43r are attached to the front and rear support substrates 43', 43r.
5 r or a large number of supporting members 44 ``. 4
4r, base frame 5r, supporting substrate 4:H
, 43r.
r45r, and vehicle body holders 46F and 46r that support the vehicle body W via brackets (not shown).

The support board 43r on the rear side further includes a plurality of vehicle body repositioning pins 4 for positioning the vehicle body W with respect to the pallet P.
7, and a number of nut holders 48r for holding nuts to be tightened at the screw fastening station s3.

On the other hand, on the front side portion of the above-mentioned pa 1 knot P, a nut holder 48r.・・・． 48r, and bolt holder 49.・・・． 49 is directly attached to the pallet P, and furthermore, the front support substrate 4
A lock pin 5I is provided to lock 3r in a predetermined position. The lock bin 51 is biased toward the engagement side by a spring (not shown), and the attached release lever 5
2, it is possible to switch to the disengagement side. Further, a locking member 53 extending downward is integrally provided on the front side support substrate 43'', and the locking member 53 is connected to the movable body 32 of the slide device Q4 (see FIG. 12). It is designed to be locked by a locking claw portion 32a provided on the top surface.The slide device Q4 is provided with an air cylinder 34 for operating the release lever 52 to the release side, so that the vehicle body W is not docked. When being lowered toward station S, the release lever 52 is operated to release the lock bin 5l in accordance with a predetermined lowering timing, and the lock bin 5l is disengaged, and the slide device Q4 is moved through the locking member 53. By moving the front support board 43f (that is, the engine 2) back and forth, interference between the vehicle body W and the engine 2 can be avoided.

As is clear from the above description, the assembly device 1 according to the present embodiment has the following main output elements constituting its operation system:
Positioning device Q1, transfer device Q, docking device Q,
, a slide device Q4, a pallet transport device Q5, and a screw tightening robot Q6. Each of these output elements is controlled by a sequence program according to a program created in advance.

In this embodiment, the various operations to be performed by the equipment on the production line are divided into a plurality of operation groups, each consisting of a series of operations that are performed independently from start to finish under normal conditions. At the same time, each of the plurality of action groups is divided into a series of action blocks that are performed independently from start to finish under normal conditions, and each of these action blocks is further divided into a series of action blocks that are performed independently from start to finish under normal conditions. Under the division into steps, a plurality of action steps in each of the above {summer number of action blocks} are sequentially executed in a preset order, and further, a plurality of action blocks in each of the plurality of action groups are executed in a preset order. Sequence control is performed so that the processes are executed sequentially in the specified order.

Below, before explaining a specific example of the above-mentioned automobile assembly line assembly apparatus, the basic concepts of the above-mentioned operation groups, operation blocks, and operation steps in the present invention will be explained first.

In order to explain the basic concept of the above-mentioned operation groups, operation blocks and operation steps, Fig. 1 shows, for example, a continuous conveyor line and the way in which parts and products are carried in or out using a tact conveyance method, for example. This is a schematic explanatory diagram showing an example of a production line that is equipped with a plurality of linear conveyor lines that perform The fourth station Stn4 includes first and second stations Stnl and Stn2, respectively, which transport parts, products, etc. to the fourth station Stn4, and the fourth station S
A third station Stn3 is provided to transport parts, products, etc. to the next process station (not shown) in accordance with the timing of unloading from tn4, and various operations to be performed at the first and second stations Stn1 and Stn2 are provided. If the above is normal, the fourth station Stn4 becomes operational, and furthermore, if the operations to be performed at the fourth station Stn4 and the third station Stn3 are normal, the station for the next process (not shown) is activated. configured to be operational.

In addition, as shown in FIG. 2, each of the stations Stn
The operations to be performed in 1, Stn2, Stn3, and Stn4 are grouped into operation groups GRI, GR2GR3, and Grl4 as units of a series of operations that are performed independently from start to finish under normal conditions.
and each of these operation groups GRI,C,
R2. Each of GR3 and GR4 is divided into a plurality of action blocks, each of which is a unit of a series of actions to be performed independently from start to finish under normal conditions, and further divided into a plurality of action blocks. Each is divided into multiple operational steps.

That is, for example, if an operation group C; Rl (first operation group) consisting of a series of operations of the first station Stnl is explained, the first operation group G
RI includes a plurality of operation blocks BL1, BL2 . It is divided into BL3 and BL4, and each of these operation blocks is further divided into a plurality of operation steps. Note that the above-mentioned action group may be composed of a single action block, and there may also be cases where the action block is substantially composed of a single action step.

The plurality of action steps in each of the action blocks are sequentially executed in a preset order, and the plurality of action blocks in each of the plurality of action groups are sequentially executed in a preset order. Sequence control is performed to sequentially execute operation groups GRI, R2, GR3, and GR4 in a preset order.

Next, the basic concept of the production line failure diagnosis method according to the present invention will be explained. As shown in FIG. 3, the failure diagnosis device has a step counter Csi for each operation block BLi.
and time registers Tsi and Tei are provided,
The step counter Csi is sequentially input with completed operation steps within the block, and the time registers Tsi and Tei are input based on the time of the built-in clock of the microcomputer of the failure diagnosis device. , the timer value at the start of the block BLi's operation is entered into the time register Tsi, and the timer value at the time the block's operation is completed is entered into the time register Tei.

These time registers Tsi. From the data manually entered in Tei, the operation time Txi (= Tei
- Tsi) is calculated and this measured operating time Txi is stored in the memory of the microcomputer. On the other hand, the microcomputer has the block BLi
For example, the reference time T sLi (= T xi
i+3a) is inputted in advance by human data, and
More preferably, the data is updated and stored every cycle, and by comparing this reference time Tsti with the measurement operation time Txi, it is possible to diagnose whether or not there is an abnormality in the block BLi. That is, if the measured operation time Tκi is less than or equal to the reference time Tsti, it is determined that the operation is normal, and if the measured operation time Txi exceeds the reference time Tsti, it is determined that the operation of the operation block BLi is abnormal.

If it is determined that the operation block BLi has an abnormality, the operation step that caused the failure can be identified by reading the count value of the step counter Csi attached to the block BLi. In other words, the operation step next to the operation step whose operation has been completed and whose step number is counted by the step counter Csi is specified as a failure step. Then, by performing a reverse search of the sequence circuit for this identified faulty step, it is possible to specifically detect which contact on the ladder diagram is faulty.

