JPH09209149A - Apparatus for managing process stage of continuous strip and method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To execute adequate management while specifying stages in case of the occurrence of abnormality, etc., during the stages by detecting the change in the prescribed event which occurs in the working stage of a blank and storing the events before and after this change. SOLUTION: A map 3000 displays the summary of the errors of a web in management of the working stages for the blanks. Error signals are displayed on this map 3000 in order of the occurrence of the errors. The reversal region 3001 in the map 3000 and the cursor 4001 in the map 4000 are made correspondent. When, for example, the operator selects the specific error code in the map 3000, the line direction corresponding to the error code is displayed in reversal and the bar display 4002 corresponding to the selected error code in the map 4000 is so displayed as to be conspicuous. When the operator selects the specific position 4001 by the cursor on the arbitrary bar display 4002, the error region including this position is displayed in reversal. As a result, the adequate management of the production of the continuous strip is made possible.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and method for manufacturing and managing a continuous body such as a belt-shaped continuous body.

[0002]

2. Description of the Related Art A big difference between so-called single-piece production in which one unit is mass-produced and in the case of producing a strip-shaped long continuous body is that in individual-piece production, it is easy to specify each individual piece. On the other hand, since there is no unit in the continuous body, conventionally, only the processing conditions are managed, or the continuous body is managed in lot units.

Managing the processing conditions means the temperature at the time of processing,
It records atmospheric pressure, humidity, etc., and then verifies those data. In addition, lot management is a continuum 1
It is considered that lots with the same number are numbered to one group, and that lots with the same number are manufactured under the same manufacturing conditions.If a defect is found in a part of a lot, all of the lots have defects. I think that it is occurring.

[0004]

That is, in the conventional control method in the production of a continuous body, it was not possible to know at which position of the continuous body there was a processing defect. Therefore, even in the step of cutting the processed continuous body into individual solids, the continuous body is visually or automatically inspected, and the cutting is performed while eliminating defective portions,
Alternatively, it has been customary to inspect uncut parts in a subsequent process to eliminate defective products.

In the case of manufacturing a strip-shaped continuous body from the conventional manual inspection of defective products and managing it with a computer or the like, an unprecedented data collection method is required. The present invention has been made in view of the above problems, and an object thereof is to provide a manufacturing process control apparatus and method capable of collecting event data before and after an abnormal event occurs. To do.

[0006]

Means for Solving the Problems The above-mentioned problems are solved,
In order to achieve the object, a continuous body manufacturing process management apparatus and method for managing a production process in which a continuous body as a processing material walks through a processing step, according to the present invention, changes a predetermined event occurring in the processing step. It is characterized by detecting, storing various events before and after the change as data, and processing the stored event data.

The various event data collected before and after the change of the predetermined event that occurred in the processing step is closely related to the predetermined event, and therefore the event data appropriately manages the continuum. can do. According to a preferred aspect of the present invention, there are a plurality of processing steps, and event data is stored including an identifier of each processing step. It is possible to manage the occurrence of abnormalities while specifying the machining process.

According to a preferred aspect of the present invention, the storage of the various event data is started with the occurrence of an abnormal event as a trigger. According to a preferred aspect of the present invention, the storage of the various event data is started with the end of the abnormal event as a trigger. According to a preferred aspect of the present invention, the various event data at the time of change of the predetermined event and the processed various events are displayed together. The time of change and past and future event data before and after the change are displayed in parallel.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, a preferred embodiment of the present invention will be described in detail with reference to the accompanying drawings.

<Solar Cell Manufacturing System> FIG. 1 is a block diagram showing an embodiment of a manufacturing process of an amorphous silicon solar cell to which the process control method according to the present invention is applied. In the manufacturing process of the product manufactured in the present embodiment, that is, the solar cell, as shown in FIG. 5, (I) cleaning, (II)
The steps of film formation A, (III) film formation B, (IV) film formation C, and (V) cutting are sequentially performed, and all steps are completed. In each film forming step, (2) Al / ZnO back surface reflection layer by sputtering method,
(3) An n / i / p type amorphous silicon semiconductor layer is formed by the plasma CVD method, and (4) an ITO transparent conductive layer is formed by the sputtering method. Further, in the cutting step (V), the processing material 22 having the three layers formed by the film forming steps 2 to 4 is cut into a fixed length by applying the shearing device 30, and this fixed length slab is mounted later. Through the process, it is completed as a final product.

Referring to FIG. 1, processing devices 12, 14, 16, 18 for each step in the manufacturing apparatus 10 of this embodiment.
Each of them is a process section P for performing actual processing, and a transfer section T for transferring the thin plate-shaped processing material 22 arranged in front of and behind the process section 22 while passing through the process section P.
It is schematically composed of That is, in each of the processing devices 12, 14, 16 and 18 in FIG. 1, the unwinding device 24 for the processing material 22 is arranged first, and after passing through the process part P such as cleaning and film forming, finally, A winding device 26 for the work material 22 is arranged. Specifically, the cleaning device 12
Then, the processing material 22 set in the unwinding device 24 is
After passing through a solvent cleaning tank, a pure water cleaning tank, a vapor replacement tank, and a process section P such as drying, it is wound by a winding device 26. Thus, the transport section T includes the unwinding device 24 and the winding device 26. As a drive system, a forward rotation motor is disposed in the winding device 26, and a reverse rotation motor is disposed in the unwinding device 24, so that a constant tension is maintained.

In the cutting step (V), the roll-shaped workpiece 2
After setting 2, the NC feeder 28 sends out a fixed amount, and the shearing device 30 cuts.

Certain processing equipment (12, 14, 16, 18)
The processing material 22 processed in (1) is conveyed to the next processing device by hand or by a robot (not shown).
That is, the work material 22 wound into a roll by being wound by the winding device 26 of a certain processing device is set manually or by a robot or the like in the unwinding device 24 of the processing device of the next step. Then, the processing material 22 is unwound again from the unwinding device 24 of the processing device of the next step, and the processing of the process in the next step is performed. Therefore, the unwinding rotation direction of the processing material 22 in one processing device and the unwinding rotation direction of the roll in the processing device adjacent thereto are necessarily opposite to each other.
That is, the processing material 22 is processed material 22 at each step.
Start point and end point are reversed.

When the processing material 22 is subjected to a predetermined processing in each of the processing devices 12, 14, 16 and 18, the processed processing material is cut to a fixed length in the final step (V).

As shown in FIG. 2, the winding device 26 of each of the processing devices 12, 14, 16 and 18 is provided with a turn-back rotary roller 33 that rotates in synchronization with the winding of the processing material 22, and is directly connected to this roller 33. The rotary encoder 34 is provided to control the winding speed of the processing material 22 at a constant level, and by counting the pulse signal in the PLC, the winding amount (distance from the origin) of the processing material 22 is measured. Figure out

Here, PLC is an abbreviation for programmable logic controller, and various kinds of control are possible depending on a program. The basic configuration is an INPUT board, a computer unit, an OUTPUT board, a communication module, and the like. Collection of signals and information is performed via the INPUT board or the communication module. In addition, the timing is also at random. The computer unit checks the input status at regular intervals,
According to the corresponding programmed logic, OUTP
A predetermined output operation is performed from a UT board or a communication module, and information is written in a fixed address memory called a register.

<PLC Configuration> Next, FIG. 3 is a diagram showing a PLC connection state of each processing apparatus, and FIG. 4 is a diagram showing the inside of the management computer 36 when some abnormality occurs in the manufacturing apparatus 10. It is a figure showing the flow of information processing.

