KR20210145103A - System for flexible manufacturing line - Google Patents

Abstract

The present invention relates to a flexible production process system through a hybrid line. An automatic guided vehicle transports products between a plurality of stations, whereby the flexible production process system increases the flexibility and expandability of a production line through an AGV-based station pool line which produces products and increases speed, stability, and safety through a track-based stationary line connecting the stations with a track.

Description

Flexible production process system {SYSTEM FOR FLEXIBLE MANUFACTURING LINE}

The present invention relates to a flexible production process system, and more particularly, an AGV-based station pool line for producing products while transporting between a plurality of stations with an automatic guided vehicle Flexible production process that proposes a hybrid line that increases flexibility and expandability of the production line through It's about the system.

A smart factory refers to a factory in which the facilities and processes of the factory are intelligently connected to the production network, and all production data and information are shared and utilized in real time to operate for optimized production.

In particular, the CPS-based smart factory configures a cyber model in which a real factory is virtualized and synchronized with a factory that exists in reality, and then applies the collected data in real time to the cyber model to perform efficient operation of the manufacturing system. It should be able to autonomously recognize and respond to changes in circumstances such as equipment failure.

In the present invention, the flexibility and scalability of the production line are increased through an AGV-based station pool line that produces products while transporting between a plurality of stations with an automatic guided vehicle, We would like to present a flexible production process system that proposes a hybrid line that increases speed, stability and safety through a track-based stationary line that connects stations to tracks.

Next, the prior art existing in the technical field of the present invention will be briefly described, and then the technical matters that the present invention intends to achieve differently compared to the prior art will be described.

First, U.S. Patent Publication No. 2015-0294045 (2015.10.15) relates to a virtual modeling device that can express all ports, structures, and constraints of a physical system through modeling. do.

In addition, US Patent Application Laid-Open No. 2017-0031663 (2017.02.02.) is for managing various software operating in a cyber-physical system, and can manage version changes, issues/change events, and the like. The present prior art can diagnose and classify the dependencies of software artifacts in the software architecture of complex cyber-physical systems, and relate change events to software artifacts with changes in the diagnosed and classified dependencies, and also, complex cyber-physical systems. can be enhanced with new functions required by market demand, and defects that appeared during maintenance and repair of complex cyber-physical systems can be corrected by correlating diagnostic and classified dependencies and diagnostic and classified dependencies.

In addition, Korean Patent Publication No. 10-1222051 (2013.01.08.) relates to a data model creation method for a virtual factory and a data model middleware system for a virtual factory, and 3D CAD and 3D software dependent on independent software. By integrating virtual factory and virtual operation technology through simulation of dimensional CAE, integrated virtual manufacturing and virtual operation can be realized.

In the prior art, the flexibility and expandability of the production line can be improved through the AGV-based station pool line, which produces products while transporting between a plurality of stations with an automatic guided vehicle. There is no suggestion for a flexible production process system that offers a hybrid line that increases speed, stability and safety through a track-based stationary line that connects the stations to the track.

The present invention was created to solve the above problems, and it is an AGV-based station pool line that produces products while transporting between a plurality of stations with an automatic guided vehicle. Flexible production process that proposes a hybrid line that increases flexibility and expandability of the production line through The purpose is to provide a system.

A flexible production process driving method according to an embodiment of the present invention includes a plurality of stations and an A-Zone smart learning factory connecting the plurality of stations with rails; and a plurality of stations and a B-Zone smart learning factory connecting the plurality of stations with rails; in a flexible production process system to which a flexible production process line is applied, in the flexible production process system, the A-Zone and B- Zone A safety zone is placed between the smart learning factories and connected with another rail to form a single line between the A-Zone and B-Zone, and a transfer robot is placed between the A-Zone and B-Zone. transporting the product to and in the flexible production process system, each of the plurality of stations is driven by being coupled to the line in a one-touch connector type, and an operator arbitrarily changes the position of each station to configure and drive the station. .

In addition, the flexible production process line includes: an AGV-based station pool line for producing products while transporting between a plurality of stations by an automatic guided vehicle; and a track-based stationary line connecting a plurality of stations to a track, wherein some stations using the AGV-based station full line and the track-based stationary line are combined into a track. and the rest are characterized in that they constitute a hybrid line that transports products using an automatic guided carriage.

In addition, in the flexible production process system, it is controlled so that a specific shuttle is stopped on the rail of the line and other shuttles are not waiting. to move directly to another process, and to secure a separate shuttle waiting section to change the order of the front and rear of the shuttle, and a touch panel is attached to the station to monitor the working status through the touch panel and controlling, when the operator manufactures the user station, characterized in that it is configured to be able to connect to the flexible production process system.

In addition, the flexible production process driving method, in the flexible production process system, comprises a monorail type that is transferred to a shuttle for product production, assembly logistics processing, and networking to perform a function of a smart logistics system, further comprising: A controller that performs acceleration, deceleration control, and forward monitoring functions is built-in inside the shuttle, and the controller has an internal memory to write and read data of the current location, providing information on products mounted on the shuttle A plurality of the shuttles operate simultaneously in the A-Zone and the B-Zone, and the monorail conveyors are dispersed and operated individually, characterized in that the smart logistics system operates regardless of the production process of the line do it with

In addition, in the flexible production process system, the conveyor of the monorail and each process station provide a one-touch method in which at least one communication cable, power supply, and pneumatic valve are collectively fastened, so that even if the position of the process station is changed, the process flow is not affected. In the flexible production process system, the shuttle, which has finished supplying raw materials to each process station, moves to another location and works with a new task, and records the work history of all shuttles. It is possible to predict the lifespan state of the shuttle through data management, and the shuttle stops at a position to collaborate with the operator, and is configured to be inclined at a predetermined inclination according to the work environment of the operator.

In addition, the flexible production process system further includes an IRM (Intelligent Routing Module), in optical communication with the shuttle, and the IRM controls the track switch installed on the rail in conjunction with the PLC system and the computer control system, IRM works with the monorail conveyor to give each shuttle ID, read ID, delete ID, or a combination thereof, so that the A-Zone smart learning factory and the B-Zone smart learning factory can It is characterized in that it includes connecting and driving by being connected to one line.

In addition, the station includes a supply station that automatically receives a raw material pallet using a mobile robot to supply raw materials, and performs external inspection and mounting inspection of the raw material using a vision, wherein the mobile robot is After transporting raw materials and inspecting the appearance of finished products, the pallets are returned and processed by separating normal and defective products, and the station provides a one-touch method in which at least one communication cable, power supply, and pneumatic valve are collectively fastened. Therefore, it is characterized in that the position can be changed without a separate wiring work.

In addition, the station includes a laser marking and labeling station that performs laser marking on the inner surface of the upper and lower case of raw materials, attaches label paper to the upper part, and traces the history of the raw material, and when the raw material is received, the finished product through vision inspection After determining whether it is for assembly or recycling, the laser marking style is XYZ 3-axis simultaneous scanning method, and the laser marking and labeling station is a one-touch connector fastening method for power, communication, pneumatic valves or these All cables are automatically fastened, including combinations of

The station also includes at least two automatic assembly stations, and an assembly and bolting station that intelligently puts material into the line according to assembly time, wherein the assembly and bolting station is between the lower case and the PCB. includes automatically performing bolt fastening, the bolts for fastening the bolts are automatically supplied, torque can be measured when the bolts are fastened, and data collection and failure are determined, and the assembly and bolt fastening station is one-touch All cables, including power, communication, pneumatic valves, or combinations thereof, are automatically fastened by the connector fastening method, so that the position can be changed without separate wiring work, including changing the thrust and speed for screw driving, The assembling and bolting station is a Z-axis servo (thrust control) ball screw method as a Z-axis descending driving method, enhancing precision by mounting an encoder, and controlling torque, rotational speed, angle, or a combination thereof. , characterized in that it includes an automatic assembly station including a screw feeder that minimizes screw pinching by horizontal forced feeding by vibration.