Taking the case of the first operation group GRI, which is composed of a series of operations to be performed at the first station Stnl of the production line (see FIGS. 1 and 2) as an example, as shown in FIG. , each operation block BLI,B
Step counters Cs l , Cs2 . Cs3 and Cs4 are attached, and the respective time registers Tsl/Tel,
Ts2/Te2. Each operation block BL I, calculated from the input data to Ts3/Te3 and Ts4/Te4.
[Measurement operation time T for 3L2, BL3 and BL4
XI, Tlh. Tlh and Tx4 are stored in the memory of the microcomputer, and these measurement operation times and reference times Tst+, Tst. ,Tst3
By comparing Tsta and Tsta, the occurrence of a failure in each block is monitored.

In addition, although not specifically illustrated, each of the above groups G
R I. GR2, GR3, and GR4 are equipped with time registers to measure the operation time from the start to the end of each group's operation, and by monitoring the measured operation time for each group by comparing it with the reference time. , it is possible to diagnose abnormalities for each group. For a group diagnosed as having an abnormality, by checking the count value of the step counter attached to each block in the group, a pick-up other than the pick-up ("999") indicating the completion of the block operation is indicated. It is possible to search for a block and specify that this block contains the cause of the abnormality, and furthermore, the faulty step can be specified from the count value of the step counter.

Next, a specific example of the assembly apparatus 1 (see FIGS. 10 to 14) for the automobile assembly line will be described.

FIG. 5 shows the order of execution of the operations of the operation system of the assembly device I, mainly taking the transfer device Q as an example, and shows that the operations are performed independently from start to finish under normal conditions. This is a flowchart showing action blocks as a unit of a series of actions.As shown in this figure, the actions to be performed in each action block are as follows:
It is divided into multiple action steps whose execution order is fixed, and in each of the above action blocks, the steps from the first action step to the last action step in the block are compared with the action steps in other action blocks. It can finish running independently without having to do anything.

In this embodiment, the operation steps of each output element of the operation system of the assembly device 1 are divided into 6g operation blocks A to F, and in order from the left in FIG. The operation blocks of the loading device Q, the docking device Q, the slide device Q4, the pallet transport device Q, and the screw tightening robot QIl are respectively displayed. In other words, the operation steps of the positioning device Q are divided into two blocks A and D, the operation steps of the transfer device Q are divided into four blocks B, D, E, and F, and the operation steps of the docking device Q3 are divided into four blocks B, D, E, and F.
The operation steps of are divided into two blocks, C and E, and the slide device Q4 completes all its operations in the E block, and the pallet transport device Q
5 and the screw tightening robot Q, all of their operations are performed within the F block. The execution order of each of the above-mentioned operation blocks is specified in advance in the program so that the blocks transition chronologically from top to bottom in FIG.

In addition, in the flowchart of FIG. 5, when multiple blocks are displayed in the same column in the vertical direction (see blocks A, B, and C), these multiple blocks (that is, the operation step calendar within each block) If they are executed in parallel at the same time, and if the same block contains operation steps for multiple output elements, the multiple output elements will work together to perform a series of operations, and the operation of each output element will be executed in parallel. This shows that the steps are combined with each other to determine the execution order of the operation steps within the block (D
, E and F blocks).

Hereinafter, the operation of the assembly device 1 will be explained with reference to the flowchart shown in FIG. 5.

In the assembly device 1, in an initial state before startup, the vehicle body W transported from the previous process is positioned at the positioning station S,
The pallet P is placed in an unpositioned state on the movable base 12 of the pallet P, and the movable base 12 is located at the starting end of the transfer device Q, in an unpositioned state, and the pallet P is locked. docking station S without
It is located in

When the introduction device 1 is started, first, the positioning device Q1, the transfer device Q, and the docking device Q start operating in parallel at the same time, and the positioning device Q, In the operation step, as a preparation for holding the vehicle body W on the carrier l7 of the transfer device Q, the moving base 12
, the vertical positioning of each vehicle body holder l3, and the positioning of the vehicle body W relative to the movable base 12 (positioning (l)). In addition, in the docking device Q3, in a series of operation steps in the C block, in preparation for docking work, the pallet P is locked in a predetermined position, and in order to avoid interference between the vehicle body W and the suspension 3 during docking. , clamp arm 26. ..., 26 grip the damper unit 3a and hold it in a predetermined posture (docking (I)).

On the other hand, the transfer device Q performs the process of transfer (1) in a series of operation steps in the B block. That is, the initial state where carrier I7 is located at the overhead position and the starting position! 13 (operation step BO) and descends toward the positioning station S (operation step B1). At this time, each vehicle body holding arm 19 at the lower end of the carrier 17
is locked in a backward position where it does not interfere with the vehicle body W.

When this operation step Bl is completed, the operation in block B is completed, and the transfer device Q! The name operation command for is reset (operation step B999).

When all the operation steps of the A and B blocks are completed, the operation of the D block is started. In this D block, the positioning (2) of the positioning device Q and the transfer device Q are performed.
, each step of transfer (2) is performed. That is, first, the lock state of each vehicle body holding arm 19 of the transfer device Q is released, and the engaging bin 19a of the holding arm 19 is released.
are advanced to a holding position where they are secured to the vehicle body W (operation step DI), and each vehicle body holding arm l9 is locked in this state.

Then, in operation step D2, the carrier 17 is raised while holding the vehicle body W, and in operation step D3, the reference pin (not shown) of the positioning device Q1 is moved backward.

Next, in operation step D4, the carrier 17 is advanced to above the docking station S, and then, in operation step D5, each vehicle body holder 13 of the positioning device Q1
is lowered, and all operations of block D are completed (completion: operation step D999). In addition, the positioning device Q, completes all the operation steps in one cycle of the assembly device 1 in the operation step D5, and returns to the initial state.

When the D block is completed, the operation of the E block is started, and the transfer by the transfer device Q, ii12(3), and the docking device Q. The steps of docking (2) by No. 3 and sliding by the slide device Q4 are performed. That is,
The vehicle body W held on the carrier 17 of the transfer device Q is gradually lowered in three steps toward the docking station S (operation steps El, E5, EIO).
, the engine 2 and suspension 3 on the pallet P are combined with the vehicle body W. During the lowering period of the vehicle body W, the damper unit 3a is moved back and forth and left and right by each clamp arm 26 and arm slide 29 of the docking device Q3 (operation steps E4, E7, E9), and the engine 2 is moved by the slide device Q4. Back and forth movement (movement step E
2. E3. E6, E8) should be carried out to avoid interference between the vehicle body W and the damper unit 3a or the engine 2 during docking. After the docking is completed, the vehicle body holding arm 19 of the carrier 17 is moved backward in operation step El1, and the state in which the vehicle body W is held by the carrier 17 is released, and the docking is completed. Next, in operation step EI2, the carrier 17 that has released the vehicle body W is raised, and after that, the damper unit 3a is released from the clamped state (operation step El3), and the clamp arm 26
is retreated (operation step E14), and the pallet P is unlocked (operation step E15), and all operations of block E are completed (completed: operation step E9).
99).

