JPH0352006A - Operation controller for production line using unmanned carrier - Google Patents

Abstract

PURPOSE:To indicate misoperation by an operator by stopping all unmanned carriers which travel in a section at a time when a process before operation completion is detected in the section. CONSTITUTION:When an operation completion controller 9 detects the process before operation completion due to misoperation and operation delay among processes in the section, a signal is sent to a travel controller 8 and all the unmanned carriers 1 which travel in the section are stopped at a time at their current positions under the command of the travel controller 8. Consequently, even if the operator himself or herself does not recognize the misoperation such as the forgetful unclamped state of a bolt, the operation completion controller 9 detects the incompletion of operation due to the misoperation or operation delay to stop the unmanned carriers 1 and also indicate the occurrence of the misoperation such as over looking unclamping state to the operator.

Description

[Detailed Description of the Invention] Industrial Application Field This invention uses a plurality of automatic guided vehicles instead of a conveyor, places a workpiece on each automatic guided vehicle, and works while sequentially moving through each process. This invention relates to an operation control device for a production line using automatic guided vehicles.

Conventional technologyIn automobile manufacturing factories, instead of assembly lines in which various parts are assembled on workpieces transported by conveyors, workpieces are loaded onto multiple automatic guided vehicles, and the workpieces are transported. Assembling line systems for assembling parts are increasingly being adopted.

For example, in this type of assembly line system shown in Japanese Patent Application No. 1-95179, a plurality of autonomous guided vehicles that travel independently are connected to guide lines laid along the travel route of the assembly line. The assembly line replaces the conventional conveyor line by moving at a constant speed at a constant distance along the automatic guided vehicle, and processing and assembling the workpieces mounted on the moving automatic guided vehicle. It is being considered to do so.

In the conventional assembly line system using automated guided vehicles, workers in charge of each process assemble parts and tighten bolts for the workpieces that are loaded and transported on each automated guided vehicle. Alternatively, various tasks such as quality checks are performed, but for example, if a worker forgets to tighten a bolt, and the worker realizes that he/she forgot to tighten this bolt, the The automatic guided vehicle was stopped by pressing the stop button, and while it was stopped, the driver tightened the bolts that had been forgotten, and after the work was completed, the automatic guided vehicle was restarted by releasing the stop button. .

Problems to be Solved by the Invention However, in the conventional assembly line system using the above-mentioned automatic guided vehicle, workers often do not realize that they have forgotten to tighten a bolt, for example. , workpieces with problems such as forgetting to tighten bolts, etc.
As a result, the quality of the assembly deteriorates due to forgetting to assemble parts, forget to tighten bolts, forget to check quality, etc. When these operational errors are discovered in a process, it becomes necessary to take countermeasures such as rework, resulting in a problem of reduced productivity.

This invention was made in view of the above circumstances, and it reliably detects the occurrence of work errors such as forgetting to tighten bolts in each process, stops the automatic guided vehicle, and notifies the worker of the occurrence of work mistakes. The purpose of this invention is to provide an operation control device for a production line using an automatic guided vehicle.

Means for Solving the Problems In order to achieve the above object, the production line operation control W device using an automatic guided vehicle according to the present invention provides a production line operation control W device that uses an automatic guided vehicle to A plurality of automated guided vehicles that are guided by guide lines laid on the travel route of the section are driven at a constant speed with a constant inter-vehicle distance corresponding to the distance between each process, and all of the vehicles traveling within this section are A travel control tg+i system that controls the automatic guided vehicles to stop and start all at once, and determines whether the work of each process in the section is completed when each automatic guided vehicle has traveled a certain distance. In addition, when even one unfinished process is detected within the section, an @ sign is sent to the traveling device so that all automatic guided vehicles traveling within this section stop at the same time. It is characterized by having a work completion pipe Nl@ position which is controlled by the work completion pipe Nl@.