The present invention configured as described above is an AGV-based station pool line that produces products while transporting between a plurality of stations with an automatic guided vehicle and a track connecting the plurality of stations By configuring a hybrid line for a track-based stationary line, it has the effect of increasing flexibility and expandability of the production line, and increasing speed, stability and safety.

1 is a view of a production process line according to the prior art.
Figure 2 is a conceptual diagram of a flexible production process line according to an embodiment of the present invention.
3 is a diagram showing the layout of a smart learning factory system according to an embodiment of the present invention.
4 is a diagram illustrating a manufacturing process flow of a smart factory according to an embodiment of the present invention.
5 is a conceptual diagram of a product production line of a smart factory according to an embodiment of the present invention.
6 is a conceptual diagram illustrating a process flow of a smart factory according to an embodiment of the present invention.
7 is a structural diagram showing a smart factory according to an embodiment of the present invention in five layers.
8 is a data flow diagram of a smart factory according to an embodiment of the present invention.

Hereinafter, various embodiments of the present invention will be described in detail with reference to the accompanying drawings. Specific structural or functional descriptions of the embodiments disclosed in the specification or application of the present invention are only exemplified for the purpose of describing embodiments according to the present invention, and unless otherwise defined, technical or scientific All terms used herein, including terms, have the same meanings as commonly understood by those of ordinary skill in the art to which the present invention pertains. Terms such as those defined in a commonly used dictionary should be interpreted as having a meaning consistent with the meaning in the context of the related art, and should not be interpreted in an ideal or excessively formal meaning unless explicitly defined in the present specification. No.

1 is a view of a production process line according to the prior art.

As shown in Figure 1, the conventional production process line includes a linear line (Linear Line) and a circulation line (Circular Line).

Here, the linear line refers to a straight-line production line in which a product is finally produced when parts are assembled at a station of each process. Stations are linearly connected to form a line, so the next station receives and processes the results processed by the previous station. Therefore, when even one of the plurality of stations is jammed, the production process time required for the production of the entire product is increased.

In addition, the circulation line is a structure in which the robot (feeding robot) inputs and outputs the product from a plurality of stations surrounding it in a situation where there is a robot supplying the product or a device corresponding to it in the center according to the order of the necessary processes in the product production process. , such a structure may be configured such that a plurality of them are connected to each other and interlocked.

This structure has traditionally been mainly used when the process is very simple, and has a planar structure, so it occupies a lot of space and takes a lot of time to perform the process.

Accordingly, the present invention intends to propose a more flexible, high-speed and stable production process line with respect to the conventional process line.

Figure 2 is a conceptual diagram of a flexible production process line according to an embodiment of the present invention.

As shown in FIG. 2 , an AGV-based station pool line for producing products while transporting between a plurality of stations by an automatic guided vehicle is provided. This production line is a process line with enhanced flexibility and scalability as an automatic guided carriage can move freely between stations.

A track-based stationary line connecting a plurality of stations to a track is also presented. This is a structure that transports products by connecting stations to a fixed track, and since the shuttle moves to a designated track, it is a process structure with excellent speed, stability and safety because it can mail products at high speed and stably.

The present invention intends to propose a new hybrid process structure by integrating these two process structures.

The production process line proposed in the present invention is a flexible production process line, some stations are tied to a track, and the rest are structured to transport products using an automatic guided carriage. From this, the flexible production process of the present invention has the advantage that flexibility, scalability, speed, stability, safety, etc. are improved.

The smart learning factory system 10 to which the flexible production process according to the present invention is applied is provided with individual smart learning factories 100 and 200 divided into a plurality of zones and a safety zone existing between them, the safety zone is connected to a separate rail 30 so that the transport robot 300 transports the product.

In each smart learning factory area, an integrated line is formed by the rail 30 and the branching device 20, and stations are installed in each part of the line to perform assembly or inspection of specific products. A transport robot operates between the zone and the zone, and raw materials supplied to the zone are supplied to the mobile robot 400, and are responsible for transporting products for shipment and recycling.

The smart learning factory system 10 of the present invention divides a plurality of smart learning factories into zones, respectively, and when each zone is connected with a rail, a line consisting of a smart learning factory of one integrated larger zone is formed, and each zone is The transport robot 300 connects the logistics and production processes, and the mobile robot 400 is responsible for transporting raw materials or products for logistics and production from outside to inside and from inside to outside in each zone. .

Therefore, the smart learning factory system 10 according to the present invention combines the smart factory with smart learning, and configures the learning factory smartly. In other words, it is easy to add or delete a new process, and it is easy to reduce or expand the process, so it is a smart factory that discovers ideas for specific products, makes samples that materialize ideas through design, and mass-produces them in factories as needed. learn to lead to

Hereinafter, a smart learning factory system to which a flexible production process line is applied according to an embodiment of the present invention will be described.

3 is a diagram showing the layout of a smart learning factory system according to an embodiment of the present invention.

3, the smart learning factory system according to the present invention is a system to which all technologies such as PLC and PC control, various sensor control, robot control, monitoring, data acquisition and analysis, and industrial virtual reality system construction are applied. .

First, [Table 1] is a specification of the specifications and uses of the smart learning factory system according to an embodiment of the present invention.

[Table 1]

In addition, the smart factory system according to an embodiment of the present invention is a process in which raw materials are supplied for a plurality of specific products and assembled, inspected, and packaged to produce finished products, and various PLC control and sensors applied to smart factories in industrial sites By acquiring technology for control, robot control, vision, and PC control and acquiring data using OPC UA method, MES (Manufacturing Execution System), CPS (Cyber Physical System), SCADA (Supervisory Control and Data Acquisition), POP (Point of Production), AR (Augmented Reality), CLOUD, etc. are possible.

Multiple PLCs are used for system control, and heterogeneous communication is possible by applying them to raw material and finished product warehouses, smart learning factories A-Zone, and B-Zone, respectively. In addition, the decomposition process station 260 can be controlled through a PC.

The entire system can control the process using PLC system and FNS (Fieldbus Network System), and automatic control practice, industrial network control, and distributed control practice are possible. In addition, IoT sensors (temperature, humidity, vibration, power, air pressure, etc.) are applied to measure, and the measured values are transmitted through Modbus communication.

In addition, a total of 10 or more CCTVs are installed in the entire system in automatic and manual work areas, enabling constant recording and video storage management.

It collects, analyzes, manages, and monitors various data by applying elements such as sensors, RFID, and vision systems for each process-specific material and process data acquisition.

Determine the specifications, models and quantities of various sensors to be applied to each process, acquire the processed signals of the applied sensors and actuators from multiple PLC systems and PC systems, and build a DB server for overall data management and analysis to provide real-time data It is collected and accumulated continuously, and desired data can be checked as needed.

Since the shuttle controller of the smart logistics system has an internal memory, it is possible to write/read the data of the current location, and provides information about the loaded product. In addition, in A-Zone and B-Zone, for example, 6 or more shuttles are transported simultaneously and work is possible.