As shown in FIG. 3, the PL of each processing apparatus is
C is connected to an upper management computer 36.
Also, except for cutting, (I) cleaning, (II) film forming apparatus A, (II
Each of the processing devices of I) the film forming apparatus B and (IV) the film forming apparatus C includes a motion control PLC for controlling the transfer section T and a process control PLC for controlling the process section P.
The stand is connected. PLC for motion control
Mainly handles operations related to the transport system such as running system abnormalities and the amount of material to be wound, and information that the operator inputs to the operation panel at the start of operation. Moreover, the PLC for process control receives an abnormal signal from a sensor or a lower-level control device to monitor the vacuum pressure, the discharge voltage / current, the gas pressure, the temperature, and the like. With respect to these inputs, a register determined for each processing device is prepared and used as an error code for output to the outside. In another register of the PLC, the winding amount of the processing material 22 (rotation amount of the roller 33) is input in parallel with the data input for the above monitoring, and the numerical value is incremented as the processing material is conveyed. And changes.

FIG. 4 shows a processing material identification number (ID = “A940
For the processing material 22 called “11”),
An example of a method of processing the event when the hydrogen gas flow rate decrease in the chamber occurs will be shown. In the case of this example, an alarm signal from the corresponding mass flow controller indicating that the preset lower pressure limit has been exceeded is input to the PLC, and the PLC immediately flags the specific register assigned to the error. These alarm signals and register flags are continuously output until the abnormality is recovered. The upper management computer 36 collects these pieces of information at regular intervals.

The first step of the abnormality processing in FIG.
An abnormality that the flow rate of hydrogen gas in the second chamber of the film forming apparatus B is low (the error code is “M12”), the winding amount (l) of the processing material 22 when the abnormality occurs, and the abnormality is recovered. The winding amount (l ') of the processed material is 1
It is to recognize it as the next data. In addition, the ID number (provisionally A94011) and time of this processing material are also stored in association with each other.

The ID number of the processing material is input by the operator directly to the PLC as the processing material replacement work each time the processing material 22 is mounted on the unwinding device 24 of each processing device, and the information is stored in the management computer 36. Collected in.

<Recognition of abnormal position> PL of each processing device
The winding amount of the processing material 22 recognized by C is the amount of rotation of itself that is detected by the folding rotation roller 33 in the winding device 26 of the processing device (the film forming device B in the example of FIG. 4). The value indicated by this rotation amount merely indicates the position of the part of the material 22 at the position of the roller 33. On the other hand, in each processing device, the unwinding device 24 and the winding device 26
Since there are multiple chambers between
The rotation amount of the roller 33 does not indicate where in these chambers the abnormality has occurred. The second to fourth steps of FIG. 4 describe a method of identifying the position where the abnormality actually occurs (the second chamber in the example of FIGS. 4 and 6) from the rotation amount of the roller 33.

In the management computer 36, the following two unique values corresponding to each abnormality are prepared in advance in the "error code table". One eigenvalue is "deviation"
(Represented by g in this example), which is g
It shows the distance from the (winding amount measurement point) to the tip of the chamber related to the signal that detected the abnormality. In other words, g
Means the distance from the winding amount measurement point to the tip position affected by this abnormality, and in this example, from the point of the folding rotary roller 33 in the winding device 26 of the film forming apparatus B to the tip of the second chamber. It becomes the distance. The other eigenvalue is a quantity (which is represented by the symbol a) indicating the maximum range in which the detected abnormality will have an influence, and is shown in FIGS.
In the above example, the abnormality is a decrease in the flow rate of hydrogen gas, and since all the materials in the second chamber at that time are affected by the abnormality, the second chamber length is a
Becomes

Then, the second step of the abnormality processing (FIG. 4)
Then, the error code table is searched promptly and their eigenvalues are obtained.

The third step of the abnormality processing is to calculate a relative defective position using these primary data (signal indicating abnormality and winding amount) and eigenvalues (g and a). In the example of FIG. 6, the winding amount detected by the roller 33 when the abnormality is first detected (referred to as 1) is the winding amount measured at the position of the roller 33 when the abnormality is first detected. It means the amount of the material 22 wound up by the device 26, and the roller 33 at the time when it is detected that the material 22 has recovered normally.
The winding amount (l ′) of 1 means the amount of the material 22 wound by the winding device 26 up to that point. Therefore, the relative defective position of the processing material A94011 is
In the range of l + g to l ′ + g + a of 94011,
It is represented as secondary data that an error of M12 has occurred.

Generally, when an abnormality is detected in the j-th chamber of the i-th processing apparatus, l is a value unique to the processing apparatus i, and a and g are the processing apparatus i. Is a value peculiar to the specific chamber j of, the defect start position = l _i + g _ij defect end position = l ′ _i + g _ij + a _ij .

The defective position detected in the third step is merely a relative defective position in the processing apparatus. In other words, before the material arrives at the processing device in which the abnormality is detected, the influence of the characteristics of the processing device through which the material (identification code “A94011”) has on the distance calculation is not considered.

The fourth step in FIG. 4 is processing for correcting and converting the relative defective position peculiar to the process in which the abnormality is detected to the absolute defective position peculiar to the processing material. This includes the total length value L for each processing material and the following two elements: (1) Variation b between each process (processing device) of the origin at which the measurement of the winding amount is started, and (2) Odd number In consideration of the difference in the unwinding rotation direction of the processing material 22 between the processing step (steps 1 and 3 in the example of FIG. 1) and the even-numbered processing step (steps 2 and 4 in the example of FIG. 1). .

As can be seen from FIG. 6, the distance b from the end point (absolute value 0) of the processing material 22 to the winding amount measurement origin (position of the roller 33) varies depending on each processing device. This distance b is added as an offset value. Distance b
Is a value peculiar to the processing apparatus i, and is represented as b _i .
Material 2 in odd-numbered steps (steps 1 and 3 in the example of FIG. 1)
The rotation direction of the second processing material 22 is an even-numbered process (see FIG. 1).
In this example, the rotation direction is opposite to the rotation direction in steps 2 and 4). That is,
When a material having a length L is wound and then unwound, the position x from the tip of the material in the winding process is L-x from the tip in the unwinding process in the unwinding process. The position. Therefore, when the winding is reversed, it is necessary to subtract the winding amount of the processing material 22 from the total length L in order to specify the abnormal position. Therefore, it is necessary to consider the rotation direction of (2).

In the management computer 36, the processing material 2
Total length value for each 2 (the length of the material identification number p and L _p)
Then, the offset value (b _{i in} this example) of the winding amount measurement origin for each process is prepared in advance as a table.
When the machining device in which the abnormality has occurred is an even-numbered machining process, the secondary data obtained in the third step is converted as follows.

L _i + g _ij → L _p − (l _i + g _ij + b _i ) l ′ _i + g _ij + a _ij → L _p − (l ′ _i + g _ij + a _ij + b _i ) Therefore, the processing material A94011 is an even number If an abnormal position is detected in the machining process, the defective position converted to the absolute position is “(L _p − (l ′ _i + g of machining material A94011.
_ij + a _ij + b _i )) to (L _p − (l _i + g _ij + b _i )) in the range of M12 error ”.

Finally, in a fifth step, this result is written in the processing result file and the data is saved.

When the processing material 22 finishes the step (IV), the operator checks the integrated result of each processing result data in the management computer 36. Here, a defective discharge area that should not be sent to the mounting process is automatically selected depending on the weight of each abnormality set in advance.

In the final (V) cutting step, it is judged whether or not each slab cut into a regular size includes the defective discharge area of the processing material 22 by using the processing result data in the management computer 36. If the defective discharge area is included, it is automatically sorted out. With these series of systems, only slabs having no problem in quality are sent to the subsequent mounting process, so that it is possible to reduce useless mounting costs or inspection costs.

Although the present system automatically determines the defective material in the final cutting step, the defective portion and the defective data are also displayed for the convenience of the operator. This display will be described later in detail with reference to FIG. XX.

<Change in Effective Length> Next, the change in effective length when the processing material is exchanged between the processing devices will be described.

