KR20050023985A - A machine control system and the same control method - Google Patents

Abstract

PURPOSE: A Web-based manufacturing equipment system and a controlling method thereof are provided to share a work order by installing a dedicated terminal to each manufacturing equipment and manage fixtures/tools through the online by making the work order fix the fixtures/tools included in the corresponding manufacturing equipment. CONSTITUTION: The dedicated terminal(200) stops operation of the manufacturing equipment(400) until work order information is downloaded from a manufacturing management system server(100) and enables a worker to input a work start signal to the manufacturing management system through the dedicated terminal after the work order information is downloaded. After input of the work start signal, a right to control operation of the manufacturing equipment is transferred to the dedicated terminal and the manufacturing equipment performs work according to contents of the work order information. Performed work information is transmitted to the manufacturing management system server.

Description

Production equipment system and its control method {A machine control system and the same control method}

The present invention provides a new production process monitoring method capable of securing high data reliability based on the production facility control function for the production site, and a web-based production facility system and its control method for real-time production management work based thereon. will be.

In order to respond promptly to various consumer demands and to quickly adapt to the production type of the multi-volume small-volume production system, even manufacturers with small and medium-sized production facilities invest a lot of investment and effort in the introduction of the information system as well as the basic information infrastructure connected with the production facilities. Is leaning. This is because the demand for digitalization of the corporate environment is naturally formed under the goal of strengthening market competitiveness due to the establishment of information infrastructure and the spread of the Internet due to the rapid growth of computers and computer networks.

Recently, many manufacturers have introduced and operated various types of production management systems as optimized information systems for maximizing the efficiency of production operations and management.

Conventional production facilities and their management systems are all based on the monitoring of the production site, regardless of its type. In addition, the various production information monitored from the production site is made into a database and then processed and used in various forms according to the needs of users or system requirements.

Therefore, data reliability for obtaining accurate production information is an important factor in monitoring the production site. In most production facilities and production management systems, for monitoring the production site, separate monitoring equipment is provided for each facility to receive and process electrical signals directly from sensors or production facility controllers. The production information through such measurement is reliable information if it is not wrong information due to problems in the production equipment, but among the various production information, information that requires direct input by an operator or a field manager, not measurement through the production equipment. Also exists. The production equipment and production information input by the operator must be correct, and above all, of course, and should not be omitted.

However, in the conventional production equipment system, there is no means for forcing the operator's input behavior in case of malfunction or non-operation of the production equipment. Since there is no disruption to operation, problems may arise that cause the monitoring of distorted production equipment and production information.

If all production equipment in the production site is fully automated and all necessary production information can be gathered without operator intervention, this would be the ideal monitoring method, but it is almost impossible to have a production facility with full automation.

In this situation, it is not possible to rule out the information input behavior of the operator who operates the production equipment at the source, but to provide a monitoring method that minimizes the distortion input of the information generated by the information input behavior of the operator and ensures data reliability. Must be taken.

In addition, the production management system that supports the management of most production equipment monitors the operation time of the production equipment, and calculates the equipment inspection interval using the equipment operating time as a parameter. In certain inspection items, the number of product produced is not a parameter but an uptime.

As described above, when only the operation / non-operation time of the production equipment is used as a reference, there is a problem in that the inspection period of the tool that is combined with the production equipment, such as a mold used in the production of a press or an injection molding, is not accurately managed.

In order to solve the problems described above, the present invention provides a dedicated terminal for each production facility to share a work order, while the work order can designate a tool included in the production facility to manage the tool management online. Make sure In addition, the maintenance period of the production equipment as well as the maintenance period of the tool is also managed by the corresponding item to notify the manager and worker at a specific time point to facilitate the maintenance of expensive production equipment and tools. In addition, it provides a flexible way of operating work orders to suit a multi-volume batch production system.