It is desirable to design the smart logistics system and each process station so that there is no problem in the process flow even if the location of the process station is changed in a way that the smart logistics system and each process station can be separated and combined freely, and various communication cables, power, and air pressure are connected together in a one-touch method.

If raw materials are provided so that a plurality of specific products can be manufactured with a plurality of specifications, a production order can be made by selecting a product with a specific specification in a separate production instruction program.

All products are manufactured in two types: for shipment of finished products and for recycling, and in the case of recycling, they are automatically disassembled in the entire packaging process and transported and loaded back to the raw material warehouse using the mobile robot 400.

Production instructions should be able to select PUSH, PULL, and TOC methods, and a comparative analysis POP for the operation rate of each process is provided for the production results of the three methods.

Through monitoring the production status, it is possible to analyze the production forecasting plan and performance through big data, and it is possible to analyze the cycle time for each process.

Using a collaborative robot, a human-robot collaboration process is applied, and in the case of automatic, manual, or semi-automatic, comparative analysis of productivity and cycle time is possible.

By applying the MES optimized to the smart learning factory system, it is installed including customization work to fit the MES engine and this process so that the MES core functions such as lot tracking, work/inventory management, process management, data collection and analysis can be used. .

By using CPS S/W, the digital twin (real-time operation on the monitor and equipment control through smart devices, etc.) is provided for the entire system.

Unit processes are individually controlled based on the basic process diagram, and improved processes and detailed components and detailed specifications for each process can be presented efficiently by referring to the basic process diagram. The above presentation is 2D/3D drawing (CAD file and printed version), smart logistics system process scenario block diagram, 2D/3D drawing for each process of smart logistics system (front view, side view, etc., detailed dimensions), Smart Learning Factory A- Zone, B-Zone There are 2D/3D drawings for each station (front view, side view, etc., detailed dimensions), and 2D/3D drawings for lab layout (front view, side view, etc., detailed dimensions).

The drawings include production information and management GUI using MES, facility monitoring view GUI, CPS implementation GUI using PLM (Product Life Management), GUI for DID (Digital Information Display) transmission, and the like.

The principle of operation can be easily understood to be suitable for training, it must be manufactured solidly, and it must ensure stable continuous operation. The MTBF (Mean Time Between Failures) is more than 30 days.

It guarantees system and operator safety against abnormal power cut-off. To this end, the computer device uses a UPS device to protect the system and data, and to ensure the safety of workers against emergency shutdown.

On the other hand, for electrical safety, the grounding is safely configured to protect the operator and the system, and the exposed metal part is insulated to prevent electric shock.

Noise is based on (1) Continuous Level: < 80 dBA, (2) Instantaneous Level: < 120 dBA, (3) Measuring device height: 1.5m, measuring distance: 1.0m, etc.

The environment for the smart learning factory can be monitored through the network. The measurement target is temperature, humidity, voltage, vibration, air pressure, etc., and the measurement period is 1 time/sec or more.

[Table 2] is a specification of specifications and uses for A-Zone of a smart learning factory according to an embodiment of the present invention.

[Table 2]

Hereinafter, the Smart Learning Factory A-Zone will be described.

Smart Learning Factory A-Zone and B-Zone should normally be operated separately, and if necessary, it is possible to operate as a single line by connecting the rails between A-Zone and B-Zone. In addition, it is a system including a safety device so that there is no safety problem when an operator or an outsider enters by forming a safety zone between A-Zone and B-Zone.

The raw material warehouse storage capacity should be able to store a total of 1,400 raw materials, for example, 100 each of 3 types of product cases (upper/lower), and transported to a conveyor belt using a 4-axis stacker crane when releasing necessary materials according to production instructions. and the mobile robot 400 makes it possible to transfer it to the aligner station 180 .

The entire process can be composed of, for example, more than 10 stations, and each station must be connected to the smart logistics system line with a one-touch connector type to be operated, and there is no problem in operation even if the user changes the location arbitrarily .

The shuttle stops on the rail of the smart logistics system to prevent other shuttles from waiting, and when the shuttle arrives at all stations, the jig is moved to the station to work, and the shuttle is immediately moved to another process. It is possible to change the order of the front and rear of the shuttle by securing a separate waiting section for the shuttle. All stations are equipped with a 10-inch or larger touch panel to monitor and control the working status, and when a learner makes the user stations 140 and 240, it is possible to connect to the smart factory system.

In addition, the smart logistics system consists of a monorail-type smart logistics system that is transported by an intelligent shuttle for production, assembly logistics processing, and networking. Inside the shuttle, the controller has built-in acceleration, deceleration control and forward monitoring functions. Since the shuttle controller has an internal memory, it is possible to write/read data of the current location, and provides information on the installed product. Six or more shuttles operate simultaneously in the smart logistics system A-Zone. The monorail conveyor is distributed and can be operated individually, and the logistics system operates regardless of the production process of the line.

The monorail conveyor and each process station are free to separate and combine, and various communication cables, power and air pressure are collectively fastened in a one-touch method so that there is no problem in the process flow even if the position of the process station is changed. The intelligent shuttle, which supplies raw materials to each process station, moves to another location, receives a new mission and works, and it is possible to predict the life of the shuttle through data management of the work history of all shuttles. The shuttle should be stopped at the position where it collaborates with the operator, and it is tilted 15 to 20 degrees to help the operator's work environment.

Since IRM (Intelligent Routing Module) is attached, optical communication with the shuttle is performed. IRM controls track switches, etc. in conjunction with PLC system and computer control system. IRM works with the monorail conveyor to assign IDs to each shuttle, read IDs, and delete IDs. A-Zone and B-Zone can be connected at any time if necessary, and the two lines are connected as one to drive. Here, the track switch is a switch installed on the rail to control whether the shuttle moves or stops on the rail.

The raw material pallet is automatically supplied using the mobile robot 400, and the raw material is input and, at the same time, the external appearance inspection and the PCB mounting inspection of the raw material are performed using vision. The vision camera is composed of 2 million pixels or more and a necessary lighting device is attached. Raw material inspection and transfer is made up of SCARA robots and products within the effective range of transfer 800 mm (31.5 "). After visual inspection, normal goods and defective goods are separated and discharged, and the storage capacity of each part is determined at the supply station. A total of 80 cases are stored, 10 cases (upper/lower) and 10 each of PCB products.The pallets that have been shipped out are transported by the mobile robot 400, and the supply station is connected to the logistics system with one-touch connectors for power, communication, All cables such as pneumatic pressure are automatically fastened, so the position can be changed without additional wiring work.

In the laser marking and labeling stations 220 and 250, laser marking is made on the inner surface of the upper/lower case of raw materials, and label paper is attached to the upper part of the PCB board to enable tracking of raw material history. Upon receipt of raw materials, it is necessary to determine whether it is for assembly or recycling of finished products through vision inspection, and subsequent work must be carried out. The laser marking style has an X-Y-Z 3-axis simultaneous scanning method. The laser marking and labeling station 250 is a one-touch connector fastening method to the logistics system, and all cables such as power, communication, and air pressure are automatically fastened, so that the location can be changed without separate wiring work.