FIG. 7 is a diagram schematically showing the method of exchanging the processing material in the above-mentioned washing step (I). In the example of FIG. 1, since the cleaning process is the first process, the length of the processing material 22 at this time is L _p . In the cleaning process, the tip of the material of length L _p (set in the unwinding device 24) is sent to the winding device 26 side by semi-automatic feeding, and the leading end is wound around the winding device 26. To be Once wound, the material is sequentially fed to the winding device 26 side while the system controls the unwinding device 24 and the winding device 26 at a predetermined speed. The material 22 is washed in the course of this feeding.

As shown in FIG. 7A, when the cleaning of the processing material 22 progresses and the remaining amount of the processing material roll 32 on the unwinding device 24 side becomes small, it is not shown that the remaining amount becomes small. Is detected by the remaining amount detection device, and the unwinding and winding of the processed material is stopped. This remaining amount detection device is constituted by, for example, a sensor for detecting the thickness of the work material roll 32 and the like.

Next, the operator operates a button or the like that can manually move the unwinding device 24 and the winding device 26 while visually confirming the remaining amount of the work material roll 32 on the unwinding device 24 side. As shown in FIG. 7B, the tip of the processing material 22 is released from the unwinding device 24 by semi-automatic feeding.

Next, as shown in FIG. 7 (c), the operator mounts a new processing material roll 32 'on the unwinding device 24, and the tip of this new processing material roll 32' and the processing material 22. The trailing end is welded at 34. at this point,

Next, as shown in FIG. 7D, the operator semi-automatically feeds the workpiece 2 while visually confirming it again.
2 to move the welding portion 34 to the winding device 26 side. Then, as shown in FIG. 7E, the work material 22 is cut at the position of the welding portion 34.

Thereafter, as shown in FIG. 7 (f), the operator removes the processing material roll 36 wound on the winding device 26 side from the winding device 26 and ends the new processing material roll 32 '. Is manually wound on the winding device 26.

With the above, the replacement of the work material roll in the cleaning step (I) is completed. In addition, in this cleaning process,
The total length of the processing material 22 is measured by the number of rotations of the rotary encoder 34 directly connected to the folding rotation roller 33 described above.

Next, a method of exchanging the processing material in each of the above-mentioned film forming A step (II) to film forming C step (IV) will be described. FIG. 8 is a diagram schematically showing a method of exchanging the processing material in the film formation A step (II) to the film formation C step (IV). Since the method of exchanging the processing material in the steps (II) to (IV) is the same, the method of exchanging the processing material in the step A of the film formation of (II), that is, the unwinding device 24
A method of sending the material 22 from the winding device 26 to the winding device 26 and exchanging the wound material in the winding device 26 will be described as a representative thereof.

In the film forming process A, since the film forming process is performed in a vacuum, the unwinding device 24, the processing device (process section) P, and the winding device 26 are placed in the vacuum chambers 36, 38 and 40, respectively. It is stored. In a state where the film forming process is being performed, the respective vacuum chambers 36,
All 38 and 40 are in a vacuum state by sucking air. On the other hand, since the material rolls in the unwinding device and the winding device are manually replaced, it is necessary to release at least the chambers 36 and 40 to the atmospheric pressure side at the time of replacement. Further, since the material in the chamber 36 is before the film forming process, there is no problem even if it is opened to the atmosphere. Further, since the material 22 in the chamber 40 has been subjected to the film forming process, there is no problem even if it is opened to the atmosphere. On the other hand, the film forming process is performed by the processing device P
In order for the material to move in the process,
Opening the chamber 38 to the atmosphere, even when the rolls are replaced, causes the film formation on the material actually remaining in the chamber 38 to become defective. That is, the material actually remaining in the chamber 38 becomes a defective portion, and the film forming process B
There is no point in performing processing in. The exchange method of the embodiment shown in FIG. 8 is devised so that defective portions of film formation do not occur as much as possible in the roll exchange process, and further, the exchange operation is completed in a short time.

First, as shown in FIG. 8 (a), when the processing of the processing material 22 progresses and the remaining amount of the processing material roll 32 on the unwinding device 24 side becomes small, the remaining amount becomes small. The remaining amount detection device (not shown) detects and the unwinding and winding of the processing material is stopped. This remaining amount detecting device is, for example, the same as in the cleaning process, for example, the processing material roll
2 is composed of a sensor or the like for detecting the thickness.

Next, as shown in FIG. 8B, the operator uses the vacuum chamber 38 in which the processing apparatus P is housed.
Are closed, the pinch valves 42 and 44 arranged at both ends. In this state, the vacuum chamber 38 is in an airtight state and a vacuum is maintained, and the portions of the processing material 22 on both sides of the processing apparatus P are sandwiched between the pinch valves 42 and 44 and are immovable. And the unwinding device 2
Only the vacuum chambers 36 and 40 in which 4 and the winding device 26 are housed are opened to the atmosphere to release the vacuum state.

Next, as shown in FIG. 8 (c), the operator positions the portions of the processing material 22 on both sides of the processing apparatus P at position 1.
Cut at 00 and 101. This cutting allows the roll to be removed by both the unwinding device 24 and the winding device 26.

Next, as shown in FIG. 8D, the operator removes the processed material roll 46 on the winding device 26 side, which has been processed, from the winding device 26. The removed material roll 46 moves to the processing apparatus B in order to perform the film forming process B. Further, the operator removes the slightly remaining unprocessed raw material roll 32 on the unwinding device 24 side, and mounts the removed roll 32 on the winding device 26. Further, the operator mounts a new processing material roll 32 ′ (this roll 32 ′ is a roll that has just been washed in the washing process) on the unwinding device 24. Then, as shown in FIG. 8 (d), the front end of a new work material roll 32 'is welded to the rear end of the work material 22 sandwiched between the pinch valves 42 and 44, and Welds the tip of the work material roll 32 mounted on the winding device 26. Thus, a new work material roll 32 'can be wound.

Assuming that the length of the material remaining on the roll of the unwinding device 24 at the time of FIG. 8C is q, the material of this length q is moved to the winding device 26 side as it is. The film forming process A is not performed. In other words,
The portion having the length q moved to the winding device side in FIG. 8D is processed as the offset b described and described with reference to FIG. 6.

In the example of FIG. 8, the work material roll 3 left on the winding device 26 side remains on the winding device 24 side in this example.
Although No. 2 is mounted, this is for effectively utilizing the waste material, and another roll in which a small amount of the processing material is wound may be prepared and mounted on the winding device 26.

Next, air is sucked from the vacuum chambers 36 and 40 in which the unwinding device 24 and the winding device 26 are housed, and the vacuum chambers 36 and 40 are brought into a vacuum state again.
Thereby, the roll 3 set in the unwinding device 24
2'material can be newly processed. In this case, the material 2 left in the chamber 38 during the roll replacement
No. 2 is not wasted because the film forming process A is completed and the film is wound around the winding 26 side.

If the processing in the second processing step affects the processing content due to the length of the processing time, the material 22 in the chamber 38 must be processed as an unfinished portion. Vacuum chamber 36,40
The roll can be exchanged as long as it has a capacity for accommodating the unwinding device 24 and the winding device 26. In other words, the vacuum chambers 36, 40 may have a relatively small volume, and therefore, after the rolls are exchanged, it takes a short time to make the vacuum again. Vacuum chamber 3
When 6 and 40 become vacuum, pinch valves 42 and 44
Is opened to bring the vacuum chambers 36, 38 and 40 into communication with each other. At this point, the processing material 22 is the pinch valve 4
Since the constraint by 2,44 is released, it can be freely transported, and the processing by the processing apparatus P is restarted.