When the E block is completed, the operation of the F block is started, and the steps of transfer (4) by the transfer device Q, transportation by the pallet transfer device Q, and screw fastening by the robot Q6 are performed. That is, in operation step Fl,
The carrier l7 of the transfer device Q is followed up to the starting end and returns to the initial state (operation step BO), and in operation step F2, the pallet P on which the docked vehicle body W is placed is transferred to the pallet transport device Q. , Fasten the screws with stainless steel
3 to advance. Thereafter, the screw tightening work is performed by the robot Q[l, and when this is completed, the transfer device Q, the pallet transport device Q, and the robot Q are moved in operation step F999. The operation command for is reset.

Furthermore, when this F block is completed, the vehicle body W on which the engine 2, the engine 3, etc. have been assembled is transported from the screw-fastened stainless steel engine S3 to the next process by the pallet transport device Q, and then transferred to the docking station S. The pallet P for the next cycle is set in , and returns to the initial state.

Furthermore, in this embodiment, the assembly apparatus 1 is provided with a failure diagnosis apparatus for monitoring whether or not the apparatus 1 is operating normally and for searching for a failure location when a failure occurs. Then, as shown in FIG. 6, a flowchart represented by the above-mentioned operation blocks is displayed on the screen of the display device 8 attached to this fault diagnosis device.
The entire operating system of the assembly device 1 can be viewed on a monitor screen. On this monitor screen, blocks before execution are colorless, and blocks that have been executed are displayed in a predetermined color. Also, the block being executed is displayed blinking. Furthermore, if a failure occurs in the operating system of the assembly device 1, the monitor screen of the display device 8 is switched, and as shown in FIG. A flowchart of a series of operational steps constituting the system, a ladder diagram of failure locations, and a comment table showing the names of each contact on this ladder diagram can be displayed simultaneously on a single screen.

Furthermore, in this embodiment, transitions between execution blocks and execution steps in the fault diagnosis program are sequentially executed by a step counter built into the fault diagnosis apparatus, and furthermore, the step counter for each block is , are provided with storage means for storing timer values of "0" and "999", respectively.

That is, each operation step basically involves an internal coil Mi of the ink clock section that is turned ON when the conditions for executing the operation step are met, as shown in FIG.
and an internal coil Msi that turns on when there is an operation command.
and an external coil Yi that is turned on and outputs to the outside when both internal coils Mi and Msi are turned on.

A step counter Cs that counts a number (register number) representing the execution order of each operation step is connected to the internal coil Msi. When both Mi are turned on, the count value is incremented. Therefore, by monitoring the count value of this step counter Cs, it is possible to know which part of the program is being executed.

In other words, the operating state of the assembling device 1 can be monitored and failure diagnosis can be performed only through the step counter Cs. It does not affect the diagnostic program and can reduce the effort required when changing the system.

The step counter Cs is provided for each operation block, and is incremented by l each time one operation step in each block is completed, and is incremented by l each time one operation step in each block is completed. It is set to start.

In addition, the timer circuit Ct provided for each block calculates the time from when the operation command for the block is set (register number 0) until it is reset (register number 999) for each operation block, that is, the time from when the operation command for the block is reset (register number 999). The operation time from the start to the completion of the operation in the block is measured, and by comparing this measured operation time with the reference operation time for the block, the presence or absence of an abnormality in each block is diagnosed.

Furthermore, in this embodiment, the presence or absence of an abnormality in the device 1 is diagnosed by measuring the cycle time of the entire operating system of the assembly device 1 and comparing this measured cycle time with a reference cycle time. There is.

In this embodiment, when setting the reference operation time for each block, the learning function updates the reference value each time the time is measured.

That is, for example, to explain the measurement of the operation time of a certain operation block, before the operation of the assembly device 1,
The average value T of the operation time of the block is determined by performing trial operation a predetermined number of times (for example, about 100 times). and standard deviation value σ. and calculate this average value T. is the reference operating time in the first cycle of startup. Note that during the calculation of the reference operation time T0, if the measured operation time t exceeds T+3σ with respect to the reference operation time T and standard deviation value σ at that time, it is excluded from the calculation target as an abnormal value.

Then, when the operation block is executed in the first cycle, the measured operation time 1 at this time is added to the data, and a new average value (reference operation time) T and standard deviation value σ1 are calculated. Ru. A similar calculation is performed every time the cycle of the introduction device 1 is repeated, and when the n-th cycle is completed, a new reference operating time Tn and standard deviation value σn for the n-thousand-1st cycle are obtained. Then, the measured operation time in the (n+1)th cycle is compared with the reference operation time Tn, and if it falls within the range of Tn+3σn, it is diagnosed as normal, and if it exceeds this, it is diagnosed as abnormal.

In addition, when an abnormality is diagnosed, if the operation of the assembly R1 as a whole is normal, only the fact that an abnormality has occurred in the block is recorded, and no alarm of device abnormality is issued. Also,
The measured values in this case are excluded from calculation targets for calculating the reference operating time and standard deviation value in the next cycle.

As described above, by using the learning function to set the standard operation time, even if the operation time of individual output elements changes over time due to long-term use, the measured operation time of each operation block due to this change over time It is possible to prevent erroneous detection in which the operation of the assembly apparatus l as a whole is diagnosed as abnormal due to a change in . Additionally, when setting a fixed standard operating time, in order to maintain the accuracy of the set value,
It is necessary to collect data by repeating trial operation many times (for example, about 1000 times) before operation. In this embodiment, the reference value is updated by taking in the measured values for each cycle as data while excluding abnormal values.
By repeating the cycle, the accuracy of the reference value can be improved, and the number of trial runs for initially setting the reference value can be significantly reduced.

Hereinafter, a method of diagnosing the failure of the assembly apparatus (2) using the above-mentioned failure diagnosis apparatus will be explained with reference to the flowchart shown in FIG.

In addition, before starting the system, as an initial setting,
Each contact and device on the ladder diagram is assigned to the contact state monitoring memory of the microcomputer built into the fault diagnosis device, and the output coil Yi corresponding to the internal coil Mi of the interlock section at each operation step is It is registered in memory, and a comparison map between the step counter and the output coil is created.