Effect By configuring as described above, the plurality of automatic guided vehicles each carrying a workpiece are controlled to travel 11jlJIIlvt@ and maintain a constant inter-vehicle distance when traveling within at least a certain section of the production line. The robot then travels at a constant speed, moves sequentially through each process within this section, and assembles parts to the workpieces mounted on each process. Then, when each automatic guided vehicle traveling at a constant speed at equal intervals has traveled a certain distance, for example, a distance corresponding to the interval between adjacent processes, work completion management vi. Depending on the location, a check is made to see if the work in each process within the section has been completed, and if the work has been completed in all processes within the section, each automatic guided vehicle will continue without stopping. , respectively move to the next process.

If the work completion management device detects that there is an uncompleted process among the processes in the section due to a work error or work delay, the
A signal is sent to the device, and all the automated guided vehicles traveling within that section stop at the same time according to a command from the travel control device. Then, the worker performs the work that he/she forgot to do on the workpiece placed on the stopped automatic guided vehicle, and when this work is completed, it is confirmed that the work has been completed in all processes within the section. completion! ! Science VR1
1F detects it and activates all the automated guided vehicles within the area again at the same time.

Therefore, even if the worker himself does not notice a work error such as forgetting to tighten a bolt, the work completion management device detects incomplete work due to a work mistake or work delay, stops the automatic guided vehicle, and Notify the operator of any work errors such as forgetting to tighten.

? EXAMPLE Below, the device of the present invention is applied to an operation control device for an automobile engine assembly line.
This will be explained based on the diagram.

The automobile engine assembly line consists of four processes, from AI stage to DI stage. In the three stages A, B, and C, parts are attached to the engine block W one after another, and in the final stage D, the nut runner is installed. Bolts are fastened by NR.

Each of the steps A to D of the automobile engine assembly line is as follows:
They are arranged in a straight line at equal intervals, and A. B. In each of the three processes of C, parts aR1. R2. R3 is installed, and a nut runner NR for bolt tightening is installed in the D process. Then, each process A, 8. A running path for the automatic guided vehicle 1 is provided in a parallel straight line on the front side of C and D, and a guide 11!2 is buried in this running path.

In addition, for each process A, B, C, and D, one worker is assigned to each process. H2. H3 and H4 are arranged &I, and in the A process, the worker port 1 takes out a predetermined part from the parts shelf Rl and assembles it into the engine block W mounted on the automatic guided vehicle 1.
In addition, in the B process, the worker port 2 is also connected to the parts shelf R2.
Predetermined parts are taken out from the engine block W and assembled into the engine block W. Furthermore, in step C, the operator port 3 is connected to the parts shelf R3.
Predetermined parts are taken out and assembled into the engine block W on the automatic guided vehicle 1, and in step D, the operator port 4 tightens the mounting bolts of each part using a nut runner NR.

The automatic guided vehicle 1 also has an I/O display that displays the type of engine block W mounted on it, the type of parts to be attached, etc.
D tag 3 is used for each process A, B. Each parts shelf RI of C. R2.
Each reading device W14 is installed in a position facing each reading device 4 installed near each component shelf R1.R3. R2. R3 is connected to the ID controller 5, and based on the information read from the 10 tags 3 of each automatic guided vehicle 1, each parts shelf R1. R2. The storage location of the part to be installed in the process from among the group of parts stored in R3 is displayed by lighting or flashing an indicator lamp 7 to prevent the operator from making a mistake in selecting the part. (see figure).

In addition, on the guide line 2 that guides the movement of the automatic guided vehicle 1,
Checkpoints 6 are provided at equal intervals at the starting and ending points of each process A to D, which are arranged at equal intervals, and the plurality of automatic guided vehicles 1 that are guided by this guide I12 and run unmanned are , before the first AI, travel is controlled so that the distance between vehicles is the same as the distance between each process, and the vehicle enters the automobile engine assembly line.