The assembly and bolting stations 120 and 130 are composed of at least two automatic assembly stations 120 or 130, and materials are intelligently put into the line according to the assembly time. The bolts between the lower case and the PCB are automatically fastened, and the bolts must be supplied automatically for bolting. The automatic assembly station (120 or 130) is a one-touch connector fastening method to the logistics system, so that all cables such as power, communication, and air pressure are automatically fastened so that the location can be changed without separate wiring work. The automatic bolt assembly system can change the thrust and speed for screw driving, and the automatic bolt assembly system is a Z-axis servo (thrust control) ball screw method as a Z-axis descending drive method. The automatic bolt assembly system must enhance the precision by installing an encoder, and can control torque, rotation speed, and angle. The screw feeder of the automatic bolt assembly system minimizes the screw pinching phenomenon by horizontal forced feeding by vibration.

For manual assembly and bolting stations 120 and 130, if there is a manual assembly instruction from the producer while assembly is being performed at the automatic assembly station 120 or 130, the raw material assigned to the production of the automatic assembly station is transferred to the manual assembly station. (120 or 130) is automatically assigned. It is possible to monitor the torque value of a manual drill for workers, and in the case of automatic drilling, it is possible to analyze the torque value during automatic/manual drilling by providing a comparison graph with the torque value. By applying VR goggles and AR, the operator can easily work according to the operation guide, and the smart logistics system shuttle at the operator's location is equipped with a tilt function.

The assembly inspection station 150 performs a product linear inspection with an LVDT (Linear Variable Differential Transformer) inspection system to inspect the bolt assembly lifting phenomenon that may occur during automatic assembly or manual assembly. Visual inspection, such as laser marking, is performed using vision, and the assembly inspection station 150 is a one-touch connector fastening method to the logistics system, and all cables such as power, communication, and air pressure are automatically fastened so that the location can be changed without separate wiring work. .

The upper case assembly station 160 assembles the upper case using a cooperative robot when the jig in which the lower case and the PCB are assembled arrives. All cables, such as power, communication, and air pressure, are automatically fastened to the upper case assembly station 160 logistics system by a one-touch connector fastening method, so that the location can be changed without additional wiring work.

With respect to the defective product discharge station 170, normal products should be bypassed, and defective products are discharged at a location where there is a defective product discharge box. Discharge according to the data analysis of the assembly inspection station (150). Defective product inspection data stores defective product information in the shuttle through IRM.

The smart logistics system shuttle arrives at the automatic mode station 230 . The shuttle product is transferred to the finished product buffer 230 through a jig capable of 3-axis motion (3-axis jig), and the empty pallet is sent to the jig supply station. The finished product is transported by lifting it with a grip system on a 3-axis jig. All cables, such as power, communication, and air pressure, are automatically fastened to the finished product buffer station 230 logistics system by a one-touch connector fastening method, so that the location can be changed without additional wiring work. According to the B-Zone scheduler, the finished product is transferred using a collaborative robot and gantry system.

Hereinafter, the smart logistics system A-Zone, B-Zone transfer robot 300 will be described.

The product in the A-Zone finished product buffer 230 is transferred to the B-Zone track using the articulated robot grip system. The articulated robot must be attached to the gantry system between the A-Zone track and the B-Zone track, and the product must be gripped during transport. Automatic door rail is applied between A-Zone and B-Zone, so if necessary, A-Zone and B-Zone should be connected with one rail to operate, and the gantry system transfer section and A-Zone, B-Zone Safety technology is applied to the section in between, so that when a person approaches, each equipment must be emergency stop. In addition, the safety of the operator is considered by double monitoring the safety zone using the Safety Light Curtain Sensor and the infrared sensor. A safety-related emergency switch should be installed in the gantry system transfer section so that the operator can forcibly stop.

For the jig feeding station, according to the sorting and sorting of raw materials shipped from the feeding station, the jig is placed on the shuttle at the jig feeding station and then transported. Type1 (jig for product A) & Type2 (jig for product B) & Type3 (jig for A/B product mix) should be loaded in the magazine storage box, and are supplied by type according to the production instructions. If production of one type of product continues, Type 3 (A/B product mixed mounting jig) is put in to ensure smooth mass production. All cables, such as power, communication, and air pressure, are automatically connected to the jig change station logistics system by one-touch connector fastening method, so the location can be changed without additional wiring work.

[Table 3] is a specification of the specification and use of the B-Zone of the smart learning factory according to an embodiment of the present invention.

[Table 3]

Smart Learning Factory A-Zone and B-Zone should normally be operated separately, and if necessary, connect the rails between A-Zone and B-Zone to operate as one line. In addition, it is a system including a safety device so that there is no safety problem when an operator or an outsider enters by forming a safety zone between A-Zone and B-Zone.

Packed finished products should be loaded on a pallet by type/color or more and transferred to the finished product warehouse using the mobile robot 400 . The finished product warehouse is configured so that more than 30 pallets for each product can be loaded. When the finished product delivery instruction is received from the upper system, the finished product warehouse transmits product inventory status information to the upper system to transmit information on whether to order product production or to issue inventory. The entire process should consist of more than 7 stations, and each station should be able to be operated by fastening it to the smart logistics system lane in a one-touch connector type, and there should be no problem in operation even if the user arbitrarily changes the location and configures it. There should be no case where the shuttle stops on the rail of the smart logistics system and other shuttles are waiting, and when the shuttle arrives at all stations, the jig is moved to the station and work is done, and the shuttle must be moved to another process. It should be possible to change the order of the front and rear of the shuttle by securing a separate shuttle waiting section. All stations must be equipped with a 10-inch or larger touch panel to monitor and control the working status. When a learner creates a user station, it must be possible to access the smart factory system.

The smart logistics system according to the present invention is a monorail-type logistics system that is transported by an intelligent shuttle for production, assembly logistics processing, and networking. Inside the shuttle, the controller has built-in acceleration, deceleration control and forward monitoring functions. Since the shuttle controller has an internal memory, it is possible to write/read data of the current location, and provides information on the installed product. The shuttle must operate in 6 or more smart logistics system B-Zones. The monorail conveyor must be distributed and able to operate individually, and the logistics system must operate regardless of the line's production process. After the labeling station 250 process, the shuttle must be transported to the second-floor rail for packaging and shipment using a lift, and for recycling products, the shuttle must be separated into two and transported to the first-floor rail. The monorail conveyor and each process station can be separated and combined freely, and various communication cables, power, and air pressure are connected together in a one-touch method. The intelligent shuttle that supplied raw materials to each process station must move to another location and work with a new mission.

The shuttle at the location where the operator collaborates is equipped with a tilt function and is tilted 15 to 20 degrees to help the operator's work environment. It is equipped with an IRM (Intelligent Routing Module) and performs optical communication with the shuttle. IRM controls track switches and the like in conjunction with PLC systems and computer control systems. IRM plays the role of assigning ID to each shuttle, reading ID, and deleting ID by interworking with the smart logistics system.

As can be seen from FIG. 3 , the A-Zone and the B-Zone are connected at any time when necessary, and the two lines are connected as one so that they can be driven.

Type1 (jig for product A) & Type2 (jig for product B) & Type3 (jig for A/B product mix) are loaded in the magazine storage box, and are supplied by type according to the production instructions. If the production of one type of product continues, Type 3 (A/B product mixed mounting jig) is put in to ensure smooth mass production. According to the transfer information of the A-Zone finished product buffer station 230, the jig of the transferred product is taken out. The jig returned from the packing station 270 or the disassembling station 260 is stored in the jig buffer again, and waits until the next transfer information instruction is given. All cables, such as power, communication, and pneumatic valves, are automatically connected to the finished product jig station logistics system by one-touch connector fastening method, so the location can be changed without additional wiring work.

