JPH0467203A - Production control system - Google Patents

Abstract

PURPOSE:To improve the production control efficiency by controlling collectively the machining order data on a machined object and a conversion file by a host controller. CONSTITUTION:A host controllers CNTc sets the machining order to a machined object (a), and this setting information is transmitted to plural lower rank controllers CNTe. A medium rank controller CNTd produces a conversion file in order to set the device type deriving sections for each machining process and transmits the file to the controller CNTc. The CNTc sends the received file to the controller CNTe. The CNTe analyzes the machining instructions given to the machining order for each device type. These analysis results are given to a machining execution means (f) which carries out a prescribed machining operation. Therefore the machining order data on the object (a) and the conversion file are collectively controlled by the controller CNTc. Thus the manhour is reduced against the input or the change of the machining order and the conversion file. Then the production control efficiency is improved.

Description

Detailed Description of the Invention "Industrial Field of Application" The present invention is used, for example, in an automobile production line that produces a mixture of different models, and distributes information on processing contents using a network. This invention relates to a production management system that instructs and executes processing such as welding for each model and number of machines.

"Prior Art" In a production line or the like, processing machines are placed at predetermined positions and perform various processing on workpieces moving along the line. By the way, like a car production line,
When producing different types of cars on the same line, each processing machine must perform processing according to the type of car. Also,
The processing order information must also be converted into a model pattern for processing according to the vehicle model of each processing machine. Furthermore, since the processing order information is miscellaneous and complicated, it is necessary to organize and consolidate the information for each processing machine.

For this reason, operators in conventional machining processes first organize and aggregate machining order information into rank data for each machining process, as shown in the order of the processes in Figure 6. The data is converted into a machine type pattern, the machine type pattern is input into the processing machine, and the workpiece is set in the processing machine based on the ranking data.

These are the first and second conversion processes performed by humans. The ranking data includes model (model year, manufacturing plant, 2-door, 4-door, etc.), derivation (grade), options (sunroof, etc.), rod number (a number assigned to each predetermined number of vehicles), and a predetermined number. It includes numerical values such as the number of machines, and is arranged based on processing order. On the other hand, the processing machine is placed within the production line area, and when the machine model pattern is input by the operator, it creates a code to determine the operation using the conversion table stored internally, and according to this code. Perform processing. This is the third conversion process using (M/C). The code includes the processing jig number and operation pattern, the robot job number (operation pattern, welding condition number, etc.), and the like.

For example, in a processing step of welding a side panel to a floor panel, processing order information is converted into order data for the processing step, further converted into a model pattern, and then input into a processing machine. , Then, based on the ranking data, the side panel that matches the model, derivation, etc. is taken out from the mounting location and set on the jig, while the processing machine creates a code to determine the operation based on the model pattern. Then, weld the necessary parts to the floor panel and assemble the floor panel and side panels.

In addition, when there is a model change of a car model, etc., when a model change of a car model occurs, the content of the work changes, so it is necessary to ask the operator each time. Provide education. Further, when the processing information is changed due to an order from a user, reprocessing, etc., the changed ranking information is transmitted to the processing process each time.

``Problem to be solved by the invention'' However, in such conventional production lines, operators (people) aggregate and convert processing order information for each processing machine placed in the line area. Save,
There were problems in that human errors occurred, production management was inefficient, and even though it was an automated line, the number of man-hours increased.

In addition, the work content of aggregating and converting ranking information changes due to model changes of car models, etc., but in automobile lines that produce different models (because model changes of car models are complicated), The number of man-hours required to train operators each time increases, and the efficiency of production management deteriorates.Furthermore, ranking information is lost due to orders received from users, reprocessing, etc.
Changes are made, but due to factors such as shortening of manufacturing lead times in recent years, ranking information has become more frequently changed. At this time, it is necessary to transmit the changes in the ranking information to each process every time there is a change, which makes the overall production management flow unsmooth and reduces efficiency.

Therefore, the present invention makes it possible to reduce the number of man-hours required for operators, and to realize the construction of an efficient automated line system even when there are changes in conversion work and processing order, thereby increasing the efficiency of production management. The purpose is to provide a production management system.

"Means for Solving the Problems" In order to achieve the above objectives, the production management system according to the present invention:
As the basic conceptual diagram is shown in Figure 1, there is a production line b that transports workpieces a including different types from the input section to the delivery section between processing steps in a predetermined order and in a predetermined number. a higher-level controller C that sets and stores the machining order for each predetermined number of machines, model, derivation, etc. for the workpiece a on b, and distributes information on the machining order using a network; A conversion file is created that divides the processing order information into model derivation classifications for each processing process in production line b, and the conversion file is distributed to the upper controller C. A lower controller e that receives ranking information and a conversion file, converts the processing ranking information into processing instruction information for each processing step based on the conversion file, and gives processing instructions.
is placed within the area of production line b, and executes a predetermined process corresponding to each model derivation in the line order on a predetermined number of workpieces a based on processing instructions from a lower-level controller e. It is characterized by comprising a processing execution means f.