The operation of this line, which is made up of a plurality of automatic guided vehicles 1 that travel guided by the guide line 2, is controlled by a travel control device 8 and a work completion management device 9.
The work completion management device 9 determines whether the work in each process A to D has been completed. This judgment is A-
Parts shelf Rl for each process of C. R2. This is performed by the operator's operation on the nut runner NR in the R3 or D process, for example, parts @RI, R2, in each process of A-C. R3
In each case, when a worker takes out a proper part from a parts shelf, a part of the worker's body or the part to be taken out blocks the light incident on the phototube, and the work in that process is carried out. In addition, in the DI process, assuming that the work in this process was performed by the worker operating the nut runner NR and tightening the bolt, a work completion signal for each process is sent to the work completion management @ 9. is sent.

Then, the work completion management device 9 receives and synthesizes the work completion signals from each process, and if all the work in each process has been completed, the traveling $1 JIII device 8
A general completion signal is sent to each automatic guided vehicle 1, and the travel control device @8 that receives the general completion signal
A command to continue driving is issued, and each automatic guided vehicle 1 moves to the next process without stopping. On the other hand, A-D
If even one of the steps in the process is incomplete, the work is completed in J! J! @ Driving system from M9
The general completion signal is not transmitted to the Il device, and therefore, the driving 8N1111 device 8 issues an operation stop command to each automatic guided vehicle 1, and each automatic guided vehicle 1 stops at the checkpoint 6 position. do. Also, like this A
When there is an incomplete process among the processes from ~D, the display panel (not shown) of the work completion management device 9 displays which process of the line is incomplete. It is now possible to do so.

Next, the operation of this embodiment configured as described above will be explained.

The automatic guided vehicle 1 that is guided by the guide line moves the engine 1 lock W just before the automobile engine assembly line fIt. After the vehicle is separated, the distance between the vehicle and the preceding automatic guided vehicle 1 becomes a preset constant distance, that is, A-D.
The engine assembly line is controlled so that the distance is the same as the distance between each process in the engine assembly line.

Each automatic guided vehicle 1 that entered the engine assembly line
First, when the first automatic guided vehicle 1 enters process A, the ID tag 3 provided on this automatic guided vehicle 1 is attached to the part aR+.
The reading device d4 of 11117 reads the information and flashes the lamp 7 indicating where in the part a4 the part to be assembled to the engine block W in the A process is stored. Therefore, the worker 1 who is in charge of the AI process moves the part whose storage position is indicated by the flashing lamp 7 to the part 11Rt.
The engine block W is then assembled into the engine block W mounted on the unmanned transport vehicle 1 that travels within the A process area.

At this time, when the worker H1 takes out a predetermined part from the parts shelf Rl, the part to be taken out or the worker 1-1
When a part of s's body blocks the light entering the phototube,
Detecting that a predetermined part has been taken out.

Then, while moving within the AI processing area, the automatic guided vehicle 1 is equipped with the engine block W whose parts have been assembled.
However, when the process progresses to the boundary with the next eight processes, the completion of process A is checked by a signal from checkpoint 6, and based on the previously detected results, it is determined whether or not the specified part has been taken out from part 11Rt. The lw recognition is performed as a substitute for the Vt recognition of work completion, and since a predetermined part has been taken out from the parts shelf Rl, a work completion signal for process A is sent to the work completion management device 9.

The work is completed when passing checkpoint 6.
The automatic guided vehicle 1 that has been checked 2 enters the B process without stopping at this checkpoint 6.

When the first automated guided vehicle 1 enters the 8th process, the second automated guided vehicle 1 simultaneously enters the AI stage. Then, the first automatic guided vehicle 1 that entered the B process is
As in the case of the process, the [D tag 3 is read with @ position 4, the position of the part to be assembled in the B process on the part 11R2 is clearly indicated by the blinking of the indicator lamp 7, and the operator port 2 is It is detected that a predetermined part has been taken out from the parts shelf R2.

On the other hand, the second automated guided vehicle 1 that has newly entered the AI area is the same as the first automated guided vehicle i1i 1 in the AI area mentioned above.
It operates in the same manner as in the above case, and parts are assembled through the operator port 1.