The laser marking station 220 performs laser marking on the upper/lower case of the raw material so that the trace of the raw material is printed. User Text, ID, Bar-code, etc. can be printed on the upper part of the product case, and a user-defined logo can be printed on the lower part by the operator. In the laser marking station 220, the product may be rotated using a rotation unit for marking on the lower part of the case to be positioned on the print sensor. The laser marking style has X-Y-Z 3-axis simultaneous scanning. The laser marking station 220 is a one-touch connector fastening method to the logistics system, so that all cables such as power, communication, and air pressure are automatically fastened, so that the location can be changed without separate wiring work.

In the vision/function inspection station 210 , when performing a functional inspection, the product may be shaken up, down, left, and right using a cooperative robot to test the operating state of the product. For product function inspection, communication test inspection by Bluetooth communication can be performed. The vision inspection of the product can distinguish the appearance and scratches caused by damage to the product, and the state of the upper and lower laser markings can be checked using a collaborative robot. Inspection result data is transmitted directly to the upper system, and when transferred to the defective discharge station, the result data is displayed and transmitted to the operator in an easy-to-understand manner. The vision & function inspection station is a one-touch connector fastening method to the logistics system, and all cables such as power, communication, and pneumatic pressure are automatically fastened so that the location can be changed without additional wiring work.

The results of automatic assembly and manual assembly are analyzed and discharged. In this case, the defective product inspection data may store defective product information in the shuttle through IRM. The normal product bypasses the bad discharge station. The station has two or more work jig fixing spaces so that when the shuttle arrives after work is completed, the jig is put down on the station and the completed work jig can be put on the shuttle.

If there is a worker in the defective product discharging station 170, if there is a manual inspection instruction from the operator, the shuttle stops in front of the operator in case of a defective product, and the operator lowers the jig, mounts it on a manual workbench, performs a function test, and then shuttles the jig again. to be able to send it to By applying VR goggles and AR, the operator can recognize which of the Jigwe products is defective, and enables easy functional inspection according to the operation guide. The smart logistics system shuttle at the operator's position is equipped with a tilt function and is designed to help the operator's working environment by tilting it by 15-20 degrees. All cables, such as power, communication, and air pressure, are automatically connected to the defective discharge station logistics system by one-touch connector fastening method, so that the location can be changed without additional wiring work.

A label paper on which a barcode and a QR code that can be distinguished by the labeling station 250 are printed is attached to the product determined as a finished product by the vision/function inspection station 210 . The label paper output should be printed with the content specified by the system operator. The labeled product sends product information to and transports to the packaging station 270 . The disassembled product passes the labeling station 250 . All cables, such as power, communication, and air pressure, are automatically fastened to the labeling station 250 logistics system by a one-touch connector fastening method, so that the location can be changed without additional wiring work.

The packing station 270 has two or more jig fixing spaces for work so that when the shuttle arrives after work is completed, the jig is put down on the station and the completed work jig can be put on the shuttle. Empty shuttles are transported to the shuttle station so that they can be ready for work. The finished product transferred to the packaging station 270 is placed on the packaging paper that is automatically supplied using a horizontal articulated robot (Delta), and PET wrapping paper made to fit the shape of the product is transferred to cover it. For certain products, it is possible to separate the battery and product for packaging. When the PET mold wrapping paper is covered on the product, the paper wrapping paper and the PET mold wrapping paper can be adhered using the adhesive unit. The packaged finished product is transferred to the finished product warehouse using the mobile robot 400 . When the product is transferred from the packaging station 270 to the finished product warehouse, product information (type, color, quantity) is sent to the finished product warehouse. All cables, such as power, communication, and air pressure, are automatically fastened to the packaging station 270 logistics system by a one-touch connector fastening method, so that the location can be changed without additional wiring work.

Blister packing includes mechanical drive method by cap method, flat plate type adhesive structure by pressing upper and lower plates, thermoforming method adhesion, and packing method suitable for quick and easy mold replacement.

The disassembly station 260 is constructed as a real-time control system using a PC to enable system control using various PC programs. The station has two or more jig fixing spaces for work so that when the shuttle arrives after work is completed, the jig is put down on the station and the completed work jig can be put on the shuttle. In the disassembly process, the type and state of the product can be identified through vision inspection. The decomposition process should be carried out in collaboration with the operator, and when there is no operator, the decomposition process should be performed as an automated process. A collaborative robot equipped with a grip system enables disassembly work in collaboration with a worker, and VR goggles and AR are applied so that the worker can easily disassemble according to the work guide. The disassembled product is transferred through a 3-axis server jig and conveyor. All cables, such as power, communication, and air pressure, are automatically fastened to the disassembly station 260 logistics system by a one-touch connector fastening method, so that the location can be changed without additional wiring work. Bolts can be removed using a 3-axis server jig for bolt fastener control. The automatic bolt disassembly system is variable in thrust and speed for screw driving. The automatic bolt disassembling system is a Z-axis descending driving method, and a Z-axis servo (thrust control) ball screw method is preferable. The automatic bolt disassembling system enhances precision by mounting an encoder, and enables control of torque, rotation, and angle. Using the upper/lower case and PCB sorting device for each product, the colors are classified and classified in the parts palette. Part storage can be classified as a 3-axis server robot. The classified parts are transferred to the raw material warehouse using the mobile robot 400, and when the parts are stored in the raw material warehouse, the parts for disassembly are classified and stored.

Here, the mobile robot 400 (Mobile Robot) will be described.

The mobile robot 400 must be a driving method based on a HAP sensor capable of forward/backward/in-situ rotation. When an obstacle appears using the front and rear sensors, it automatically stops and enables re-running. Make it work with the onboard system using the controller. Process control is possible by optimizing with the process system. It is possible to simultaneously control and monitor the mobile robots 400 by using Enterprise Management, and to control traffic through simultaneous control of multiple mobile robots 400 and communication between adjacent robots. The battery charging of the mobile robot 400 must be performed efficiently and the battery state is shared with the smart learning factory system. It is possible to maintain and manage task traffic by sharing information between the mobile robots 400 . The mobile robot 400 performs a transfer operation using a mechanism of a stacker crane structure. Transfer the stored finished product using the clamp-type structure. It should be a front and rear drive system using a stacker crane structure in the front and a clamp structure in the rear. The data communication method of the smart factory using the mobile robot 400 controller and the loading system and WiFi is preferable. Using a robot system, pallets are shipped from the raw material warehouse and supplied to the sorting and supplying station. Defective products are collected during assembly and finished products are packaged before shipment and transported to the finished product storage warehouse. In addition, each part disassembled in the decomposition process station 260 is transferred back to the raw material warehouse.

The loading system enables communication and interlocking control of data with the smart learning factory system. It is possible to transfer the stored material in the warehouse / enter the supply process / transfer the finished product to the warehouse. It is possible to transfer more than 14 kinds of materials from the material warehouse using the conveyor mounted on the mobile robot 400, and it is possible to simultaneously transfer two or more pallets using a conveyor and a stopper. Data communication using the integrated control system and WiFi, data sharing and control of location information and work information are possible, and when realizing equipment of the smart learning factory system, it automatically avoids and corrects the path when people and obstacles occur, so that the collision avoidance system is is attached

The conveyor system is a conveyor belt type, and the driving method is composed of a DC motor and a reducer attachment type. A sensor and a stopper are configured so that two or more pallets can be transported at the same time. A sensor and a driving motor can be operated using I/O provided by the mobile robot 400 .