Further, in a preferred embodiment, the intermediate controller d
is characterized in that it has a function that complements the functions of each of the upper controller C and the lower controller e, and further includes the upper and lower controllers eS.
e is characterized by distributing processing instruction information based on a predetermined number of units to the lower-level controller e and processing execution means f by batch communication.

"Operation" In the present invention, the processing order is set and stored for each predetermined number of machines, each model, each derivation, etc. for the workpiece certificate by the upper controller C, and this information is transmitted to multiple lower controllers using a network. It will be distributed to e. In addition, a conversion file is created by the middle-level controller d to classify it into model derivation categories for each machining process, and this conversion file is distributed to the high-level controller C. Further, the conversion file is distributed from the upper controller C to the lower controller e. Then, the lower controller e analyzes the machining instructions for the machining order of each different model, and the machining execution means f
is given, and predetermined processing corresponding to each model, each derivation, etc. is executed.

Therefore, the machining order data and conversion file for the workpiece a are collectively managed by the higher-level controller C, reducing the number of man-hours required for inputting or changing the machining order or conversion file, and improving the efficiency of production management.

"Example" Hereinafter, the present invention will be explained based on the drawings.

2 to 5 are diagrams showing an embodiment of the production management system according to the present invention.

First, the configuration will be explained. FIG. 2 is a schematic configuration diagram showing a network in the welding department of an automobile production line to which the present invention is applied. In this figure, l is a host computer (upper controller) as a processing order file computer, 2C12D, 2E are derivative integrated maintenance computers (middle controllers), 2A, 2B are line area computers (lower controllers), 3
．． 3A is a network. For example, network 3 has a total of 44 nodes, and personal computer network 3A has a total of 6 communication terminals. 4A to 4X are terminal sequencers (processing execution means)
It consists of a welding robot that performs the welding process. 5
is a production line, from the input section to the output section, bodies (workpieces) 6 including different types are placed on transport carts (path shown) and transported in a predetermined order in units of a predetermined number.

The host computer 1 receives, for example, weekly machining rank data from the external computer IA, checks the joints of the machining rank data, stores the data, and distributes the machining rank data to the line area computers 2A and 2B. That is, for each body 6 on the production line 5, a machining order is set and stored for each model derivation, such as every predetermined number of units, and information on the machining order is distributed using the personal computer network 3A. A predetermined number of each body 6 is arranged on the production line 5 in a predetermined order, and the processing details for each body 6 are determined on a weekly basis, for example, and are preloaded from an external computer IA to a host computer L. be done. Further, the information of the host computer 1 is transferred via the personal computer network 3A to 2E, which is one of the derived integrated maintenance computers, in a state of constant communication, thereby backing up the data. That is, 2E, which is one of the derived central maintenance computers, stores data and has an alternative function. In addition, the switch I
O is used to switch to an alternative device.

Also, a derived aggregate maintenance computer 2C.

2D and 2E create a conversion file that divides the processing order information into model derivation classifications for each processing step of the production line 5, and distributes the conversion file to the host computer I.

Further, the converted file distributed to the host computer 1 is backed up at the same level by 2E, which is one of the derivative aggregation maintenance computers that are in constant communication.

That is, the host computer I stores data as a file server function, and 2E, which is one of the derived integrated maintenance computers, stores the data of the host computer I at the same level as an alternative function. Further, among the derived integrated maintenance computers, 2C12D has a function of converting into line area convisitor 2A12 work instruction information. That is, in 2C and 2D of the derived integrated maintenance computers, the line area computer 2
A and 2B are replaced, and after processing order information is distributed from the host computer 1, it satisfies the function as a line area computer. The host computer 1 has a disk drive device 11, a printer 12, a keyboard 13, and a CRT display 14 as attached devices, and the same is true for the other derived integrated maintenance computer 2E (however, the others are not shown).

The information from the derived central maintenance computer 2C12D is once stored in the host computer 1, and then sent to the line area computers 2A, 2 via the network 3A.
These computers receive the machining order information and the conversion file from the host computer 1, convert the machining order information into machining instruction information for each machining process based on the conversion file, and process each body 6. Processing instructions corresponding to processing contents for each different model, each different derivative, etc., are outputted to the sequencers 4A-4X via the network 3. The derived integrated maintenance computer 2C has a disk drive device 21, a printer 22, a keyboard 23, and a CRT display 24 as attached devices, and the same is true for the other derived integrated maintenance computers 2D and line area computers 2A and 2B. (However, others are not shown). Note that 25 is a transceiver for the PC network 3A, and the reference numerals are omitted for other transceivers to avoid complication.