That is, if the material roll is exchanged by the above method, the vacuum chamber 3 having a large volume can be obtained.
Since the processing materials can be exchanged while maintaining the vacuum state of No. 8, it is possible to shorten the time until the vacuum of the entire vacuum chambers 36, 38, 40 is restored, and to shorten the downtime of the manufacturing equipment. Become. Further, in the example of FIG. 8, the number of chambers for the film forming process is one, but this method of exchanging the rolls can be similarly applied even when there are a plurality of chambers.

Next, in FIG. 9 to FIG. 13, the above-mentioned method of exchanging the processing material is performed by the four processing steps (cleaning, film formation A, film formation B, film formation C) shown in FIG. It is the figure which showed the gap of the origin of the processing material which arises in each case, and the relationship of the total length value. 9 shows the cleaning step, FIG. 10 shows the film formation A, and FIG.
1 shows the film formation B, and FIG. 12 shows the film formation C.

Cleaning Process First, the relationship between the origin position and the total length value in the cleaning process (I) will be described with reference to FIGS. 9 and 13A.

In the washing process, the processing material roll 32 is
After being set in the unwinding device 24, the tip (origin O) is unwound by hand and wound around the winding device 26 as shown in FIG. 9A. As described above, the roller 33 (see FIG. 2) is provided on the winding device 26 side, and the length of the material 22 that has passed through this roller can be measured at that position (M _{1 in} FIG. 9). It is possible. Therefore, when the tip end of the material roll 32 is manually wound around the winding device 26 side, the roller 33 is wound from the tip end thereof.
The distance to the position (point M ₁ ) is defined as the “winding length”, which is indicated by WT. Assuming that the distance of the material 22 passing through the roller 33 detected by the tachometer of the roller 33 is WM, the processing from the position M1 deviated from the origin O (the tip of the roll) by WT by the detection of the rotation amount of the roller 33 The effective roll length WM of the material 22 can be measured. As shown in (a) of FIG. 13, the material portion located at a distance WM from the material portion located at the distance WT from the tip of the roll of the winding device 26 has been cleaned.

The end point of the processing material 32 on the unwinding device 24 side is L point (the coordinate from this origin O is L).
And

Then, the cleaning proceeds, and when the remaining amount of the work material roll 32 on the unwinding device 24 side becomes small as shown in FIG. 9B, the cleaning is stopped. At this point, processing material 2
The measurement of the effective roll length WM (t _x ) of 2 is completed. Therefore, at this point, WT + W
The processing material 22 having a length of M (t _x ) is wound up.
Here, the length of the processing material remaining in the cleaning device at the time when the winding is stopped (time t _x ) is defined as the cleaning inline length WI, and the length of the processing material remaining on the unwinding device side is set. Assuming the remaining cleaning length WR, L = WT + WM + WI + WR holds for the entire length of the roll of the work material 22, that is, the coordinate position of the tip point L from the origin O. Here, since the shape of the cleaning device is known, WI and WR are known values.

After this, the operator visually moves the workpiece 22 to the position 34 by semi-automatic feeding to the position shown in FIG. 9C. Then, a new processing material roll 32 'is set on the unwinding device 24 side, and the original processing material 2
The tip point L of 2 and the tip point O ′ of the new work material roll 32 ′ are welded as shown in FIG. 9D.

Next, as shown in FIG. 9 (e), the processing material 2
2 is moved by semi-automatic feeding, and the tip point (coordinate position is L) of the new processing material 22 is moved to the winding device 26 side.
Then, as shown in FIG. 9 (f), the processing material 22 is cut at the joint between the point L and the point O '. With this, in the winding device 26, the cleaned material roll can be removed. Here, the roll 36 wound around the winding device 26 has a length of L, of which 0 to WT: winding length WT to WT + WM (t): washed portion WT + WM (t) to WT + WM (t ) + WI: inline length WT + WM (t) + WI to WT + WM (t) + WI + W
R: Remaining length.

The cleaning process of the work material roll 32 is completed as described above. Then, in this cleaning step, although cutting and welding are performed, as can be seen from the above description, the length of the roll 32 when the unwinding device 24 is attached and the length of the roll 32 wound around the rotary hook 26 as the roll 36. There is no change in the length when taken, and it is L.

Film Forming A Process Next, referring to FIGS. 10 and 13B, the film forming A of (II)
The relationship between the origin position and the total length value in the process will be described.

In FIG. 10A, the film forming step A is finished for a certain roll 36 ", and the processing material 2 for the roll 36" is finished.
2 shows a state in which the roll 2 is wound around the winding device 26 as a roll 50 ′. At this point, as shown in FIG. 10A, the work material roll 36 ″ having the remaining length AR is left on the unwinding device 24 side in the film forming A step. The processing material roll 50 ′ for which the film formation A has been completed is left on the apparatus 26 side.
The processing material 22 having the length of the in-line length AI is left. On the unwinding device 24 side, the material 22 is cut at a position of a length AR from the end point of the roll 36 ″, and at the winding device 26, the material 22 is also cut at the position of a roller 33 (not shown in FIG. 10A). If cut, the roll 50 'on which the film A has been formed can be removed.

In this state, operations required for processing the next roll will be described. As shown in FIG. 10 (b), the work material roll 36 ″ left on the unwinding device 24 side is mounted on the winding device 26 side. The processing material roll 36 is mounted on the unwinding device 24. Then, the processing material roll 36 and the processing material 22 in the film forming device (this is the last one
The rear end of the work material roll 36 ″ and the front end M2 of the work material 22 are welded together with the rear end of the work material 22). The total length of 22 is L + AI + AR, of which length L: the material from the cleaning step, length AI + AR: the remaining portion of the previous roll (deposition A has not been performed). 10 (b), the origin is set at the rear end of the roll 36 of the unwinding device 24. Then, the roll 36 of the unwinding device 24 and the roll of the winding device 26 are set. For all the materials including 36 ", the coordinate position of the leading end point (the head of the roll 36", which is indicated by a black star in FIG. 12B) is L + AI + AR.

The measurement of the effective roll length AM of the processing material whose total length is L + AI + AR is started from point M2.

The processing of the film formation A is performed in the process of winding the processing material 22 on the winding device 26 side. Finally Figure 1
As shown in 0 (c), when the remaining amount of the processing material roll 36 becomes small, the processing unit in the film formation A process is stopped.

Next, as shown in FIG. 10D, the front and rear of the processing material 22 in the film forming apparatus are cut. At the time of cutting, the processing material roll 3 on the unwinding device 24 side
The remaining length of 6 is AR, as in the case of FIG. 10A, and the in-line length of the material 22 remaining in the processing device is AI. Therefore, at the time point after the cutting, the coordinates from when the origin point (indicated by a black star) of the processing material roll 50 wound on the winding device 26 side is the origin is L + AI + AR, and End point (indicated by white star in FIG. 10 (d))
The coordinates are AI + AR. This state is shown in FIG.

In the series of processes shown in FIGS. 10A to 10D, since AI and AR are unchanged, as long as the roll having the length L is supplied from the cleaning side, the film forming A apparatus is used. The length of the roll fed to the Membrane B device is always L.

Film Forming Process B Next, the relationship between the origin position and the total length value in the film forming process B of (III) will be described with reference to FIGS. 11 and 13C.

First, at the end of the previous processing of the film forming B step, as shown in FIG. 11A, the unwinding device 24 side of the film forming B step has a long remaining amount of the previous processing. The processing material roll 50 ″ of BR is left, and the processing material roll 52 ′ for which the film forming B process is completed is left on the winding device 26 side. Processing material 22 having a length of in-line length BI is left.

Here, the remaining amount B of the processing material roll 50 "
R is set so that BR> AR + AI. This is for the following reason.
In the film formation A step, which is a pre-process of the film formation B step, as described above, the film formation A is not processed for the material of the portion of the length AR + AI at the rear end of the roll 50. Since there is no point in applying the film formation B to this unprocessed portion, BR> AR + AI is set so as to avoid this unprocessed portion.