When the system is started, in step #1, monitoring of the cycle time of the assembling device 1 and the operation time of each operation block is started, and at the same time, in step #2, the assembling device 1 is displayed on the monitor screen of the display device 8. A flowchart of the entire operating system is displayed (see FIG. 6). Next, in step #3, the presence or absence of an abnormality in the entire operating system is diagnosed, and if there is no abnormality (NO), the monitoring in step #l is continued. In addition, in the diagnosis of step #3 above, an abnormality is diagnosed only when the measured cycle time of the assembly device l exceeds the reference cycle time by a predetermined value (+3σ), and in other cases, even if each block Even if an abnormality is detected during the operating time of the device, it is not determined that the device is abnormal, and no alarm is issued.

If the diagnosis result in step #3 is YES, in step #4, each block is diagnosed for the presence or absence of an abnormality, and the block in which the abnormality has occurred is identified. In this embodiment, a block whose operation has not been completed even though the measured cycle time is longer than the reference cycle time by a predetermined value or more, that is, the register number of the operation step in the block is O (ready state). ) or a block indicating a number other than 999 (completed status). Incidentally, simultaneously with step #4, the monitor screen of the display device 8 is switched to a four-split screen (see FIG. 7) in step #5.

Next, in step #6, the presence or absence of an abnormality is diagnosed for each operational step in the abnormal block, and the operational step in which the abnormality occurs is identified.

In this embodiment, the faulty operation step can be easily identified from the current value of the execution step number of the abnormal block displayed on the step counter Cs. Incidentally, this faulty operation step and the abnormal block are highlighted in a predetermined color on a monitor screen that is divided into four parts or allocated to a four-page screen. Then, in step #7, the output coil Yi on the ladder diagram corresponding to this faulty operation step is identified.

After the output coil Yi is specified, in step #8,
Specifically, a search for a faulty contact is performed to find out which contact on the ladder diagram is faulty.

This search for faulty contacts can be performed by sequentially checking each contact on the ladder diagram corresponding to the faulty operation step according to the ladder diagram, but more preferably, the position of each contact on the ladder diagram is Addresses are displayed using predetermined symbols, and based on the displayed addresses, each of the above contacts is allocated on the memory of the microcomputer built into the failure diagnosis device to create an address map, and this address map is sequentially followed. You can automatically search for faulty contacts by going to

The fault location searched as described above is highlighted in a predetermined color on the monitor screen of the display device 8 (
Step #9). Then, the worker performs the restoration work on the failed part, and in step #lO, it is confirmed whether the restoration work has been completed or not. If the answer is No, the restoration work continues, and if the answer is YES, the restoration work is continued. In step #l1, it is checked whether the output coil Yi of the failure operation step is ONL in response to the completion of the restoration work.

If the result of this step #ll is No, the recovery of the failure location has not been completed, and each step from step #8 onward is repeated. And step #1
If the result of step 1 is YES, the process returns to step #l and normal monitoring is resumed.

As explained above, according to this embodiment, the assembly device 1
Since the presence or absence of an abnormality in the overall operation is diagnosed based on cycle time, it is possible to prevent false detections caused by abnormalities in individual operation blocks and operation steps that do not affect the operation of the device as a whole. can.

In addition, in the event that an abnormality occurs in the assembly device 1, the step counter provided for each block will easily detect the block in which the abnormality has occurred, and quickly and accurately trace the operation step that caused the abnormality. can be detected.

The above-mentioned embodiment (hereinafter referred to as the first embodiment) is an assembly device for assembling suspension parts such as suspension and an engine to a car body! However, the method of the present invention is applicable not only to the above-mentioned assembly device 1 but also to other devices, equipment,
Furthermore, it can also be applied to fault diagnosis for the entire production line.

Hereinafter, a case will be explained in which the second embodiment of the method of the present invention is applied to, for example, a method for fault diagnosis and fault location identification of the entire production line of an automobile assembly factory.As shown in FIG. An automobile assembly line has two trim zones, a first and a second trim zone 2.2. , the first and second automation zones Z s , Z , a door-only zone Z, and an adjustment zone Z8. Among these zones, two automation zones Z s , Z s A large number of automatic assembly devices are arranged in a loop to automate almost all processes, and in the remaining four zones,
Assembling is mainly done manually by workers.

In the above-mentioned first trim zone Z1, after the painting process has been completed, the vehicle bodies that have been brought to the assembly line L are subjected to initial work such as the installation of outer wire harnesses, antenna feeder wires, top ceilings, brake pedals, and reserve tanks. 1. Assembly work that should be performed before automatic assembly work in automation zone Z3 is performed. In this first trim zone Z1, the door is removed from the car body that was brought in with the door attached, and the removed door is moved to the door-only zone Z2 where only the trimming of the door is carried out. Sent.

The vehicle body that has completed the assembly process in the first trim zone Z1 is processed by various automatic assembly machines J1, Jt.・First automation zone Z where Jn is arranged in a predetermined assembly work order
, and work such as assembling functional parts such as the engine and transmission, suspension parts such as the suspension, and the underfloor is automatically performed. Incidentally, the assembly apparatus 1 according to the first embodiment is arranged in this first automation zone Z3.

After completing the assembly process in the first automation zone Z, the vehicle body is sent to the second trim zone Z4, where it undergoes automatic trimming in the second automation zone Z, such as installing the instrument panel, speakers, and assonue tray. The assembly work that should be performed before the assembly work is performed.

In the second automation zone Z, various automatic assembly devices K1, K, . . . are arranged in a predetermined order of assembly operations.
．． Kn... automatically performs tasks such as introducing tires, front/rear windshields, and seats. In addition, doors completed in the door-only zone Z,
It is attached to the vehicle body in this second automation zone Z.

The car that has completed the above assembly work is in the adjustment zone Z.
6, where adjustment work such as adjusting the level difference between the vehicle body and the door when the door is closed is performed, and once this adjustment is completed, it is transported to the tester line (not shown) for the subsequent process. There is.

In the assembly line configured as described above, a failure diagnosis unit is provided for the entire line L, each zone, and each level of assembly equipment in each zone, and when a failure occurs in the entire line L, Failure diagnosis is performed in the order of each zone, each assembly device, each operation block in the operation system of the device, and each operation step within the block.

FIG. 16 is a block diagram schematically showing the hierarchical structure of the vehicle assembly line L and showing the fault diagnosis units for each hierarchy. , a line failure diagnosis unit 01 that performs failure diagnosis for the entire line L, and each zone Z1 to Z.
. A zone fault diagnosis unit Uz, ..., Uz is provided for each zone and performs fault diagnosis for each zone.
and each automatic assembly device J in the first automation zone Z. ,J
t,..., Jn. . . . and each automatic assembly device K,,K, .・・・． Kn. . . . One unit is provided for each assembly device, and one unit for diagnosing the failure of each assembly device U', . . .
Each is provided. The failure diagnosis apparatus according to the first embodiment corresponds to the apparatus failure diagnosis unit U''.