The sequencers 4A to 4X are arranged within the area of the production line 5, and are connected to a line area computer 2A.

Based on the processing instructions from 2B, a predetermined welding process corresponding to each model derivation is performed on a predetermined number of bodies 6 in the order in which they are arranged.

Here, the network of the processing instruction system described above is shown in FIG. 3 in an easy-to-understand manner. In the figure, IA is an external computer that performs information processing such as creating weekly processing ranking data, l is a processing ranking file computer 2C serving as a host combinator l.

2D, 2E are derived aggregation maintenance combinators, 2A
, 2B is a line area computer, 2G is a performance monitor display screen, 2H is a performance data collection controller, 4A~
4X is an M/C controller as a sequencer.

31 to 35 are performance monitor computers, which are placed in, for example, an office, a maintenance department, a planning room, a shipping room, etc.
Display machining results in real time. The performance monitor computer 3I has a main body 41. Printer 42, keyboard 43
and a CRT display 44, and this is the same for the other performance monitor computers (however, the other numbers are omitted). 51 is a line server in the network 4, and 52 is a power supply device.

The information handled by the network 3 includes the following information.

■Processing instructions ■According to the number of machines processed ■Line stop time ■Line tact 2 Processing time per unit number ■Flow between lines Relationship between the cumulative number of machines in the second process and the cumulative number of machines in the next process.

■Line automatic operation signal 2 channels, including manual and abnormal signals.

■Maintenance communication signal ■Engineer communication signal ■Line status signal Next, the operation of this embodiment with the above configuration will be explained.

In the production process that involves welding, first the external computer IA
For example, processing contents (in particular, processing order) for the body 6 are determined and sent to the host computer 1 on a weekly basis, and are loaded into the host computer I in advance. This information is provided for each body 6 on the production line 5.
The processing order is set and supplemented for each predetermined number of machines and each model.
It is distributed to the line area computers 2A, 2B via the personal computer network 3A. In addition, some of the information is
For example, body 6 model (body model name and 4 door,
(2-door type, etc.), derived information (destination distance, destination: cold region, etc.). In addition, the derivation aggregation code for each line and model can be set using the derivation maintenance computer 2C,
This is done by 2D and 2H, and in particular, processing order information is created as a conversion file that divides the production line 5 into model derivation classifications for each processing process, and this conversion file is distributed to the host computer 1 and sent to the host computer as setting data. It is stored in computer I and further distributed to line area computers 2A and 2B.

Next, the line area computers 2A and 2B analyze the machining order information from the host computer 1 using the conversion file, and perform machining corresponding to the machining content for each different*W, for each derivation, for each open item, etc. for each body 6. Instructions are output to sequencers 4A-4X. On the other hand, on the production line 5, bodies 6 including different models are placed on transport vehicles from the input section to the output section, and are transported between processing steps in a predetermined order and in predetermined numbers. .

Then, based on the above processing instructions, sequencers 4A to 4X
Accordingly, a predetermined welding process corresponding to each model, each derivation, etc. is performed on a predetermined number of bodies 6 placed on the production line 5 in the order in which they are arranged.

Fig. 4 shows a specific example of welding process, steps 101-
106 to assemble the rear frame, rear floor panel, front wheel house, front floor, rear floor, and front combination (components: COM
F), inspect the rear floor with 1 Keyaki 107, and proceed with step 1.
At 08.109, the rear floor and front floor were removed.

In step 110, each part assembled so far (rear feed,
In step 111, the floor kelp is assembled.

Next, in step 112, submain general welding (SMGW) processing is performed. Prior to this step, downloading (DL) from the 2nd floor of the factory to the IF is executed in steps 114 to 118. That is, in step 114, the roof is lowered from 2F to IF, in steps 115 and 116, the left and right rear inner panels are respectively lowered, and in step 117.1.
Step 18: Lower the left and right sides of the side panels. Note that in steps 119 and 120, the left and right sides of the pillar inner are lowered respectively. Next, in step 121-, additional welding is performed on the sub-main general welding, and similarly, in step 122, additional welding is performed using a spot welding robot (SR). Next, in step 123, final MIG welding is performed, and if necessary, in step 124, a spot welding supplementary step ('manual supplementary step in case of robot trouble) is executed, and in step 125, doors and the like are attached. Further, in steps 126 to 132, the hood is assembled, the right rear door is assembled, and the left and right fenders are assembled, respectively, or these are performed in parallel with or in advance of the previous step.