In addition, the present invention enables the on / off control of the operation regardless of the automation of the production facility through a dedicated terminal of the production facility. Of course, as it is a web program based system, remote on / off control of production facilities via the Internet is also possible. The operation on / off control of the production facility provides a method for determining the stop point of the production facility or limiting the operation of the production facility. The dedicated terminal installed in the production facility automatically stops the production facility according to the specific condition, and likewise, it is configured to suppress the arbitrary starting of the production facility until the specific condition is satisfied.

By realizing such a facility control function, a mandatory force is added to the information input behavior of the worker in the field which has been pointed out as a problem in the related art. For example, if a worker does not perform the input required by the system in a particular situation, the operation of the production facility is restricted so that no more production facilities can be operated. The present invention provides the user with the appropriate information to the sales person on the basis of the work status and inventory status that can be used in any place where the user of the production facility system is available on the Internet and is identified in real time.

In addition, since the reliability of the data is secured, production managers can quickly respond by analyzing and providing the operation / non-operational status of the production equipment accurately.

In addition, between the user of the production facility system of the present invention and a dedicated terminal installed in the production facility can be configured to provide a message transmission and call service to resolve the site gap between the production site and the office.

Accordingly, an object of the present invention is to provide a production facility system and a control method for accurately obtaining production management information of a product produced by the production facility, and to accurately provide and secure tool maintenance maintenance information of the production facility. It is about providing.

Another object of the present invention is to be able to control the operation of the production facility by connecting to the intranet and the Internet network.

The present invention is a production facility system is connected to the production management system server and the production management system server having a dedicated terminal to achieve the above object and the production management system server is configured to be connected to the production management system client PC using the Internet network ,

The dedicated terminal stops the operation of the production facility until the work order information is downloaded from the production management system server, and after the work order information is downloaded to the dedicated terminal, the worker manages the production through the dedicated terminal. It is configured to input a job start signal to a system server, and after the operation start signal is input, the operation control right of the production facility is transferred to the dedicated terminal so that the production facility executes work according to the work instruction information. The job information to be executed is configured to be transmitted to the production management system server in real time.

When the production equipment is switched to the non-operational state in the course of carrying out work, the operator transmits the cause information of the non-operation of the production equipment to the production management system server through the dedicated terminal and restarts the production equipment. It is configured to be possible.

In addition, the production management system server is configured to be connected to the production management system client PC through the Internet network.

The control method of the production equipment system of the present invention configured as described above is a step in which the dedicated terminal of the production equipment downloads the work order information from the production management system server in the state of the operation of the production equipment is stopped,

Worker sends a start signal to the production management system server through a dedicated terminal of the production facility,

Operating the production facility according to the work instruction information after the work start signal is transmitted to a production management system server;

When a non-operational state occurs during operation of the production facility, a worker inputting a non-operational cause through a dedicated terminal of the production facility,

Including the step of restarting the production facility by the operator,

 Operation information and non-operation cause information of the production facility is characterized in that it is transmitted to the production management system server in real time through the dedicated terminal.

The non-operation cause information includes tool management information of the production facility.

Hereinafter, a production facility system and a control method of the present invention will be described in detail with reference to FIGS. 1 to 6.

The present invention connects the production management system server 100 and the production management system client PC 300 via an intranet or Internet network 500, the production management system server is dedicated to each of the production facilities 400 of the workplace It is configured to be connected to the terminal 200 and the fieldbus control network.

Specifically, if a production plan is established based on sales order information entered by the sales representatives online into the production management system server 100 through the production management system client PC 300, the production personnel in charge of the production management system is in real time. Work order information for each production facility is created on the basis of the current inventory status provided by the system and transmitted to the dedicated terminal 200 connected to each production facility. Afterwards, the production progress is all monitored by the dedicated terminal 200, and the production results, defect status, operation / non-operational status, and causes of non-operation are updated in real time in the production management system DB 101 to process management tasks and facilities. Perform management tasks, inventory management tasks, quality control tasks, and sales shipment management tasks.

The schematic information flow of the production management system according to the present invention configured as shown in Figure 1 is a work order creation step (step 1), work order transmission step (step 2), work order operation step (step 3), production information monitoring step (4 steps), production management work execution step (5 steps).