Then, when the first automatic guided vehicle advances to the boundary between process 8 and process C, the second automatic guided vehicle 1 advances to the boundary between process A and process B, and reaches the position of checkpoint 6. Then, the completion of each work in process A and process B is checked. When it is confirmed that the work in each process has been completed, a work completion signal for AI and a work completion signal for process B are sent to the work completion management system [9, and In the device 9, the work on each engine block W on the two automatic guided vehicles 1 in the engine assembly line has been completed! Once approved,
A comprehensive completion signal is sent from the work completion management device 119 to the traveling control device 8, and the traveling control device 8, which has received this comprehensive completion signal, continues driving the two automatic guided vehicles 1 on the line. The command is sent, and the first automatic guided vehicle 1 goes to process C.
The second automatic guided vehicles 1 each enter the B process, and the third new automatic guided vehicle 1 enters the AI stage.

In the same way, three automatic guided vehicles 1 are installed in process C and process 8.
The process and process A are driven at a constant speed while maintaining a constant distance between vehicles, and while passing through the areas of each process, predetermined parts are assembled, and each process is monitored by work completion management a and 9. Completion of the work was confirmed, and three parts were placed on the engine assembly line.
When it is confirmed that all three automatic guided vehicles 1 have completed their respective tasks and a comprehensive completion signal is sent, the three automatic guided vehicles 1 on the line are sent from the traveling system tIIg station 8. A command to continue driving is sent, and the first automated guided vehicle 1 is D.
In the process, the second automatic guided vehicle 1 enters the C process, the third automatic guided vehicle 1 enters the B process, and a new fourth automatic guided vehicle 1 enters the AI process.

In the three steps A, B, and C, predetermined parts are assembled in the same manner as in each step described above.
In the D process, the bolts are tightened by the nut runner NR while passing through the D process area.

Then, when the four automatic guided vehicles 1 advance to the boundaries on the traveling direction side of each process area A to D, the second automatic guided vehicle 1 advances to the boundaries between CI stage and DI stage, respectively. When the position of checkpoint 6 is reached, the completion of the work in each process is checked. When it is confirmed that the work in each process is completed, A. B. A component assembly work completion signal is sent from each process in C, a bolt tightening work completion signal is sent from process D, and the work completion management system @ 9 sends a signal on top of four automatic guided vehicles 1 in the engine assembly line. When it is confirmed that all the work for each engine block W has been completed, the work completion management device 9 sends a general completion signal to the driving system a equipment @8, and the driving PI that received this general completion signal
The IwJ device 8 sends a command to continue driving to the four automatic guided vehicles 1 on the line, and the second, third, and fourth automatic guided vehicles
Each of the first automatic guided vehicles 1 proceeds to the DI step, the C step, and the B step, and the first automated guided vehicle 1 equipped with the assembled engine block W proceeds to the transfer step. After the engine block W is transferred to the Ill mounting line etc. by a transfer aircraft, the engine block W is transferred in an empty state.
The engine then travels to the loading position, where a new engine block W is transferred by the transfer aircraft, and it enters the A process of the engine assembly line again.

As described above, the plurality of automatic guided vehicles 1 traveling at a constant speed and at a constant inter-vehicle distance sequentially move through each process from A to D on the engine assembly line to assemble parts and bolts. Tightening work, etc. is performed repeatedly.

Also, to explain the case where a work error such as forgetting to assemble occurs, for example, four automatic guided vehicles 1 are
Predetermined work is performed in each process while the vehicle is traveling at a constant speed and a constant inter-vehicle distance in each process area of ~D. Then, when each automatic guided vehicle 1 advances to the boundary of each process area and reaches the check point 6, the completion of each process is checked. As a result, if a part is forgotten to be assembled in process B,
A. C. Work completion signals are transmitted from the three processes D, but not from the B process. Therefore, in the work completion management @@9, as a result of confirming the received completion signal, the work of process B is not completed, so no comprehensive completion signal is sent. Therefore, as a result of not receiving the comprehensive completion signal, the traveling control I1l installation M8 sends an operation stop command to the four automatic guided vehicles 1 on the engine assembly line, and each automatic guided vehicle 1 on the line All vehicles stop at each checkpoint 6 while maintaining a following distance of .