Next, the roll 52 'of the winding device 26.
(This roll has been subjected to the film formation B process last time), and subsequently, the work material roll 50 ″ left on the unwinding device 24 side is removed and then mounted on the winding device 26 side. Further, the processing material roll 50 for which the film forming A step of the previous step is completed is mounted on the unwinding device 24. Then, the leading end of the processing material roll 50 and the processing material remaining in the film forming B apparatus. The work material roll 5 mounted on the winding device 26 while welding the rear end of the roll 22
The end portion of 0 ″ and the front end portion M32 of the processing material 22 are welded. The length of the processing material 22 left in the film forming B apparatus is BI. As described with reference to FIG. The coordinate position of the fixed end of the roll 50 that has undergone the film formation A process is L + AI.
If + AR, the coordinates of the free end of the roll 50 are AI +
AR. The position further away from the free end by the distance BI to the right, that is, the coordinate position of point M3 in FIG. 11B is AI + AR-BI. This M3 point is film formation B
Roller 33 for measuring the effective length of the processing material in the device
(33 in FIG. 2) is the installed position and also the position where the free end of the roll 50 ″ is located.
At the time of 1 (b), the origin O of the fixed end point (indicated by a white diamond mark) of the work material 22 wound on the winding device 26 side.
The coordinates from are AR + AI-BI-BR.

Thereafter, the processing material 22 is processed while the processing material 22 is being wound up on the winding device 26 side, and finally, as shown in FIG. 11C, the remaining amount of the processing material roll 50 is reduced. When the number becomes small, the processing unit in the film forming B step is stopped. If the remaining amount is detected by the same method for each roll, the remaining amount of the material of the roll 50 in FIG. 11D is the same as the remaining amount in FIG. 11A, that is, its length is BR. Is.

Next, as shown in FIG. 11D, the front and rear of the processing material 22 in the film forming apparatus are cut. At this time, the remaining length of the work material roll 50 is BR as in the case of FIG. 11A, and the in-line length is BI. Therefore,
After the cutting, the coordinates of the fixed end point (the cutting point, which is indicated by the white diamond mark) of the work material roll 52 wound on the winding device 26 side from the origin O is AR + AI-BR-. BI, and the coordinates of the free end point (indicated by a black diamond mark) are L + AI + AR-BR-BI. This state is shown in FIG.

Thus, the film forming B is formed in the winding device 26.
The formed roll remains.

Film Forming C Step Next, referring to FIG. 12 and FIG. 13D, film forming C of (IV)
The relationship between the origin position and the total length value in the process will be described.

First, at the end of the previous processing of the film forming C step, as shown in FIG. 12A, the processing unit of the film forming C step has a length CR on the unwinding device 24 side. The material roll 52 ″ is left, and the processing material roll 54 ′ for which the film formation C is completed is left on the winding device 26 side. Further, the in-line length CI of the film formation C is set in the film formation device. Processing material 22 is left. Here, the remaining amount CR of the processing material roll 52 ″ is set to avoid an unprocessed portion (length BR + BI) in the film forming B step which is the previous step. It is set so that CR> BR + BI.

As shown in FIG. 12B, the work material roll 52 ″ left on the unwinding device 24 side is taken up by the winding device 2
Processed material roll 5 mounted on side 6 and completed the film formation B process
2 is attached to the unwinding device 24 side in the film forming C step. Then, the leading end point of the processing material roll 52 (coordinates L + AI + AR
While welding the free end in BR-BI and the rear end of the work material 22 in the film forming apparatus, the end (free end) of the work material roll 52 ″ and the work material in the film forming apparatus Two
The front end portion M4 of No. 2 is welded. At this point, the coordinates of the free end point (indicated by a black square mark) of the work material 22 wound on the winding device 26 side from the origin O are L + AI + AR-BR-BI + CI + CR. The measurement of the effective roll length CM of the processing material is started from point M4 which is the front end of the processing material 22.

The film C is processed while the processing material 22 is being wound on the winding device 26 side. Finally Figure 12
As shown in (c), when the remaining amount of the processing material roll 52 becomes very small, the processing unit of the film forming C step is stopped.

Next, as shown in FIG. 12D, the front and rear of the processing material 22 in the film forming apparatus are cut. At this time, the remaining length of the work material roll 52 is CR as in the case of FIG. 12A, and the in-line length is CI. Therefore,
After the cutting, the coordinates of the free end point (indicated by a black square mark) of the work material roll 54 wound on the winding device 26 side from the origin O is L + AI + AR-BR-BI + CI + CR, which is fixed. The coordinates of the end points (indicated by white squares) are AR + AI-BI-BR + CI + CR. This state is shown in FIG. 13D.

As described above, the coordinates of the processing material that changes for each processing step are converted into absolute coordinates.

<Detection of Defect Position in Each Step>
A method of calculating the manufacturing defect position when the above-described method of exchanging the processing material is applied will be described.

FIG. 14 shows a cleaning process, a film forming process A, and a film forming process B.
The winding length, the remaining length, and
It is a figure which shows the structure of the table which memorize | stores the value of in-line length and roll length. Such a table is stored in advance in a memory (not shown) in the management computer 36. FIG. 15 is a diagram showing a method of calculating coordinates of a manufacturing defect when a manufacturing defect occurs in each process.

In FIG. 15, the measurement origin of the effective roll length in each step, that is, the M1 point in the cleaning step, the M2 point in the film forming A step, the M3 point in the film forming B step, and the film forming C step. Point M4 is shown as the origin of the measurement value scale of the length of the processed material. Thus, M1, M2, M3, M
If four points are set as the starting points in each process, the cleaning process, the film forming A process, the film forming B process, and the film forming C process should be understood in a unified manner, that is, the transition in each process of one roll. It becomes possible to grasp and display it if necessary.

Here, as an example, an abnormality occurs in the second chamber of the film forming apparatus B at time t ₀ , and the abnormality occurs at time t _0.
It is assumed that the device is stopped at. In this case, FIG.
As shown in (c) and FIG. 16, at the time t ₀ , the work material having the length AR + AI−BI + BM (t ₀ ) is wound on the winding device 26 side. Where BM (t ₀ )
Is the winding amount of the processing material measured from the M3 point at time t ₀ . If the second chamber is measured from the reference position (M3 point) and exists at the positions E _{L to} E _T , the processing defect starts from the point AR + AI-BI + BM (t ₀ ) + E _L. . On the other hand, at time t ₀ when the apparatus is stopped, only AR + AI-BI + BM (t ₀ ) of processing material is wound on the winding apparatus 26 side. Where BM (t
₀ ) indicates the winding amount of the processing material from point M3 at time t ₀ . Thus, the processing defects, so that the ends at a point AR + AI-BI + BM ( t) + E T. Accordingly, by performing such a calculation, it is possible to accurately grasp at which point of the processing material and how long a processing defect has occurred.

By performing similar calculations in other cleaning steps, film formation A step, and film formation C step, it is possible to grasp at which position of the processing material the processing defect has occurred.
This data is stored in a memory in the management computer 36.

The data shown in FIG.
When a specific value as shown in 7 is applied, the total length is 800
When the m roll is applied from the cleaning process to the film forming C process, the processing result for the rolls performed in each process is shown in FIG. <Cutting Step> Next, based on the position information of the processing defect obtained as described above and stored in the management computer 36, the processing material roll 54 in which the film-forming C processing is completed in the V cutting step. A method of cutting each into individual pieces (hereinafter referred to as slabs) will be described.