 Referring to Figure 2 showing an example of the work order information applied to the production equipment system of the present invention, the production equipment system according to the present invention establishes a production plan based on the order information received from the sales representative and the production representative on the day You will create a standard work order.

At this time, the work order to be created is composed of a workplace (production line information) (1), worker information (2), planning start and end time (3), non-operation occurrence time (4), production instruction information (5) do. The production instruction information includes contents of production product information, target quantity, equipment and tool information, and the like.

The work order composed of the above items enables the production plan to be established on a daily work order basis based on the experience of the production planner, and the work order can be changed from time to time. As a result, most companies do not have the inconvenience of printing on the form of work order and delivering it to the workers, and the work order creator uses the work order related web page to create work order information for each work place. It transmits to the dedicated terminal of the site installed at each production facility and shows it to the worker, so that the production work can proceed according to this work instruction.

In particular, the production instruction information included in the work instruction may be composed of a lot unit (Lot) or a plurality of products (task 1, task 2, task N), each production instruction information is produced product information, target quantity and It includes information about equipment and tools, and one or more production instructions are included in the work orders to produce in sequence. As such, the non-operation recognition time and equipment and tool information are included in the work order, and even if frequent work order changes or non-operation factors occur, it is possible to cope with the facility control function so that the production time of the production equipment and the tool is accurate in real time. Remote management is possible by knowing information such as overtime, downtime, and stroke information. In addition, this information allows the program to inform the program when to replace or inspect equipment and fixtures, as well as record inspection and maintenance details.

3, the driving process of the production management system of the present invention will be described in detail with reference to an operation process of a dedicated terminal.

When the production management system is operated and the production management system server is driven (S101), a work instruction prepared in advance in the dedicated terminal 200 installed in each production facility 400 is transmitted together with the work instruction transmission signal (S102). When the work instruction transmission signal is transmitted from the production management system server, the operation of the production equipment is stopped (S103), and the dedicated terminal 200 of each production equipment starts to download work instruction information (S104).

As described above, stopping the operation of the production facility until the dedicated terminal downloads the work status information after the start of the operation is performed to ensure on-site control function and reliable data, which are features of the dedicated terminal of the production facility of the present invention. It is a preliminary preparation work which makes it impossible to start production equipment in the absence of a work instruction. Once the terminal is powered up, the facility at the site is shut down (if the facility is running), and the operator has control over the operation switch of the site production facility so that it cannot be arbitrarily operated by the operator. After shutting down the field facility, the dedicated terminal waits for work orders from the production management system server. Unlike other POP terminals, the dedicated terminal of the production facility performs all field management of the work orders by the dedicated terminal itself, not the production management system server, and controls the production equipment. Although it is impossible, once the work order is issued, it is configured to manage the site regardless of the operation of the production management system server. When all of the one or more work orders are downloaded, the dedicated terminal enters a work start waiting state and waits for a worker to input a work start signal by pressing a work start button (S105). Dedicated terminal 200 notifies the start of the work to the production management system server through the work start signal to operate the given work instruction.

The control function of the production equipment dedicated terminal allows the operator to control the control of the operation of the production equipment by turning the power on and off of the operation switch of the production equipment. Since the dedicated terminal of the production equipment cannot directly operate the production equipment, pressing the work start button by the operator starts the operation of the production equipment (S106), and when the operation is started, transmits the operation start information to the production management system server. .

After the production facility is in operation, operations such as non-operation or defects are repeatedly performed until the production operation is completed, and production management is performed in real time for various events that occur by repeatedly shutting down and restarting the production facility. It is sent as a message to the system server.

If a non-operation occurs, the operation of the production facility is stopped, and a message is displayed on the screen of the dedicated terminal to inform the worker of the non-operation occurrence through a warning light and input the cause. If the cause of non-operation is not input, the dedicated terminal of the production equipment has control, so even if the cause of the non-operation is removed, the production cannot be restarted.