FIG. 5 shows the state of each line in the production line 5. Lines 203 to 212 are provided around the management office 201 and maintenance department 202 for each welding process. In the diagram, the black areas are areas where welding is performed automatically, the hatched areas are areas where welding is performed manually, and the white areas are areas where vehicle model change preparation is being performed. be.

Considering the effects of this embodiment, it is as follows.

(1) Processing order data and conversion files for the body 6 are collectively managed by the host computer l, which is a higher-level controller, and the order data is analyzed in the line area computer, so operators can Unlike analyzing machining order data and machining instruction data, the number of man-hours required for analyzing or changing the machining order or instruction data can be reduced, and the efficiency of production management can be improved. In other words, even if there is a change in the processing order or conversion file, it is possible to construct an efficient automated line system.

For example, by storing data such as immediate response to machining order when there is a change in machining order and responsiveness when there is a change in displacement file on the host computer 1, change data can be input. It is simple and reduces the burden on the operator.

(II) Furthermore, in this embodiment, since the processed information is distributed using the network 3.3A, it is possible to improve the reliability of the data receiving equipment and prevent loss and duplication of received data. Furthermore, it is flexible in changing the processing order, always retains only the latest data, ensures data reliability, and has excellent data maintainability. Note that by setting the number of communication lines in the network 3 to an appropriate number, the burden on the network 3 can be reduced.

(1) Also, in this embodiment, the line area computer 2
Data is distributed to sequencers 4A to 4X (processing execution means) by two controllers A and 2B (lower controllers). Therefore, like this, sequencers 4A to 4X
By reducing the data processing burden on the line area computers 2A and 2B (lower controllers) by using a large number of (processing execution means), the data processing speed is increased, and the operations on the sequencers 4A to 4X (processing execution means) are A sex factory is planned.

(ff) Derived aggregate maintenance computer 2E.

Since the 2F has a substitute function for the host computer 1, which is a file server, and performs data backup, data reliability is ensured from this aspect as well. Note that even more reliability can be maintained by ensuring a certain amount of continuity of data communication to the terminal in the event of a file server failure or communication down.

In the above embodiment, welding is performed as the processing for the workpiece, but the application of the present invention is not limited to this, and can also be applied to other processing, such as assembly. Moreover, the workpiece is not limited to the body of a vehicle, but may be other objects.

[Effect Go] According to the present invention, the machining order data and conversion files for the workpiece are collectively managed by a higher-level controller, so it is possible to reduce the man-hours required for changing the machining order and conversion files. In addition, human errors can be prevented and the efficiency of production management can be improved.

[Brief explanation of the drawing]

Fig. 1 is a basic conceptual diagram of the present invention, Figs. 2 to 5 are diagrams showing an embodiment of the production management system according to the present invention, and Fig. 2 is a schematic diagram showing a network in the welding department of the automobile production line. 3 is a diagram showing the network of the processing instruction system, FIG. 4 is a diagram showing the specific process of welding, FIG. 5 is a diagram showing the status of each production line, and FIG. 6 is a diagram showing the network of the processing instruction system. FIG. 2 is a diagram illustrating processing order in a conventional production management system. IA... External host computer...
・Host computer (upper controller), 2C, 2D, 2E... Derived central maintenance computer (middle controller), 2A, 2B... Line area computer (lower controller), 3・・・・・・Network, 3A・・・PC network, 4A~4X・
...Sequencer (processing execution means), 5...
・Production line, 6...Body (workpiece), IO...Switcher, 11.21...Disk drive device, 12.
22.42...Printer, 13.23.43.
...Keyboard, 14.24.44...
CRT display, 25... Transceiver, 31-35... Performance monitor computer, 41
...--Main body, 51... Line server, 52... Power supply device. Figure 1

Claims (3)

[Claims] (1) A production line that transports workpieces, including different types, from the input section to the delivery section in a predetermined order and by a predetermined number of machines; For each model,
A high-level controller that sets and stores the machining order for each derivation, and distributes information on the machining order using the network, and divides the information on the machining order into model derivation classifications for each machining process on the production line. a middle-level controller that creates a conversion file to be processed and distributes the conversion file to a higher-level controller; and a middle-level controller that receives processing order information and the conversion file from the upper-level controller, and transmits the processing order information based on the conversion file. A lower-level controller that converts processing instruction information for each processing step and gives processing instructions, and a lower-level controller that is placed within the production line area and processes a predetermined number of workpieces based on the processing instructions from the lower-level controller. A production management system comprising: processing execution means for executing predetermined processing corresponding to each model derivation in line order. (2) The production management system according to claim 1, wherein the intermediate controller has a function that complements the functions of the upper controller and the lower controller. (3) The production management system according to claim 1, wherein the upper and lower controllers distribute processing instruction information based on a predetermined number of units to the lower controllers and processing execution means by batch communication.