In the line failure diagnosis unit UQ, a vehicle body to be assembled is brought into the first trim zone Z and then moved to the adjustment zone Z. By measuring the time (line IN-00T time) required for the line to be carried out (OUT) and comparing this measured time with a reference time, the presence or absence of a failure in the assembly line as a whole is diagnosed.

In addition, the zone failure diagnosis unit Uz measures the time (zone IN-OUT time) required for the vehicle body to be carried in (IN) to the zone and to be carried out (OUT) to the next process zone, By comparing this measured time with a reference time, the presence or absence of a failure in the zone as a whole is diagnosed. The diagnosis results from each zone failure diagnosis device Uz are input to the line failure diagnosis device Ud, and if an abnormality is found in the entire line L, it is possible to identify which zone has the failure. can do. On the other hand, if the line IN-OUT time is within the standard range, even if the zone IN-OUT time of an individual zone exceeds the standard range, the line is not considered abnormal as a whole, and the line is checked. No warning will be issued.

Further, the device failure diagnosis unit U' measures the cycle time of the device and compares the measured cycle time with a reference cycle time to diagnose whether or not the device is malfunctioning. The diagnosis results from each device failure diagnosis unit Ur are manually input to the zone diagnosis unit Uz of the zone in which each device is included, and if an abnormality is found in that zone, which device has failed? It is possible to identify what is being done. In this case, as long as there is no abnormality in the zone as a whole, no alarm will be issued for the zone if an abnormality is recognized in an individual device.

Furthermore, in the device failure diagnosis unit Uf, as explained in detail in the first embodiment, the operation time of each block in the operation system of the device and the output time of the operation step in each block are measured, respectively, If an abnormality is found in the device, the block and faulty step in which the abnormality occurred can be identified by comparing the measured operation time and measured output time with the respective standard operation time and standard output time. This makes it possible to specifically identify where the failure has occurred in the device.

As described above, according to this embodiment, the line failure diagnosis unit UQ diagnoses whether or not there is a failure in the entire line, and if there is a failure, identifies the zone where the failure has occurred, and The failure diagnosis unit Uz identifies the device in which the failure has occurred. Then, the failure location of the device can be identified by the device failure diagnosis unit Ur.

Also, check whether there is a failure in each layer by checking each IN-OUT
Since the diagnosis is based only on time, it is possible to detect abnormalities caused by the operator rather than due to malfunctions of actuators, machines, equipment, etc.

In addition, in the first embodiment, the main output elements (positioning device Q, transfer device QR, docking device Q3, slide device Q4, pallet transport device Q, and screw When dividing each operation step of the operation to be performed by the tightening robot Q. In other words, it was divided into blocks so as to span each output element (see blocks D, E., and F), but now each block is composed of a group of operation steps for one output element. You can divide it into blocks.

Furthermore, as is well known, a great deal of effort is usually required to create a computer program such as a sequence control program used in a sequence control system. For this reason, automatic creation of computer programs has been considered, but the automatic creation devices that have been proposed so far do not require data input operations, etc. to cause the computer of the device to automatically create a sequence control program. There is a problem in that the proportion of work that relies on human operations is relatively high, making it difficult to sufficiently reduce the number of man-hours required for production.

Below, we will discuss another production line divided into blocks using a different division method from the first embodiment, and a third embodiment that discloses an automatic creation device for a sequence control program that can effectively reduce the number of man-hours required for program creation. explain.

As shown in FIGS. 17 and 18, in the vehicle assembly line according to this embodiment, the body 111 of the vehicle is placed on the cradle 1.
12, control the position of the pedestal +12, and place the pedestal +12 on the pedestal +12.
A positioning station STI for positioning the body Ill on the top and an engine l placed at a predetermined position on the pallet +13! 4. Front suspension assembly (not shown) and rear suspension assembly +15
A docking station ST2 for combining the body 111 with the body III, and a fastening station ST3 for fastening and fixing the engine 1l4, front suspension assembly, and rear suspension assembly 115 combined thereto to the body 111 using screws. ing.

Further, an overhead transfer device 116 for holding and transporting the body Ill is provided between the positioning station ST+ and the docking station ST2, and an overhead transfer device 116 is provided between the dobbing station ST2 and the fastening station ST3. is provided with a pallet conveying device 117 that conveys the pallet 113.

The pedestal 112 in the positioning station ST+ is supposed to move back and forth along the rail 118, and although not shown in the figure, the pedestal 112 is arranged in relation to the pedestal 112 in the positioning station STI. cradle 11
2 in the direction perpendicular to the rail +18 (vehicle width direction) and the direction along the rail 118 (front-rear direction),
Positioning means (BT;
'), a positioning means (BR) for positioning the rear vehicle width direction, and a positioning means (TL) for positioning the rear vehicle width direction,
Lifting reference pins (FL, PR, RL, Rl1) are provided which engage with the front left and right portions and the rear left and right portions of body III to position the body III relative to the pedestal +12.

By using these positioning means and the lifting reference pin, the positioning device in the positioning station 3
19 are configured.

The transfer device 116 includes a guide rail +20 disposed above the positioning station ST1 and the docking station ST2, spanning between the two, and a carrier +21 that moves along the guide rail 120.
A lifting hanger frame 122 is attached to the carrier 121, and the body III is supported by the lifting hanger frame 122. The pallet conveyance device +17 also includes a pair of guide rollers 124L and +24R, each of which is provided with a number of support rollers 123 for receiving the lower surface of the pallet 113. Guide parts 124L and 124R
A pair of transport rails extending parallel to each other! 25L and +25R, each having a pallet locking part 126 that locks the pallet 113, and transport rails +25L and 125, respectively.
A pallet transport platform 127 that moves along R
L and 127R, and pallet transport platforms 127L and I
27R and a near motor mechanism (not shown).