FIG. 19 is a schematic diagram showing the structure of the shearing device 30 for performing the cutting step. In FIG.
The processing material roll 54 that has undergone all the film forming steps is mounted on the unwinding device 60. Then, the material from the roll 54 unwound from the unwinding device 60 is fed by the feed guide 6
It is conveyed via 2 to the gripper 64. The gripper 64 grips and pulls out the tip of the processing material 22 from the feed guide 62, and the processing material 22 is pressed by the press 66.
To send out. The press machine 66 cuts the work material 22 into a fixed size with a cutting die 68 and separates the work material 22 into single slabs. The slab separated into a single item is sorted by the sorting device 70,
Non-defective products are stored in the storage box 72, and defective products are discarded in a recovery stocker (not shown).

The unwinding device 60, the feed guide 62,
The operations of the gripper 64, the press 66, and the sorting device 70 are controlled by the NC controller shown in FIG.

<Slab Sampling> Next, FIG. 20A is a diagram for explaining a method of selecting defective slabs. In the present embodiment, the processing material roll 22 has a length of 800 m.
Each slab has a length of about 300 mm. Therefore, from one processing material roll, about 250
You can take about 0 slabs. In this embodiment, about 2500 slabs are divided into, for example, 50 lots each, and good / defective is selected.

Each lot is composed of 50 slabs and one QA coupon consecutive to the last slab. Here, the QA coupon is an abbreviation of a quality assurance coupon, and means a test sample representative of the lot. QA coupon is
It is a sample for inspection (length about 60 mm) smaller than a normal slab and is discarded after the inspection.

In the present embodiment, by the method as described above, it is stored as data which part of the work material roll 54 has a defect of what length. Therefore, the number of slabs of each lot is set based on this data while avoiding defective portions.
The setting of this lot is performed by the management computer 36 before the actual cutting process and is displayed on the display as shown in FIG. 20B.

FIG. 20B specifically shows how to allocate the number of slabs to each lot displayed on the screen of the display. In FIG. 20B, 300 is 1
It is a bar showing the total length of one roll. The black band in bar 300 indicates the defect. List 301 shows a portion of seven lots generated from rolls with IDs non-950025 "represented by bar 300. For each lot, QTY is the number of slabs in that lot and SLAB NO is.
First slab number of the lot, FIRST POSITION
Is the distance from the beginning of this roll to the starting position of this lot, and DEFECTS AFTER LOT is the length of the defect starting from FIRST POSITION in slabs.

The roll of FIG. 20B will be described with reference to FIG. 20C. In this example, the effective processing area starts 24 m from the edge of the processing material. First
The lot begins to pick the first slab from this 24m point and contains a total of 50 slabs plus one QA coupon. The second lot takes 50 slabs and one QA coupon from the end point of the first lot, like the first lot. Similarly, 50 slabs and 1 QA
Take lots of coupons one after another.

Here, for example, in the third lot, 36
It can be seen from the middle of the first slab that there are processing defects for seven slabs. The third lot ends with 35 slabs, and one QA coupon is taken from the portion between the end of the 35th slab and the point where the processing defect begins. If the interval between the end point of the slab (the 35th sheet in the above example) and the point where the processing defect begins is not enough to take the QA coupon, the slab immediately before (the 34th sheet in the above example) Slab)
Is the end point, and the QA coupon is taken from the next (35th) part.

Similarly, in the example of FIG. 20B, for example, if there is a processing defect for 21 slabs in the middle of the 21st slab of the 4th lot, the lot ends with 20 slabs. Then, one QA coupon is taken from a portion between the end point of the 20th slab and the start point of the processing defect. In this way, the number of slabs is assigned to each lot.

On the screen of the display, as shown, the ID number of the processing material roll, the length of one slab, the length of the QA coupon, the basic number of slabs in one lot, and the processing material roll. Of the effective processing area, total lot number after lot allocation (47 in the example of FIG. 20B), total slab number (1880 in the example of FIG. 20B), total defective slab number (93 in the example of FIG. 20B) ), Defective product rate (Fig. 20B
In the example, 4.7%) or the like is displayed.

When the lot allocation is displayed on the display in this way, the operator judges whether or not there is a problem, and if there is no problem, the CONFIR on the screen is displayed.
Click the M button to confirm lot allocation.
Further, for example, in the case where a processing defect starts immediately after a part where one certain lot has started and one lot ends with several sheets, the lot is determined to be the previous lot or the next lot by the judgment of the operator. It is also possible to perform such an operation as to be included in the.

Further, in the cleaning process and the film forming process before the cutting process, the position of the work material roll and the defect position are measured as described above, but the measured values include some errors. There is. Therefore, if the lots are allocated with the measured values being completely correct, there is a possibility that non-defective products may be included in the range of the processed material determined to be defective, resulting in waste of materials. Therefore, in the present embodiment, it is determined that there is a defective portion when a region having a processing defect continues for, for example, 3 m or more, and then a range excluding, for example, 1 m before and after the defective region of 3 m or more (that is, (1m part in the center)
Is determined to be a reliable defective part. That is, when there is a defect range of just 3 m, only the central portion of 1 m is excluded from the lot allocation as a reliable defect area.
The portion 1 m before and after the 1 m range at the center is a portion where it is not clearly known whether it is a good product or a defective product, but it is treated as a good product for the time being. When the product is completed, a 100% inspection is performed, and if it is determined that the product is defective, the product is discarded again.

When the lot allocation as described above is completed, the shearing device 3 is operated according to this allocation data.
0 causes the actual disconnection to take place. Here, when setting the work material roll 54 in the unwinding device 60, the operator sets the ID number and the slab length of the work material roll to NC.
Input to the controller. Thus, communication between the NC controller and the management computer 36 is performed. In the management computer, the lot allocation information set as shown in FIG. 20B is collated with the input information, and if there is no difference, the cutting instruction information is collectively downloaded to the NC controller side. If there is an error, an error signal is output to the NC controller and an error is displayed on the display.

After that, when the actual cutting work is started,
Each time the processing of one lot is completed from the NC controller, the lot number, the number of lots, and the leading slab number are sent back as actual data, so the management computer 36 files the data and displays it on the display. Also, during the cutting work,
Defective parts that are not subject to lot allocation are not cut in fixed-size units, but are cut together.

FIG. 21 shows data displayed on the display in real time as the cutting work progresses. As shown in FIG. 21, the ID number of the work material roll, the slab length, the lot number, the number of lots, the start slab number, the start coordinate of the lot, the number of defect slabs, and the like are displayed on the display as the processing result data. You.

As the cutting work progresses, the sorting apparatus 70 carries out the sorting work so that the good slabs are stored in the storage box 72 and the defective slabs are discarded under the control of the NC controller. As described above, according to the above-mentioned embodiment, based on the information on which position of the processing material roll measured before the cutting step and how long the processing defect exists, each slab The cutting operation is controlled. Therefore, in the cutting step, only the true defective portion can be cut and discarded, so that waste of material is reduced.

<Monitoring> Next, a system for displaying the monitoring charts shown in FIGS. 20B and 20C will be described. This system is a system mainly controlled by the management computer 36 in the production management system of FIG. The management computer 36 collects process data from each PLC.

FIG. 22 shows the structure of a processing result file provided in a memory (not shown) in the computer 36. The data of this file is PLC
Change in signal detected by (with time of change)
And the value of the signal at the time of change and the winding length (M) detected by the roller 33 of the processing device of the signal.
As shown in FIG. 23, the computer 36 stores in advance a lower limit value and an upper limit value for a signal detected by each PLC as a table for determining whether or not the value of the signal is acceptable. Therefore, no matter which PLC detects a change in some signal, the change in that signal is
The value detected by the LC and the signal thereof can immediately determine whether or not the machining operation is defective.