That is, when the production equipment starts to operate, the dedicated terminal determines whether the production equipment is in a non-operational state (S107). When the production equipment is switched to the non-operational state, it is inoperable due to a defective product (S108). It is determined whether the non-operation caused (S109), and the cause of the non-operation is input through the input device of the dedicated terminal (S110).

Of course, after the production management system server is driven or after the production equipment starts to operate, the message information may be output through the screen of the dedicated terminal (S111), and the operator may check the information on the screen (S112) and respond appropriately. Make sure

In addition, if the operator of the site wants to communicate with the production management system client PC (production management director) connected to the production management system server while the cause of the production equipment is inactive or during the operation of the production equipment, a call signal is sent to the dedicated terminal. It is configured to communicate with the production manager in charge (S113).

After the non-operation cause information is input, a restart signal is input (S114) to restart the production facility (S115).

After the production process of the production equipment through the process as described above (S116) after the dedicated terminal determines whether there is additional work (S117), if there is additional work to go to step (S105) to perform additional work. If it does more and there is no further work, it ends. All the information that occurs until the end of the work is transmitted to the DB 101 of the production management system server in real time through a dedicated terminal.

By constructing a production facility system as described above, more reliable production information data can be secured.

Defect processing requires you to enter a defect reason code and quantity if a defect occurs on the production site. However, the input of the cause of the defect can be input only while the operation is in progress, and the defect generated in the post inspection after the operation cannot be input through the dedicated terminal of the production equipment. The sum of the defective quantity entered is immediately reflected in the quantity of good produced now, and the quantity of good in production is adjusted.

When production is carried out as much as the target quantity of the work order, the dedicated terminal of the production facility notifies the worker with a warning light and waits for the worker's work to end.

When the work is finished, the production equipment is shut down and the work management message is sent to the production management system server in order to prevent unnecessary overproduction.

If there is an additional work instruction after the work is finished, it waits for the next work order to be ready to start work and waits for the worker to prepare for the next work and press the start button. After all the work has been done as much as the work orders delivered in this way, the work waits for completion.

By operating the workshop through a dedicated terminal of the production equipment based on the work instruction, more reliable production quantity information, operation information of equipment and tooling tools, and non-operation occurrence information are aggregated and stored in the production management system DB 101. Based on this, various management tasks can be performed.

Figure 4 shows the configuration of a dedicated terminal of the production facility. The terminal can be divided into six parts. The worker uses the warning light and the screen output to provide the necessary information to the operator, and collects the information on the work site using the key input and the sensor input.

It exchanges information with the server using CAN communication and controls the production equipment using the relay output.

Dividing the dedicated terminal of the production facility into functional parts can be divided into the following three parts.

Providing work information: It downloads work instruction containing all contents related to on-site production from the server and informs the workers of the contents, and can also give orders to the site by using message information transmitted from the server.

Site information collection: It collects all information related to production such as the information input automatically such as the operation status of the production facilities of the site, the production quantity, and the information input manually by the operator such as the start and end of the work, the failure information and the non-operation information. To transmit.

Production facility control: It has facility stop function and facility start switch on / off function to control the operation status of production facility. In order to control the production facilities, it is necessary to know the details of the work to be carried out and all the information on the work in progress.

The dedicated terminal of the production facility manages and controls all the work in the field.

5 shows the software configuration of the production management system. The software configuration can be largely divided into a production management system server-side software which is in charge of various management tasks based on the dedicated terminal side of the production equipment operating the work orders and the aggregated production information.

First of all, the production management system server-side software configuration shows that the software provided by the production management system is all web programs except for some internal configuration programs.

Therefore, production management system software can be used anytime and anywhere on a computer connected to the Internet. It also controls the program's access rights to departments or specific users, thus maintaining the integrity of the information and providing security against the leakage of sensitive information.

The server-side software of the production management system is largely divided into sales management and work order management, production management, facility management, and various report management.

First, the work order of the production management system is divided into daily work plans, and the production products and production targets are prepared according to a predetermined company working time table.