The docking station ST2 includes a pair of left and right front clamp arms 130 that respectively support the struts in the front suspension assembly and the struts 115A in the rear suspension assembly +15 to take an assembly posture when the front suspension assembly and the rear suspension assembly 115 are assembled. and 13OR, and a pair of left and right rear clamp arms 131L and 131R
is provided. Left and right front clamp arms 13 0
L and! 30R has mounting plates 132L and 132, respectively.
The left and right rear clamp arms 131L and +31R are attached to the mounting plates +33L and +33H, respectively, so as to be movable in a direction perpendicular to the transport rails 125L and 125R, and are perpendicular to the transport rails 125L and 125R. It is attached so that it can move forward and backward in the direction, and the left and right front clamp arms 13OL and 13
The mutually opposing tips of 0R and the mutually opposing tips of the left and right rear clamp arms 131L and +31H are struts in the front suspension assembly, but are struts II5 in the rear suspension assembly I15.
It has an engagement ring that engages with A. Then, the mounting plate part l32L is mounted on the fixed base +35L by the arm slide 134L, and the transport rail 125L and I2
It is movable in the direction along 51N, and the mounting plate part l32R
is arm slide 1 34r {fixed base 135R
In contrast, the mounting plate 133L is movable in the direction along the transport rails 125L and 125R, and the mounting plate 133L is fixed to the base +37 by the arm slide 136L. 25L and 125R, and furthermore, the mounting plate portion 133R is connected to the fixed base +37H by the arm slide 136R, and is attached to the transport rail l 2 5
It is movable in directions along L and I25R. Therefore, the left and right front clamp arms 130L and 130R are movable back and forth and left and right with their tips engaged with the struts in the front suspension assembly, and the left and right rear clamp arms 131L and +31R are movable back and forth and left and right when their tips are engaged with the strut I15A in the rear suspension assembly +15, and the left and right front clamp arms 130L and 130
R, arm slides 134L and I34R, left and right rear clamp arms 131L and +31R, and arm slides 136L and 136.1 are docking device 140
is in charge.

Furthermore, the docking station Yon ST2 has a pair of slide rails 141L and +41 installed in a lattice manner extending parallel to the transport rails +25L and 125R, respectively.
11. A movable member 142 and a movable member 1 are configured to slide along a slide rail 141L and a length of 141.
Slide device 1 consisting of a motor 143 etc. that drives 42
45 is provided, and the movable member 142 of this slide device 145 is provided with an engaging means 146 that engages with a movable engine support member (not shown) provided on the Palesot + 13. . Furthermore, two elevating pallet reference pins l47 are provided for positioning the pallet 113 at a predetermined position. The slide device 145 connects engines 1!4. arranged on a pallet l13 to a body II1 supported by an elevating hanger frame l22 in a transfer device +16. When the front suspension suspension assemblies and the rear suspension tie stand II5 are combined, the engaging means 146 is moved back and forth while engaging with the movable engine support member on the pallet +13 positioned by the lifting pallet reference bin +47, As a result, Ennon 11 against Body II1
4 is moved back and forth to avoid the collision between the body Il+ and the engine 114.

The fastening station ST3 includes the Rohot 148A, which is used for tightening screws to fasten the engine +14 and front suspension assembly assembled to the body II1, and the rear suspension assembly assembled to the body 111. Robot 148B was supposed to perform screw tightening work to fasten +15.
Further, the fastening station ST3 is also provided with a plurality of lifting pallet reference pins 147 that position the pallet +13 at a predetermined position.

In the vehicle assembly line as described above, the positioning device 1l9 and the transfer device 1 at the positioning station ST+
16. The docking device +40, the slide device 145, the pallet transport device 117, and the robots 148A and 148B in the fastening station ST3 in the docking station ST2 are controlled by the NOKENS control unit connected to them based on the NOKENS control program. It is considered to be equipment (equipment subject to sequence control) whose operations are subject to non-event control.

The operations performed by each of these units of equipment to be controlled are as follows:
When divided into action blocks defined as units of a series of actions that can be performed independently from start to finish, 12g action blocks 130 to [311 are obtained as shown below.

BO An operation block for positioning the pedestal +12 and the body Il+ thereon by the positioning device +19 (pedestal positioning operation block).

B1 Operation block for preparing for transfer of body II1 by transfer apparatus +16 (transfer apparatus preparation operation block).

B2: Preparation using the docking device 140 to clamp the strut of the front suspension suspension assembly using the left and right front clamp arms 13OL and 130R, and clamping the strut 115A of the rear suspension assembly +15 using the left and right rear clamp arms 131L and 131R. (strut clamp preparation motion block).

83: The body 111 on the pedestal +12, which has been positioned by the u positioning device +19, is placed tS on the lifting hanger frame 122 in the transfer device +16, and the operation block (transfer device receiving operation block).

B4 Movable member +42 by slide device 145
An operation block (slide device preparation operation block) for making preparations for engaging the engagement means 146 provided on the pallet 113 with the movable engine support member on the pallet 113.

B5: Rest using positioning device +19! 12 to the original position (cradle original position return operation block).

A pallet +1 is attached to the body 111 supported by the lifting hanger frame 122 in the B6F multi-loading device 116.
The engine I l =1 placed on 3 and the pallet +1
3, and the left and right front clamp arms 13
An operation block (engine/suspension docking operation block) that combines the front suspension assembly strut clamped by 0L and +30R, and the strut I15A of the suspension suspension assembly +15 that is re-clamped on the left and right rear clamp arms 131L and 131R.

B7: Operation block for returning to the original position by the transfer device 116 (transfer device original position return operation block).

B8: Left and right front clamp arms by docking device 140! Operation block for returning 30L and +3OR and left and right rear clamp arms 131L and 131R to their original positions (clamp arm original position return operation block)
.

B9 Pallet conveying device 1] Activate the linear motor according to 7 and move Ennon 1l4. An operation block (linear motor propulsion block) for transporting the podium 113 on which the front suspension assembly and rear suspension assembly II5 are placed and transports it to the fastening station ST3.

BIO: An operation block (screw tightening operation block) in which the robot 148A performs screw tightening work to fasten the engine + 14 and front suspension assembly assembled to the body 11l.

B11: An operation block (screw tightening action block) in which the robot 148B performs a screw tightening operation for fastening the rear suspension assembly 115 combined with the body I11.

Further, each of the above-mentioned operation blocks BO to Bl1 is divided into a plurality of operation steps each accompanied by an output operation. For example, for the pedestal positioning operation block BO, the 10 operations of BOSO-BOS9 are as follows. Divided into steps.

BOSO + operation step for checking various conditions (row stirring confirmation operation step).

BOSI: An operation step (BF positioning operation step) in which the positioning means BF moves the pedestal I12 and positions the front part of the body II1 in the vehicle width direction.

An operation step (BR positioning operation step) in which the pedestal 112 is moved by the BOS2+positioning means Brt and the rear of the PODII1 is positioned in the vehicle width direction.

BOS3: An operation step (TL positioning operation step) in which the positioning means TL moves the pedestal 112 and positions the body Ill in the direction along the rail Ill8 (front-back direction).