Next, I would like to explain the set of raw materials.

Raw materials for a specific product must be supplied, and the upper case, lower case, and packaging case of each product are provided as injection products. For example, a timer should be in the form of a hexagon, displaying a number on each side, and a built-in LED light should be lit on the corresponding number. In addition, it should be possible to set the time by shaking the product, an alarm should sound according to the specified mobile phone and distance, and an app should be provided to enable various settings through the mobile phone app. In addition, the tag must be made in the form of an oval or polygon, and an alarm sounds according to the specified distance from the mobile phone and an app is provided so that various settings can be made through the mobile phone app. A battery must be provided for a specific product, and in order to minimize battery consumption, the components in the PCB use low-power products. In addition, for certain products, a battery charging function is included.

The following is to explain the production operation system (MES/Manufacturing Execution System).

Products can be ordered through web and mobile apps, and the process from ordering to shipment can be monitored and visualized. It is possible to manage all production activities from product ordering to quality inspection management of finished products. Production performance, product management, facility utilization rate, and product quality information on the site are available. Lot management for product history is possible. It is possible to aggregate/analyze/monitor the collected data. It is configured so that data can be acquired and analyzed using the server. It is possible to manage user, user group, and reference information for each user. Daily/monthly production performance can be inquired through Report by process/product. If you build a system on the server and issue a license so that you can access and use it at any time without any restrictions, users can use it without any restrictions on time or place.

The system management function consists of multi-language function (Korean and English support available), user authority management, system performance management, alarm management, etc. The production progress management function consists of manufacturing standard information setting and work standard management. The barcode label management function consists of barcode ID management and barcode ID definition functions.

Production management functions include production plan upload, production progress management, production history management, and production status inquiry functions. Material management functions include material receipt/transfer/release, material lot status/history inquiry, and material lot inquiry by warehouse. Quality control functions include measurement data collection, process quality, and release inspection functions. The facility management function includes facility status management, facility failure management, and facility data inquiry function.

The user information/authority management function registers and manages users, user groups, and usage screens, so that users are assigned to user groups with basic information such as user groups, e-mails, and names, so that different screens can be used for each user group. do.

The alarm management function enables delivery of various notifications that occur during product production through alarm messages. Alarm can be delivered through text message or user E-Mail. The code management function enables a variety of codes to be used in a program. Code management such as defective code, rework reason code, pending code, and lot type is possible.

The system performance management function is a function that analyzes the system performance, so that the service performance can be inquired and the overall performance can be stably maintained. The standard information management function standardizes the master information required for process progress by type, so that it can be systematically systemized and managed so that it can be organically connected.

The product management function should be able to define the standard information management for the product through the screen, and even detailed items can be managed through the pages divided into general/property/group setting/user-defined fields. The work order management function can register work orders by creating work orders and uploading them to the program.

The production progress and production management function can create daily/monthly production reports based on the performance input at the production site, and the production performance can be viewed through the report by process/product. The process management function enables processing and tracking by work order/lot/product/process, etc., and management of lot status change history. With the history management function, all manufacturing history from creation to shipment can be traced for products that have undergone the process, and facility history and measurement data generated along with the manufacturing history can be managed together.

The material management function must be able to manage the materials required for production, and the properties of materials can be defined through the screen. With the quality data function, the quality data generated during production can be directly input by the operator through the screen or can be automatically collected by interfacing with the equipment. The quality data analysis function can display the change trend of the collected quality data through a chart.

The facility management function is capable of managing the connection information of the facility input along with the lot performance and the event history that occurs in the facility. In addition, standard web reporting functions are provided. It includes the ability to provide various types of reports related to work orders, production, quality and equipment. The self-reporting function is included using MS EXCEL.

Next, the Cyber Physical System will be described.

It enables 3D-based process planning/design and process/line verification simulation practice. It should be possible to implement a digital twin of equipment connected with PLC and PC, and 3D virtual test operation practice is possible. 3D visualization is possible by applying the 3D model format that has been registered in the ISO standard format and secured, and it can be linked with the OPC UA server. By composing BOP (Bill of Process), process organization and construction method planning can be done. It should be possible to define the kinematics of equipment and equipment and to implement the operation. By defining the kinematics of the articulated robot, the properties of the robot can be defined and the robot motion simulation can be performed. Virtual sensors (proximity/light) can be implemented, and 3D layout configuration and review are possible. A sequence of operations for the line can be configured and reviewed. It is possible to review the 3D Section (cross-section) of the equipment, and it is possible to check/review the collision. It is possible to measure the dimension of a 3D object. You can implement/review 3D point cloud based 3D Plant Layout. 3D assembly/disassembly of equipment can be reviewed and verified. Digital twin engineering for the entire process of Smart Learning Factory A-Zone and B-Zone is included so that virtual equipment identical to actual equipment operates identically using data obtained through OPC UA.

The OPC UA and POP (SCADA) system acquires all data of sensors and actuators in the OPC UA method through the controller installed in each process, and can be used in various ways such as management, monitoring, and analysis using POP and SCADA.

Next, the cloud platform system will be described by dividing it into two cloud platforms 1 and 2.

Cloud Platform 1 enables quick and easy connection of various industrial machinery and automation systems using different communication protocols. Data collected from the smart learning factory system is uploaded to the cloud, and data analysis including predictive diagnosis of facilities is possible using various applications provided by the cloud platform. Delivered as work progresses. It provides a gateway to enable data collection through standard industry protocols. Always update to the latest version by using the software update management function. Allows the use right and data amount for a predetermined period to be granted. The gateway is used to collect the information of each facility, and the encrypted data is transmitted to the cloud through the secure Internet. Through the open interface, the cloud based on the open interface can collect data by directly connecting without going through a gateway if it is a protocol that can apply communication standards such as OPC UA or Modbus. A dashboard and visual analyzer with situation summary information are provided. Here, a gateway is a device that collects and transmits data using various protocols to the cloud, which supports data transmission over a secure internet connection to enable cloud-based applications and services. All data sources that can be provided through OPC UA server can be collected. Depending on the configuration, up to 32 PLCs can be connected, and the data collected from the PLC is transmitted to the cloud as encrypted information through the secure internet.

Cloud Platform 2 enables quick and easy connection of various industrial machinery and automation systems using different communication protocols. Data collected from the smart learning factory system is uploaded to the cloud, and data analysis including predictive diagnosis of facilities is possible using various applications provided by the cloud platform. Delivered as work progresses. The right to use and the amount of data corresponding to a predetermined period are granted. From mobile DevOps to serverless computing, it supports productivity and enables you to build the way you want using existing tools and open source technologies. The cloud platform supports a variety of operating systems, programming languages, frameworks, databases and devices. A hybrid cloud should allow you to build and deploy anywhere you want, and connect to your data and apps in the cloud and on-premises, maximizing portability and value of your existing investments. It also provides hybrid consistency across application development, management and security, identity management, and data platforms. It can create data-driven intelligent apps, leverage data services and artificial intelligence from image recognition to bot services to create scalable new environments and support real-time analytics, deep learning, and HPC simulations for data of all shapes and sizes. A dashboard with context summary provides a central view of all resources to detect and mitigate threats.