After this work order is transmitted to the dedicated terminal of the production facility, the production information according to the current work order is monitored in real time. That is, through production management, real-time information such as currently produced products, production quantity, quantity defective, cause of failure, non-operation time, non-operation time, non-operation cause and progress rate are displayed on the screen. Another form of information is processed or databased for use as analytical data.

Production facility management makes it possible to monitor the operation / non-operational information of the facility in real time through the terminal in the field and analyze / view it. In addition, it provides periodic management function of specific production facility, and informs the operator or manager of the scheduled inspection and repair schedule of registered facility. Then, the details of the repair and inspection of the facility are made into a database.

Production management system can output various reports required for production management work. It provides various forms of inquiry screens and reports using graphs and charts, such as production performance inquiry, production facility inquiries, work order inquiry, and performance against plan.

In addition, purchase management manages raw material inbound and outbound shipments, and inventory management for finished products supports real-time product shipments and import / return processing. In addition, it identifies the defect information of each product obtained from the dedicated terminal for the production site in real time and makes a database to support the evidence data to reduce the defect rate during the process.

On-site dedicated terminal-side software is divided into four categories: work order processing, non-operation processing, failure processing, and message processing.

First, the work order processing unit downloads the work order created in the production management system server-side software to the dedicated terminal of the production facility, and the dedicated terminal directly operates the work order and collects production information. Therefore, even if the network connection with the production management system server is lost, the data on the production site is not lost because the dedicated terminal of the production facility holds the work orders and the production information on the work orders.

The non-operating part is used when the production facility is inactive and includes downtime and cause information. If there is no downtime for the equipment on site, the On / Off control right for the equipment has a dedicated terminal of the production equipment and generates a downtime event. At this time, the time stamp is recorded and the production management system server side is informed that the downtime has occurred. Once the non-operation occurs, the terminal of the production facility is notified to the worker through a warning light, and the display screen of the dedicated terminal displays a request for inputting cause information for the non-operation occurrence.

At this time, the operator inputs the reason for the inoperation and, when the inactivity is finished, informs the production equipment terminal of the start of work again. If the operator does not perform the input action required by the system, the production activity is no longer possible by restricting the operation of the production facility.

The defect processing unit is used only when a defect occurs during work at the production site, and receives the quantity and the reason code from the dedicated terminal of the production facility and transmits the information to the production management system server. The sum of the defective quantity sent at this time is immediately reflected in the quantity of the good.

The message processing unit eliminates the dislocation between the production site and the office by providing a notification service for sending a message from the production management system server side to a dedicated terminal of the production equipment and a call service for sending a message from the dedicated terminal to the production management system server side.

First of all, the notification service plays a role of transmitting production information of the production site to the server side and can process various messages from the server side. If a user selects a dedicated terminal of a target production facility in a web program and sends a message, inputs a message, and presses a send button, a message is displayed on a dedicated terminal for the production site. When the message is sent, the terminal notifies the worker of the warning through the beacon, and after the worker confirms the message, the beacon is turned off. In addition to these messages, the inspection and repair notification of the production facility can be sent to the production site dedicated terminal in the form of a message. In this way, other work instructions can be delivered to the worker through the message service. In addition, the worker can check the dedicated terminal of the production facility whenever the warning light is turned on and perform the corresponding work according to the contents of the given message.

In contrast, the paging service allows the operator to inform specific situations about the administrator or the system. Workers encounter various situations while working on the production site. In most cases, skilled workers are good at dealing with certain situations and do not require the assistance of other site managers. However, inexperienced workers do not know how to deal with the situation. In this case, use the paging service to inform the site manager of this fact and for any instructions or assistance.

FIG. 6 shows how real-time uptime information and stroke number information of equipment and tools collected during production of the product according to the work instructions are used for counting the utilization rate or managing the maintenance cycle.