130S4: Operation step in which the lifting reference pin FL engages with the front left side of the body Ill (1?L engagement operation step).

BOS5: Operation step in which the lift reference bin PR engages with the front right side of the body Ill (PR engagement operation step).

BOS6: Operation step in which the lifting reference bin RL engages with the rear left side of the body 11 (RL engagement operation step)
.

BOS? + Elevation reference bin RR is on the rear right 1 of body II+
Operation step of engaging the 1111 section (Rn engagement operation step).

BOS8: Operation step in which the positioning means BF returns to the original position from the state in which the front part of the body III has been positioned in the vehicle width direction (BP original position return operation step).

BOS9: An operation step in which the positioning means BR returns to the original position from the state in which the rear part of the body II+ has been positioned in the vehicle width direction (BR original position return operation step).

Next, we will discuss an automatic sequence control program creation device according to the present embodiment, which creates a sequence control program for performing sequence control on the operations of equipment subject to sequence control on a vehicle assembly line as described above. FIG. 19 shows an example of an apparatus for automatically creating a sequence control program according to this embodiment. This example includes a programming device 150 and a
It is equipped with a heart disk device 151 as an external memory and a printer +52. The programming device 150 is connected to a central processing unit (CPU) +62 . through a bus line 161 . Read only memory (ROM) I 63, random access memory (RAM) 16'l and input/output interface (I/
O interface) I65 is built in, and furthermore,
A cathode ray tube (CRT) +66 for display connected to an I/O interface +65 and a keyboard 167 for inputting data and control codes are provided. Hard disk device 151 and printer 1 as external devices
52 through an I/O interface 165.

In order to create a sequence control program according to such an example, first, the above-mentioned operation blocks BO-Bl1 are converted into an operation block map in which respective attributes are expressed as shown in Table 1. It can be summarized in Table 1
In the operation block map of , "SC-REG" is
Represents a 16-bit register, operating block BO-B
Each time each operation step is executed, the step No. are written down. “F.R.
"OM" represents the immediately preceding action block that becomes the condition for starting the action of the action block, and "TO" indicates that the action is started upon completion of the action of the action block.
Represents an action block immediately following the relevant action block, "clear condition" represents an action block in which the equipment related to the relevant action block returns to its original state, and "equipment"
represents equipment subject to sequence control related to the relevant operation block. The contents of "No." and "SC-REG" are automatically created, and the "block name". “F.R.O.
M “TO”. The contents of "clear condition" and "equipment" are input by operating keyboard +67.

Further, for each of the motion blocks BO to all, a plurality of motion steps therein are summarized into a motion step map in which each attribute is represented.

For example, for operation steps BOSO to BOS9 in the aforementioned operation block BO, first, an input/output map for the positioning device 119 is created as shown in Table 2. In the input/output map of Table 2, "comments" represent the contents of each operation step. “No.” is automatically created and “comment”. “Movement” and “original position”
is human-powered by operating the keyboard +67,
“Output coil device”, confirmation manual contact device”
and “manual input contact device” are automatically set.

Subsequently, by calling "comment" in Table 2, the motion step map is compiled as shown in Table 3. Furthermore, each of motion blocks B1 to Bl+ is also summarized into similar motion steps.

Based on the motion step map for each motion block, multiple types of stylized step ladder patterns corresponding to each motion step are created as shown in Table 3, for example, in FIGS. 20A, B, and C. These are prepared and stored in advance in the hard disk drive 151 to form a database of standardized step ladder patterns.

In this way, a sequence control program is created in the form of a ladder program according to the procedure shown in the flowchart shown in FIG. The formation of such a sequence control program in the form of a ladder program will be described below along with the flowchart shown in FIG.

First, in initial setting, variables m and n are each set to 0 (step PI). Next, keyboard 167
is operated, data on each of the motion blocks BO to B+1 shown in the motion block map of Table 1I and their attributes are input, and the motion blocks as shown in Table 1I are displayed on the CRT 166. A map is created and stored in RAMI 64 (step P2).

Then, in the CPU 162, the conversion program is read out from the ROM 163 and is based on the data of the motion block map stored in the RAM+64. An operational block flowchart as shown in FIG. 22 is formed and stored in the TIAM+64 (step P3
).

After that, the keyboard +67 is operated again, and the data on each of the operation steps [30SO to BOS9 and their attributes] for the operation block BO shown in the operation step map of Table 3 is entered manually, and the CRT+67 is inputted manually.
An operation step map as shown in Table 3 is formed on the CPU 6 and stored in the RAM+64. Subsequently, in the same manner, data regarding each operation step and its attributes of each operation block Bl-Bll is manually inputted to form an operation step map for each operation block Bl-B11, and is stored in RAM+64. The operations are performed sequentially. As a result, a total of 12 motion step maps for each of motion blocks BO to Bll are stored in RAM+64 (step P4).

Next, from the hard disk device 151, among the stylized step ladder patterns, for example, a common step ladder pattern for operation blocks as shown in FIG.
From the operation block flowchart and operation block BO
When the operation step map for the operation block BO is read out by the CPU 162, the start condition SRT in the operation block BO, the related output contact device MA, and the stop condition STP are added to the operation block common step ladder pattern.
Parameters such as related output contact device MS are written, and an element of the operation block co-linked step ladder for operation block BO is created, which is then transferred to the CPU.
162 (steps P5 to P7)
).

Next, from the hard disk device 151, for example, the step ladder pattern shown in FIG.
The output step ladder pattern as shown in
162, and the contents of the operation step BOSO are read out from the RAMI 64 to the CPUI 62 from the operation block flowchart and the operation step map for the operation block BO.
2, according to the program read from the ROM 163, the parameters for the operation step BOSO: confirmation contact device x are added to the output step ladder pattern.
O. Manual contact device XA, output contact device YO
etc. are written, and output contact devices MA and MS, interlock release contact device x 1, etc. are added, and an operation is performed to automatically form an element of the output step ladder corresponding to the operation step BOSO. C.P.
It is stored in a register in UIG2.

Further, from the hard disk device 151, a standardized step ladder pattern, for example, FIG.
The output step ladder pattern as shown in
called by l62, and also from RAM l64,
When the contents of the operation step BOS 1 are read out to the CPUI 62 from the operation block flowchart and the operation step map for the operation block BO, the CPU 1
6 2, according to the program read from the ROM 163, parameters for the operation step BOSI: confirmation contact device XI. Manual contact device xB, output contact device Yl, etc. are written and created, and output contact device M
A and MS, interlock release contact device XI,
A confirmation contact device XO, etc. is added, and an operation is performed in which an output step ladder element corresponding to the operation step BOS 1 is automatically formed, and it is stored in a register in the CPU 1 6 2.