FIG. 24 is a control procedure showing a routine for collecting processing management data such as error signals. Step S1
0 is a step of reading management data. Step S
At 12, the value of the flag FLG is checked. This flag will be described later. In step S14, the read management data and the previously read management data are compared to determine whether there is a change. If there is a change in the error signal (change in value, or change from normal → abnormal, or abnormal → return to normal), in step S16, the time, signal name, and movement of the processing member at that time Write quantity M etc. to disk.

In step S18, it is determined whether the change in the error signal is a change from normal to abnormal, or a change from abnormal to normal. In this embodiment, when the signal change is either normal → abnormal, or abnormal → return to normal, the respective 5 minutes of data before and after the change are stored in the disk as a log file. To do. That is, in step S20, a flag FLG indicating that there is a change is set, and in step S22, RA is set.
The management data for 5 minutes stored in M is stored in the disk.

It should be noted that the change from normal to abnormal or the change from abnormal to normal in step S18 is judged using a variable threshold value. This threshold value is determined according to the upper limit value and the lower limit value in FIG. That is, the judgment as to whether the value of a certain signal is abnormal or normal is judged to be normal (or abnormal) if it is between the upper limit value and the lower limit value. This threshold can be changed by operating the "threshold change icon" in FIG. Some error signals have an analog value such as a pressure signal, and it is difficult to uniquely determine normality / abnormality when determining normality / abnormality based on the value of the signal. . Therefore, in this embodiment, the threshold can be changed. When changing the threshold value, for example, by selecting the error signal shown in the map of FIG. 32 with a mouse or the like and operating the aforementioned “threshold change icon”, the threshold value of the selected error signal is displayed in the table (FIG. 23). ) Change it in

Once a change in event data is detected,
After that, the process proceeds from step S12 to step S24,
While monitoring the progress for 5 minutes (step S24), the 5-minute data of the management data collected periodically is written to the disk. When 5 minutes have elapsed, the flag FLG is reset in step S28. In the present embodiment, FIG.
Three modes are prepared for how to display the management data collected in the control procedure. One is a real-time display mode, and the other is a trend display mode and an error map display mode. These three modes are not contradictory, and the real-time display at a certain time point and the trend up to that time point may be displayed on the same screen.

FIG. 25 shows three types of icons (real time display, trend display, error map display) displayed on the CRT. FIG. 26 is a flowchart showing the control procedure for display of this embodiment. In step S30 of the figure, a trigger for checking whether any icon in FIG. 25 has been operated is checked. If this operation is a real-time display icon operation, in step S36,
The work management data temporarily stored in the memory is read and "real time display" is performed. As an example of the real-time display, the one when the lot number 1880 in FIG. 20B is detected is shown.

If the icon operation is trend display, the management data stored in the past is read from the disk in step S40 to display the trend. 27 and 28 show examples of trend display. In FIG. 27, A,
B, ... P indicate chambers. Selecting the icon labeled RT will give a real-time display of the chamber corresponding to that RT. Further, icons such as B and C below each chamber icon are icons for prompting the historical trend display of the chamber.

FIG. 29 shows a control procedure when the error map display icon is operated. In the figure, step S50 monitors the operation of the icon. When this icon is operated, the error range is calculated in step S56. Figure 1 shows the calculation of the error range
5 has been described. A map is generated in step S58, and the map is displayed in step S60.

30 and 32 show display examples of error maps. The error map in FIG. 30 has two map parts 10.
Includes 00 and 2000. Map 1000 displays statistical data for each individual web. In the example of FIG. 30,
The web has 6 identification numbers 940010-940060
One. For each web, the date when the web was processed (Date), the time when the web was processed (Start), the processing end time (End), and the web identifier (Web
ID), time required for processing (RunTime), time required for pre-processing
(PreRunTime), stop time (StopTime), stop count (Sto
pNo), stop ratio (StopRatio = StopTime / RunTime), and error count (ErrorNo) are displayed.

The map 2000 displays the information obtained by the map 1000 for each web for each graph. "0010" and the like on the horizontal axis of the map 2000 are obtained from the last four digits of the WebID. The items that can be displayed on the map 2000 include, for example, a stop time (StopTime) and a stop count (StopN).
o), stop ratio (StopRatio = StopTime / RunTime), error count
There are 4 items of (Error No). Checkbox 2 determines which of these four items is displayed in area 2000.
Mark X with 001. In the example of FIG. 30, all four items are displayed, the stop time (StopTime) is indicated by the line I, the number of stops (StopNo) is indicated by the line II, and the stop ratio (StopRatio = StopTime / RunTime) is indicated by the line. By III, the error number (ErrorNo) is indicated by line IV.

In FIG. 30, the map 1000 shows WebI.
D is "940040" is highlighted. Web ID is "9400
Process records for the 40 "web are on map 20
In 00, it is specified by the area 2002. In other words, the inversion area in the map 100 and the frame 2002 in the map 2000 match. Further, if the operator moves the reversal area in the map 1000, the frame 2002 in the map 2000 also moves according to the movement. By associating the table map 1000 and the map 2000 with the inversion area and the frame, the operator can determine the relation between each web and another web, and the relation between the error of one specific web and the error of another web. It can be confirmed visually.

FIG. 31 is a flow chart showing a control procedure for realizing the error map display of FIG. In step S100, it is checked whether the graph cursor (frame 2002 in FIG. 30) has been moved by the operator, and step S102
Then, the list cursor (inversion area in map 1000)
To detect if was moved. When the graph cursor 2002 is moved by the operator, it is checked in step S104 which web of the identifier is moved. In step S1106, the address of the destination identifier is sent to the object of map 1000. The transfer to this object is realized, for example, by OLE of Microsoft Windows. On the map 1000 side, the list cursor is moved according to the sent address.

On the other hand, when the list cursor is moved, it is checked in step S110 which line of the list 1000 the cursor is moved to. Step S
At 112, the line number of the destination (web identifier) is sent to the map 2000 side. On the map 2000 side, the graph cursor is moved in correspondence with the destination line. FIG. 32 is an error map display for individual webs that can be obtained by selecting a specific web and then pressing the “magnify” icon 2003 in the map of FIG. In particular, FIG. 32 is an example in which the web having the identifier “940010” is enlarged and displayed.

In FIG. 32, the map 3000 displays a summary of the error of the web "940010". In the map 3000, error signals are displayed from top to bottom in the order of error occurrence. For each error signal, the error code (ErrorCode), the start position where the error occurred (Start), the position where the error ended
(End), the length of the error (Length), and the comment (Comment) for the error are displayed together. In the example of FIG. 32, the error code "B0301" meaning emergency stop is 113.9
"W0201" that occurs at the position of m and means a pressure drop
It occurs at the position of 200.0m, which means abnormal temperature. "C05
"07" occurred at 398.9m and "C0802" which means pinch valve error occurred at 513.2m.

Map 4000 is a graph showing the position where the error has occurred for the errors listed in map 3000. On the map 4000, for the convenience of display, the initials (W, B,
C, T) are used as identifiers. In the example of FIG. 32,
The emergency stop error (B) occurs first, the pressure drop error occurs at the position 200 m in combination with the emergency stop error, and the temperature error occurs at the positions 400 m and 513 m. In the map 4000, each error code is displayed in color from an error occurrence point to an end point.

The reverse area 3001 in the map 3000 and the cursor 4001 in the map 4000 indicate the area of interest of the operator. That is, the inversion area 3001 and the cursor 4001 correspond to each other. In the example of FIG. 32, the operator selects the map 3000.
When a specific error code "C0802" is selected in, the line direction corresponding to that error code is highlighted and
The bar display 4002 corresponding to the error code selected in the map 4000 is displayed so as to stand out from the other bar displays. On the contrary, the operator displays an arbitrary bar (for example, 4
002) When a specific position (for example, 4001) is selected, the error area including the specific position is highlighted.