The equipment and tool information management software part (equipment management) of the production management system server includes maintenance items of all equipment and tool tools and maintenance cycle information for each item as basic information. On the basis of this basic information, a cycle calculation is performed for each maintenance item by comparing the accumulated values of operating time and stroke information of each equipment and tool that are transmitted from the dedicated terminal of the production equipment. In this process, the maintenance targets of the equipment and tool are identified, and the maintenance notification function is used to inform the dedicated terminal of the production equipment, and the maintenance history is fed back.

Referring to FIG. 6 which shows the process of maintenance cycle management of an equipment and a tool, if this information is transmitted from the production site and the production results and operating hours of the equipment and the tool, this information is accumulated in the production management system DB 101 (S201). In operation S202, the facility and tool management software unit calculates the period.

Subsequently, the production management system DB 101 determines whether it matches the recorded notification period (S203), and if the notification period value of the maintenance item pre-registered in the facility and the tool management software unit matches the notification period value after the period calculation, This item is notified of the maintenance item to the terminal of the production facility, the production site to take the appropriate action for the maintenance item, and then send the maintenance history information back to the production management system server (S204).

Finally, the production management system server 100 stores the maintenance history information of the corresponding item and initializes the maintenance cycle value (S205).

The production management system of the present invention stops the operation of the production facility until the work order information is downloaded from the production management system server, and after the work order information is downloaded to the dedicated terminal, the worker manages the production management system server through the dedicated terminal. After inputting the work start signal, the operation control right of the production equipment is transferred to a dedicated terminal so that the production equipment can execute the work according to the contents of the work order information. The production management information of the products produced by the can be obtained accurately.

In addition, since the work order information includes data related to the tool of the production equipment, it is possible to accurately provide and secure the tool maintenance management information.

In addition, by controlling the operation of the production equipment in connection with the intranet and the Internet network, it is possible to obtain more accurate operation information than in the past, thereby improving the productivity.

1 is a block diagram of a production system of the present invention,

2 is a view showing an example of a work order information document applied to the production equipment system of the present invention,

3 is a flowchart for explaining a production system of the present invention,

Figure 4 is a block diagram of a dedicated terminal of the production facility of the present invention,

5 is a block diagram showing the configuration of a production management system using the production system of the present invention,

6 is a flowchart illustrating a management process of the production equipment of the present invention.

* Description of the symbols for the main parts of the drawings *

100-Production management system server 200-Terminal for production equipment

300-Production Management System Client PC

400-Production Equipment 500-Internet or Internet Network

Claims (5)

In the production equipment system is configured to connect the production equipment having a dedicated terminal to the production management system server and the production management system server can be connected to the production management system client terminal using the Internet network, The dedicated terminal stops the operation of the production facility until the work instruction information is downloaded from the production management system server, and after the work instruction information is downloaded to the dedicated terminal, the operator manages the production through the dedicated terminal. It is configured to input a job start signal to a system server, and after the operation start signal is input, the operation control right of the production facility is transferred to the dedicated terminal so that the production facility executes work according to the work instruction information. The production facility system, characterized in that configured to be transmitted to the production management system server in real time. The method of claim 1, When the production equipment is switched to the non-operational state in the course of carrying out work, the operator transmits the cause information of the non-operation of the production equipment to the production management system server through the dedicated terminal and restarts the production equipment. Production equipment system, characterized in that configured to be possible. The method of claim 1, The production management system server is a production facility system, characterized in that configured to be connected to the production management system client terminal through the Internet network. In the state in which the production equipment is stopped, the dedicated terminal of the production equipment downloads work order information from the production management system server, Worker sends a start signal to the production management system server through a dedicated terminal of the production facility, Operating the production facility according to the work instruction information after the work start signal is transmitted to a production management system server; When a non-operational state occurs during operation of the production facility, a worker inputting a non-operational cause through a dedicated terminal of the production facility, Including the step of restarting the production facility by the operator,  The operation information and non-operation cause information of the production facility is transmitted to the production management system server in real time through the dedicated terminal. The method of claim 4, wherein The non-operation cause information includes the tool management information of the production facility system control method.