Thereafter, operation step 130 in operation block BO
The output step lag element corresponding to each of S2 to BOS9 is sequentially automatically operated by repeating the same operation as the output step ladder element corresponding to the operation step BOS 1 while increasing the change n by 1. formed, CPU
It is stored in the reno star in I62. As a result, a ladder program for the operation block BO as shown in FIG. 23 is formed (steps P8 to P12).
). Note that after one element of the output step ladder corresponding to the operation step BOS9 is formed, the variable n is returned to 0 (
Step P13).

Then, following the action block BO, the action block B l
- Ladder programs for each of B I I,
In accordance with the motion block flowchart shown in FIG. 22, the variable m is incremented by 1, and the same creation procedure as in the case of the ladder program for the motion block BO is repeated, thereby sequentially forming the motion blocks.

As a result, in the end, the ladder programs for each of the operation blocks BO to Bl+ are sequentially connected, and the equipment to be sequence controlled in the vehicle assembly line as shown in FIGS. 17 and 18 is A no-kense control ladder program for performing sequence control of operations is obtained (steps P14, PI5). The obtained sequence control ladder program is then checked to determine whether or not it is appropriate as a whole. If there is a part that is not appropriate, that part can be corrected. done and made proper (
Stethop PIG. Pl7). Obtained in this way,
Sequence control ladder program is RAM 164
and is printed out by, for example, the printer 152, if necessary.

As is clear from the above description, the automatic sequence control program creation device according to the present embodiment can create a sequence control program used for sequence control of operations to be sequentially performed by each of various pieces of equipment installed on a production line. , the main part of which is automatically formed based on the input of data about each action block and its attributes, and for each action block, the input of data about each action step therein and its attributes. It is possible to obtain a ladder program in which one step ladder element corresponding to an operation step is connected, and therefore, it is possible to effectively reduce the number of steps required to create a sequence control program.

[Brief explanation of the drawing]

Fig. 1 is a schematic configuration diagram showing an example of a production line for explaining the basic concept of action groups, action blocks, and action steps in the present invention, and Fig. 2 shows various actions on the production line in action groups, action blocks, and actions. A flowchart showing steps divided into steps, FIG. 3 is a schematic explanatory diagram of the above operation block with a step counter and a time register, and FIG. 4 shows various operations in the first operation group of the production line in operation blocks and operation steps. FIG. 5 is a flowchart of operation blocks and steps for explaining the operation of the assembly apparatus according to the first embodiment of the present invention, and FIGS. 6 and 7 are the same as those described above. A front view of the monitor screen of the display device according to the first embodiment, FIG. 8 is an explanatory diagram schematically showing the basic configuration of the operation steps, and FIG. Flowchart for explanation, FIG. 10 is a schematic front view showing the overall configuration of the assembly device according to the first embodiment, FIG. 11 is a side view of the vehicle body holding arm of the carrier, and FIG. FIG. 13 is a plan view of the pallet, FIG. 14 is a side view of the pallet, and FIG. 15 is a schematic configuration diagram showing the overall configuration of an automobile assembly line according to a second embodiment of the present invention. , FIG. 16 is a block diagram showing the hierarchical structure of the automobile assembly line and fault diagnosis unit according to the second embodiment, and FIGS. 17 and 18 are diagrams of the sequence control program according to the third embodiment of the present invention. FIG. 19 is a schematic configuration diagram showing an example of a vehicle assembly line in which equipment is installed that performs sequence control of its operations based on a sequence control program created by an automatic creation device, and FIG. 19 is related to the third embodiment described above. A schematic configuration diagram showing an example of an automatic sequence control program creation device, FIG.
FIG. 21 is a diagram for explaining the creation of a sequence control program by an example of the automatic sequence control program creation device according to the embodiment, and FIG. 21 shows sequence control by an example of the automatic sequence control program creation device according to the third embodiment. FIG. 22 is a flowchart showing the procedure for creating a program; FIG. 22 is an operation block flowchart for explaining the creation of a sequence control program by an example of the automatic sequence control program creation device according to the third embodiment; FIG. FIG. 7 is a ladder diagram showing an example of a sequence control program created by an example of an automatic sequence control program creation device according to a third embodiment. 1...Assembling device, A, B, C, D. E. F... Transition block, Cs... Step counter, C (timer circuit,... Automobile assembly line, J l.. J 2,
．． J n, Kl, Kt. Kn...Automatic assembly device, Q.
ll9・Positioning device, Q. , +16...transfer device,
Q3, +4 0...Docking device, Q4, +45
...Slide device, Q5. I17... Pallet transport device, Q. , 148A and 148r3 nenojime robots,
Uf...equipment failure diagnosis unit, UQ...line failure diagnosis unit, Uz...zone failure diagnosis unit,
Z1/1st trim zone, Z, Door exclusive zone, Z1
...First automation zone, Z4...Second trim zone,
ZS...Second automation zone, Zll/Adjustment zone. Figure 1 Figure 3 Figure 2 Figure 4 Figure 8 Figure 9: 190 150 No? 20■

Claims (2)

[Claims] (1) The various operations that the equipment on the production line should perform are
A unit of a series of actions that is performed independently from start to finish under normal conditions is divided into a plurality of action blocks, and each of the plurality of action blocks is divided into a plurality of action steps. Under the classification,
In the above-mentioned equipment that is sequence-controlled to sequentially execute a plurality of operation steps in each of the plurality of operation blocks in a preset order, the operation time for each block from the start to the end of the series of operation steps is and compares the measured operation time with a reference operation time for the block to diagnose the presence or absence of an abnormality for each block, and also provides a storage means for storing the completion of operation of each step for each block,
A method for diagnosing a fault on a production line, characterized in that a faulty block and a faulty step are identified from the contents of the storage means. (2) The various operations that the equipment on the production line should perform are
A series of actions that are performed independently from start to finish under normal conditions is divided into a plurality of action groups, and each of the plurality of action groups is divided into a plurality of action blocks. Under the classification,
In the production line, which is sequence-controlled to sequentially execute a plurality of action blocks in each of the plurality of action groups in a preset order, the operation time for each group from the start to the end of a series of action blocks. and compares the measured operation time with a reference operation time for the group to diagnose the presence or absence of an abnormality for each group, as well as providing a storage means for storing the operation completion of each block for each group,
A method for diagnosing a failure in a production line, characterized in that a failure group and a failure block are identified from the contents of the storage means.