FIG. 33 is a flow chart showing the control procedure for realizing the error map display of FIG. In step S200, it is checked whether the error map cursor (cursor 4001 in FIG. 32) has been moved by the operator. In step S202, it is detected whether the list table cursor (reverse display area in the map 3000) has been moved. When the error map cursor 4001 is moved by the operator, it is checked in step S204 which identifier error has been moved. In step S206, the address of the destination identifier is sent to the object of map 3000. On the map 3000 side, the list table cursor is moved according to the sent address.

On the other hand, when the list cursor is moved, it is checked in step S210 which line of the list 3000 the cursor is moved to. Step S
At 212, the line number (error identifier) of the destination line is sent to the map 4000 side. On the map 4000 side, the error map cursor is moved corresponding to the destination line. The present invention can be applied to a modified or modified version of the above embodiment without departing from the spirit of the invention.

For example, in the above-described embodiment, the case of manufacturing a solar cell has been described, but the present invention is not limited to this, as long as a plurality of articles are manufactured using a continuous body as a processing material. It is also applicable to.

[0125]

As described above, the continuous body manufacturing process control apparatus and method of the present invention for controlling a production process in which a continuous body as a processing material travels through a working process is provided. It is characterized in that a change in an event is detected, various events before and after the change are stored as data, and the stored event data is processed.

That is, the various event data collected before and after the change of the predetermined event occurring in the processing step is closely related to the predetermined event. Can be managed.

[0127]

[Brief description of drawings]

FIG. 1 is a configuration diagram showing an embodiment of a manufacturing process when a manufacturing apparatus and a manufacturing method for a continuous body according to the present invention is applied to manufacturing a solar cell.

FIG. 2 is a diagram showing a configuration of a winding device according to an embodiment.

FIG. 3 is a diagram showing a connection state of PLCs of the respective processing apparatuses of FIG.

4 is a diagram showing a flow of processing in the system of FIG. 1 when some abnormality occurs in a manufacturing apparatus.

FIG. 5 is a view showing a flow of a manufacturing process of the solar cell.

FIG. 6 is a diagram showing a positional relationship of a belt-shaped continuum.

FIG. 7 is a diagram schematically showing a method of exchanging the processing material in the cleaning step.

FIG. 8 is a diagram schematically showing a method of exchanging a processing material in the film forming A step to the film forming C step.

FIG. 9 is a diagram showing the relationship between the deviation of the origin of the processing material and the total length value, which occurs when the processing material replacement method according to the embodiment is performed.

FIG. 10 is a diagram showing the relationship between the deviation of the origin of the processing material and the total length value, which occurs when the method of exchanging the processing material according to the embodiment is performed.

FIG. 11 is a diagram showing the relationship between the deviation of the origin of the processing material and the total length value, which occurs when the method of exchanging the processing material according to the embodiment is performed.

FIG. 12 is a diagram showing the relationship between the deviation of the origin of the processing material and the total length value, which occurs when the method of exchanging the processing material according to the embodiment is performed.

FIG. 13A is a diagram showing the relationship between the deviation of the origin of the processing material and the total length value in the cleaning process.

FIG. 13B is a diagram showing the relationship between the deviation of the origin of the processing material and the total length value in the film forming A step.

FIG. 13C is a diagram showing the relationship between the deviation of the origin of the processing material and the total length value in the film forming B step.

FIG. 13D is a diagram showing the relationship between the deviation of the origin of the processing material and the total length value in the film forming C step.

FIG. 14: Cleaning process, film formation A process, film formation B process, film formation C
Winding length, remaining length, in-line length in each process,
It is a figure showing roll length.

FIG. 15 is a diagram showing a method of calculating coordinates of a manufacturing defect when a manufacturing defect occurs in each process.

FIG. 16 is a diagram showing a method of calculating coordinates of a manufacturing defect when a manufacturing defect occurs in each process.

FIG. 17 is a diagram showing an example in which actual numerical values are applied to FIG.

FIG. 18 is a diagram showing an example in which actual numerical values are applied to FIG. 15.

FIG. 19 is a schematic view showing a configuration of a shearing device that performs a cutting step.

FIG. 20A is a diagram for explaining a method of selecting a defective slab.

FIG. 20B is a diagram specifically showing how to allocate the number of slabs to each lot displayed on the screen of the display.

FIG. 20C is a diagram showing an error position occurring in one slab.

FIG. 21 is a diagram showing data displayed on the display in real time as the cutting work progresses.

FIG. 22 is a diagram showing the configuration of a log file that stores error signals.

FIG. 23 is a diagram illustrating a relationship between an error signal and a PLC that should generate the error signal.

FIG. 24 is a flowchart showing a control procedure for collecting event data.

FIG. 25 is a diagram showing types of icons used in the embodiment.

FIG. 26 is a flowchart showing a control procedure for separating real-time display and historical trend display.

FIG. 27 is a view showing a display screen of an icon requesting real-time display and historical trend display.

FIG. 28 is a diagram showing an example of a historical trend display.

FIG. 29 is a flowchart showing a control procedure of error map display.

FIG. 30 is a diagram showing an example of an error map display.

FIG. 31 is a flowchart showing a control procedure for obtaining the display of FIG. 30.

FIG. 32 is a diagram showing one form of error map display.

FIG. 33 is a flowchart showing a control procedure for obtaining the display of FIG. 32.

[Explanation of reference numerals] 10 manufacturing device 12, 14, 16, 18 processing device 22 processing material 24 unwinding device 26 winding device 28 NC feeder 30 shearing device 33 folding back rotary roller 34 rotary encoder 36 management computer P process unit T transport unit

Claims (14)

[Claims] 1. A manufacturing process management apparatus for a continuous body, wherein a continuous body as a processing material manages a production process that travels across processing steps, and a detecting means for detecting a change in a predetermined event that has occurred in the processing step. A manufacturing process control apparatus comprising: a storage unit that stores various events before and after the change as data, and a processing unit that processes the stored event data. 2. The manufacturing process management apparatus according to claim 1, wherein there are a plurality of processing processes, and the storage unit stores event data including an identifier of each processing process. 3. The detection means detects the occurrence of an abnormal event, and the storage means starts the storage of the various event data triggered by the occurrence of the abnormal event. Manufacturing process control equipment. 4. The detection means detects the end of an abnormal event, and the storage means starts the storage of the various event data triggered by the end of the abnormal event. Manufacturing process control equipment. 5. The manufacturing process control apparatus according to claim 1, wherein the storage unit stores data of the predetermined event as the various event data. 6. A display means is further provided, and the display means displays the various event data at the time of change of the predetermined event and the various events processed by the processing means together with the data. The manufacturing process control apparatus according to any one of claims 1 to 5, wherein 7. The manufacturing process control apparatus according to claim 1, wherein the various event data includes data relating to the environment in the processing process. 8. A manufacturing process control method for a continuous body, wherein a continuous body as a processing material manages a production process that travels across processing steps, wherein a change in a predetermined event occurring in the processing step is detected and the change is detected. A manufacturing process management method characterized in that various events before and after are stored as data, and the stored event data is processed. 9. The manufacturing process management method according to claim 8, wherein there are a plurality of the processing processes, and the various event data including the identifiers of the individual processing processes are stored. 10. The method according to claim 8, wherein the detection means detects the occurrence of an abnormal event, and the storage means starts the storage of the various event data triggered by the occurrence of the abnormal event. Manufacturing process control method. 11. The manufacturing process control method according to claim 8, wherein the storage of the various event data is started by using an end of an abnormal event as a trigger. 12. The manufacturing process control method according to claim 8, wherein the data of the predetermined event is stored as a part of the various event data. 13. The various event data at the time of change of the predetermined event and the processed various events are displayed together with the data.
13. The manufacturing process control method according to any one of 1 to 12. 14. The manufacturing process control method according to claim 8, wherein the various event data includes data relating to the environment in the processing process.