By using the Augmented Reality System (Augmented Reality System), the manual operation of the smart learning factory system includes engineering so that it is possible to easily work while receiving work guidance in the smart glasses screen. It includes engineering to recognize devices of interest on mobile devices (such as smartphones or tabs) and smart glasses and to view various real-time information about those devices on the screen. The range of interest can be set for the entire process, for each station, and for each device. Real-time information types require production information, process status, and operation status. All data on the smart glass screen is provided by WiFi through the OPC UA server.

The Digital Information Display System is configured so that motion videos and various contents of the smart learning factory system are linked and played. The system consists of at least 6 multi-displays, and can be implemented in various forms depending on the distribution configuration as a single display or a complex display. Each system is configured in the form of a 56-inch or larger display. The system ensures stable operation even in unsafe environments (long operation time, high temperature and humidity, inflow of foreign substances, etc.). By using this system, it is possible to transmit various screens such as POP, MES, and CPS.

Server & Storage System consists of MES Server, OPC Server, CPS Server, Server Rack, etc. The MES server installs the MES engine and ensures that there is no problem in connecting and using the client PC to the campus network. Various production information data are provided from OPC Server, and it can be analyzed and predicted. OPC Server installs OPC UA Server, acquires data of each facility, and saves it in log files and databases without any problems. Various application programs such as MES, CPS, POP, SCADA, and AR can access this servo and receive necessary data.

CPS Server installs programs for CPS and Digital Twin implementation and receives status information data of various production facilities from OPC Server so that there is no problem in Digital Twin implementation.

As described above, the present invention is a process in which raw materials are supplied with a plurality of specifications for a plurality of products and assembled, inspected, and packaged to produce a finished product, and various PLC control technology and sensor technology applied to smart factories in industrial sites MES (Manufacturing Execution System), CPS (Cyber Physical System), SCADA (Supervisory Control and Data Acquisition), POP (Point of Production) by acquiring , robot control technology, vision technology, PC control technology and OPC UA method ), AR (Augmented Reality), CLOUD, etc. are possible.

In addition, three or more types of PLCs are used for system control, and communication between different types must be possible by applying them to raw material and finished product warehouses, A-Zone, and B-Zone, respectively, of the smart learning factory. In addition, the decomposition process station can be controlled through a PC.

4 is a diagram illustrating a manufacturing process flow of a smart factory according to an embodiment of the present invention.

As shown in FIG. 4 , in the manufacturing process of a smart factory according to an embodiment of the present invention, products are transported through an automatic guided vehicle (AGV), and functions through machine vision An AGV-based station pool line that produces products while transporting between a plurality of stations by an automatic guided carriage between a plurality of stations and a plurality of It contains a track-based stationary line connecting the stations to the track. Through this, it is possible to construct a hybrid line in which the AGV-based station full line and the track-based fixed line are mixed.

Mobile MES is a mobile manufacturing execution system that notifies product selection and shipping time so that the actual manufacturing line operates accordingly. The Cassette System is a system that loads and transports baggage on a cassette (or pallet), and can be used to supply materials necessary for the manufacturing process. These materials are transported using an automatic guided carriage, and functional inspection, including inspection of materials such as cases and PCBs, is performed through machine vision, ID is marked with a laser marker, and then moved to the assembly line. In this process, it can be moved to a track-based fixed line. The assembled product is transported through a conveyor, and the finished product is evaluated. As a result of the evaluation of the finished product, defective products are recovered and good products are packaged. Packaged products are shipped out through collaborative robots and delivered to consumers.

Here, in order to perform IoT environment monitoring, various sensors are used to detect the temperature, humidity, gas, etc. of the workplace including CCTV.

5 is a conceptual diagram of a product production line of a smart factory according to an embodiment of the present invention.

As shown in Fig. 5, the product production line of the smart factory according to an embodiment of the present invention is divided into A-zone and B-zone, and a structure in which an Autonomous Navigation Vehicle and a shuttle coexist An AGV-based station pool line that produces products while transporting between a plurality of stations with an automatic guided vehicle and a track that connects a plurality of stations with a track- It includes a track-based stationary line. Through this, it is possible to construct a hybrid line in which the AGV-based station full line and the track-based fixed line are mixed.

When an upper case, a lower case, and a PCB are put through an automatic navigation vehicle (ANV), each is stacked with stock. Next, the upper and lower cases are inspected for appearance and component mounting, and functions are inspected for the PCB. Next, IDs are assigned to the PCB and upper and lower cases, the lower case is loaded into the shuttle, the PCB is assembled into the lower case, and then loaded back into the shuttle. After that, inspect the fastening state such as bolting, transport it through the shuttle, and assemble it with the upper case. Through this process, the work in A-Zone is completed.

Then, it is transported to the B-Zone through the track, and in the B-Zone, the finished product appearance inspection, finished product function inspection, and finished product ID are given, and then it moves again through the shuttle, and finished product packaging, finished product storage (stock), and finished product are taken out through ANV. . In addition, by disassembling the finished product, the parts are stored back in the stock and the parts are taken out by ANV, which can be used for repeated practice.

6 is a conceptual diagram illustrating a process flow of a smart factory according to an embodiment of the present invention.

As shown in FIG. 6, the process flow of the smart factory according to an embodiment of the present invention inspects and assembles raw materials through A-Zone (line), inspects finished products through B-Zone (line), and It can be configured for packaging.

The smart factory system according to an embodiment of the present invention is a process in which raw materials of various specifications are supplied to a plurality of products and assembled, inspected, and packaged to produce finished products, and various PLC control technologies applied to smart factories in industrial sites , sensor technology, robot control technology, vision technology, PC control technology, and data acquisition through OPC UA method to obtain MES (Manufacturing Execution System), CPS (Cyber Physical System), SCADA (Supervisory Control and Data Acquisition), POP ( Point of Production), AR (Augmented Reality), CLOUD, etc. are possible.

For system control, three or more types of PLC are used to apply to raw materials and finished product warehouses, smart learning factory A-Zone, and B-Zone, respectively, so that heterogeneous communication is possible. In addition, the decomposition process station can be controlled through a PC.

Process control is possible using PLC system and Fieldbus Network System for the entire system, and automatic control practice, industrial network control, and distributed control practice are possible. In addition, IoT sensors (temperature, humidity, vibration, power, air pressure, etc.) are applied to measure, and the measured values are transmitted through Modbus communication.

For example, line A can communicate with stations such as raw material warehouse, label/marking, manual assembly, top assembly, and finished product buffer through CC-Link communication, and these processes and results are communicated through OPC UA industry standard communication protocol It can communicate with ERP through MES production information management system, HMI remote control system, and WiFi. In addition, data can be transmitted and received with the server on CLOUD through Ethernet, SCADA/POP real-time data monitoring is possible, and communication with the CPS virtual physics system is possible.

B line communicates with stations for finished product marking, vision inspection, defect discharge, packaging and disassembly through OPC communication, and these processes and results are communicated through OPC UA industry standard communication protocol to MES production information management system, HMI remote control system , it is possible to communicate with ERP through WiFi. In addition, data can be transmitted and received with the server on CLOUD through Ethernet, SCADA/POP real-time data monitoring is possible, and communication with the CPS virtual physics system is possible.

7 is a structural diagram showing a smart factory according to an embodiment of the present invention in five layers.

7, the smart factory according to an embodiment of the present invention has a component level composed of IoT devices using sensors and actuators, and PLC programming, industrial/mobile robot control, and process simulation are performed at the field level. (PLCs), data visualization, data communication and networks, IoT monitoring and virtual/augmented reality are implemented and executed at the operation/control level (SCADA/HMI), production management by production management system (MES), and system and data security. It consists of five layers: the executed plant level (MES) and the enterprise level (ERP) where ERP/PLM/SCM and integrated control take place.