In this way, if a work error such as forgetting to assemble occurs in any of the multiple processes on the engine assembly line, the work is completed! 1. The detection M9 detects the process in which the work error has occurred, displays it on a panel, etc., and notifies each worker or manager on the line of the process in which the work waste has occurred.

When all four automated guided vehicles 1 on the engine assembly line stop at the same time, the work is complete! ! The display panel of the control device 9 quickly identifies the process (Process B) in which work waste has occurred, and the worker in charge of the process (port 2) or line manager, etc. Predetermined parts are assembled to the engine block W on the automatic guided vehicle 1 that is stopped in the process area. At this time, when the automatic guided vehicle 1 is stopped, the light 714 detects that a predetermined part is taken out from the part 11R2, so when the assembly work of the corresponding process is completed, the line is started all at once. When done, check J at each checkpoint 6.
3, the completion of each process is checked again, and A-D
A work completion signal is sent to the work completion control device from all processes of A driving continuation command is sent to each automatic guided vehicle 1, and each automatic guided vehicle 1 proceeds to the next step while maintaining a constant inter-vehicle distance.

Effects of the Invention As explained above, the production line operation control device 611 using an automatic guided vehicle of the present invention is installed in a section of a production line that has at least a plurality of work processes, and is installed on the travel route of that section. A plurality of automated guided vehicles are guided along a guide line and run at a constant speed at a fixed inter-vehicle distance corresponding to the distance between each process, and all automated guided vehicles traveling within this section are simultaneously controlled. Stopping and rising all at once vJ'Tj
When each automatic guided vehicle has traveled a certain distance, it is checked whether the work of each process in the section has been completed, and when the automatic guided vehicle is controlled to When an uncompleted process is detected at a location, a signal is sent to the travel control device to control all automatic guided vehicles traveling in this section to stop at the same time. ! ! This system automatically detects the occurrence of unfinished work in even one of the multiple processes on the production line, and all unmanned machines running on that line In order to stop the guided vehicles all at once, a constant inter-vehicle distance between multiple automatic guided vehicles on the line is maintained, and when they are started all at once, transport can be resumed with a fixed inter-vehicle distance.

In addition, checkpoints are set up at the boundaries of each process area on the path of the automatic guided vehicle to check whether the work has been completed in each process, eliminating the need for an assembly inspection process as the final process. In addition to reducing the number of processes and workers, it is possible to remove the assembled parts one by one and go back through several processes to resolve the problem, as in the case where an assembly defect is discovered during the conventional final process inspection. Productivity is improved because there is no need to do this.

Furthermore, forgetting to assemble parts, forgetting to tighten bolts, forgetting to check quality, etc. can be prevented, and the quality of product assembly can be greatly improved.

[Brief explanation of drawings]

Figures 1 to 3 show an embodiment of the operation control device of the present invention. Figure 1 is a block diagram showing control to stop all automatic guided vehicles, and Figure 2 is a block diagram of the engine assembly line. FIG. 3, a block diagram showing the arrangement, is a diagram showing the relationship between the automatic guided vehicle and the parts shelf. 1...Automated guided vehicle, 2...Guidance line, 3...I
D tag, 4...10 tag reader, 5...
ID controller, 6... Checkpoint, 7
...Indication lamp, 8...Driving control 1lI device, 9
... Work completion management device, Ri = R3 ... Parts shelf, NR ... Nut runner, W ... Engine block.

Claims (1)

[Claims] In one section of a production line that has at least a plurality of work processes, a plurality of automated guided vehicles are guided by guide lines laid on the travel route of that section and run at a certain distance corresponding to the distance between each process. A travel control device that controls all automatic guided vehicles traveling at a constant speed with an inter-vehicle distance, stops and starts all at once, and when each automatic guided vehicle has traveled a certain distance. , checks whether the work of each process in the section is completed or not, and when even one uncompleted process is detected in the section, sends a signal to the travel control device, 1. An operation control device for a production line using automatic guided vehicles, comprising a work completion management device that controls all automatic guided vehicles traveling therein to stop all at once.