For big data processing, analysis is performed using cloud computing, artificial intelligence/machine learning, etc., and the programming language is not limited such as Java or Python.

8 is a data flow diagram of a smart factory according to an embodiment of the present invention.

As shown in Figure 8, the smart factory according to an embodiment of the invention can monitor or manage the production status through MES, analyze data on a public or private cloud, predict failure, and It is possible to provide a wide variety of services in connection with personal user terminals, such as creating reports.

On the other hand, optimization (optimization) and reconfiguration (reconfiguration) is possible for the smart factory according to an embodiment of the present invention.

The present invention configured as described above is an AGV-based station pool line that produces products while transporting between a plurality of stations with an automatic guided vehicle and a track connecting the plurality of stations By configuring a hybrid line for a track-based stationary line, it has the effect of increasing flexibility and expandability of the production line, and increasing speed, stability and safety.

In addition, in the above, the preferred embodiment according to the present invention has been mainly described above, but the technical spirit of the present invention is not limited thereto, and each component of the present invention may be changed or modified within the scope of the present invention in order to achieve the same purpose and effect. will be able

In addition, although preferred embodiments of the present invention have been illustrated and described above, the present invention is not limited to the specific embodiments described above, and in the technical field to which the present invention pertains without departing from the gist of the present invention as claimed in the claims. Various modifications may be made by those of ordinary skill in the art, and these modifications should not be individually understood from the technical spirit or perspective of the present invention.

10: Smart Learning Factory System 100: Smart Learning Factory A-Zone
20: branch device 30: rail
200: Smart Learning Factory B-Zone 110: ID Reader/Marker
120, 130: Assembly and bolting stations (manual or automatic)
140, 240: user station 150: assembly inspection station
160: upper case assembly station 170: defective product take-out station
210: vision/function inspection station 220: laser marking station
230: finished product buffer station 250: labeling station
260: disassembly process station 270: packaging and unloading station
300: transport robot 400: mobile robot

Claims (9)

A-Zone smart learning factory connecting a plurality of stations and the plurality of stations with rails; and a plurality of stations and a B-Zone smart learning factory that connects the plurality of stations with rails; in a flexible production process system to which a flexible production process line is applied,
In the flexible production process system, a safety zone is placed between the A-Zone and the B-Zone smart learning factory and connected with another rail to form one line between the A-Zone and the B-Zone. and transferring the product with a transfer robot between the A-Zone and the B-Zone; and
In the flexible production process system, each of the plurality of stations is driven by being coupled to the line in a one-touch connector type, and an operator arbitrarily changes the position of each station to configure and drive the station; How to drive the production process. The method according to claim 1,
The flexible production process line,
an AGV-based station pool line that produces products while transporting between a plurality of stations with an automatic guided vehicle; and a track-based stationary line connecting the plurality of stations to the track;
Flexible production process, characterized in that some stations that mix the AGV-based station full line and the track-based fixed line are tied to a track, and the rest constitute a hybrid line that transports products using an automatic guided carriage How to drive. The method according to claim 1,
In the flexible production process system, it is controlled so that a specific shuttle is stopped on the rail of the line and other shuttles are not waiting, and when the shuttle arrives at all stations, the jig is moved to the station and work is performed, and the shuttle is to move directly to another process,
This includes changing the order of the front and rear of the shuttle by securing a separate waiting area for the shuttle;
A touch panel is attached to the station and includes monitoring and controlling the working state through the touch panel,
When the operator manufactures the user station, the flexible production process driving method, characterized in that it is configured to be connected to the flexible production process system. The method according to claim 1,
The flexible production process driving method,
In the flexible production process system, it is composed of a monorail type that is transferred to a shuttle for product production, assembly logistics processing, and networking, and further comprising performing a function of a smart logistics system,
A controller that performs acceleration and deceleration control and forward monitoring functions is built in the shuttle,
The controller has a built-in internal memory so that it is possible to write and read data of the current location, providing information on the product mounted on the shuttle,
A plurality of the shuttles are operated simultaneously in the A-Zone and the B-Zone, and the conveyor of the monorail is dispersed and operated individually,
Flexible production process driving method, characterized in that the smart logistics system operates regardless of the production process of the line. 5. The method according to claim 4,
In the flexible production process system, the conveyor of the monorail and each process station provide a one-touch method in which at least one communication cable, power and pneumatic valve are collectively fastened, so that even if the position of the process station is changed, the process flow is not disturbed. Including separating and combining so as not to
In the flexible production process system, the shuttle, which has finished supplying raw materials to each process station, moves to another location and receives a new task to work, and through data management on the work history of all shuttles, the life status of the shuttle is monitored. Flexible production process driving method, characterized in that it is predictable, the shuttle stops at a position to cooperate with the operator, and is configured to be inclined at a predetermined inclination according to the working environment of the operator. The method according to claim 1,
The flexible production process system,
It further includes an Intelligent Routing Module (IRM),
Optical communication with the shuttle, and the IRM controls the track switch installed on the rail in conjunction with the PLC system and computer control system,
The IRM serves to provide ID to each shuttle, read ID, delete ID, or a combination thereof in conjunction with the monorail conveyor, so that the A-Zone smart learning factory and B-Zone smart learning factory are Flexible production process driving method, characterized in that it is connected at any time and connected to one line and driven. The method according to claim 1,
The station is
The raw material pallet is automatically supplied using a mobile robot so that the raw material is input, and the external inspection and mounting inspection of the raw material includes a supply station that is performed using a vision,
The mobile robot is
After transporting the raw materials and inspecting the appearance of the finished product, the pallets are transported and processed by separating normal and defective products,
The station is
A flexible production process driving method, characterized in that by providing a one-touch method in which at least one or more communication cables, power and pneumatic valves are collectively fastened, the position can be changed without separate wiring work. The method according to claim 1,
The station is
It includes a laser marking and labeling station capable of laser marking on the inner surface of the upper and lower case of raw materials and attaching a label on the upper part to trace the history of the raw material,
When the raw material is received, the work proceeds after determining whether it is for assembly or recycling of finished products through vision inspection, and the laser marking style is XYZ 3-axis simultaneous scanning method,
The laser marking and labeling station comprises:
Flexible production process driving method, characterized in that it includes a one-touch connector fastening method, including power, communication, pneumatic valve, or a combination thereof, where all cables are automatically fastened so that the position can be changed without separate wiring work. The method according to claim 1,
The station is
at least two automatic assembly stations, including assembly and bolting stations that intelligently place material on the line according to assembly time;
The assembly and bolting station comprises:
It includes automatically performing bolt fastening between the lower case and the PCB, the bolts for fastening the bolts are automatically supplied, torque can be measured when the bolts are fastened, and data collection and defect determination are made,
The assembly and bolting station comprises:
All cables, including power, communication, pneumatic valves, or combinations thereof, are automatically fastened in a one-touch connector fastening method so that the position can be changed without separate wiring, and it includes changing the thrust and speed for screw driving. ,
The assembly and bolting station comprises:
It is a Z-axis servo (thrust control) ball screw method as a Z-axis descending driving method, and it includes controlling the torque, rotation speed, angle, or a combination thereof, enhancing precision by mounting an encoder, and using horizontal forced feeding by vibration. A method of driving a flexible production process comprising an automatic assembly station comprising a screw feeder that minimizes screw jamming.

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