WO2023157889A1 - 生産システム及び生産方法 - Google Patents

生産システム及び生産方法 Download PDF

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Publication number
WO2023157889A1
WO2023157889A1 PCT/JP2023/005317 JP2023005317W WO2023157889A1 WO 2023157889 A1 WO2023157889 A1 WO 2023157889A1 JP 2023005317 W JP2023005317 W JP 2023005317W WO 2023157889 A1 WO2023157889 A1 WO 2023157889A1
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WIPO (PCT)
Prior art keywords
virtual
production
unit
information
state
Prior art date
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Ceased
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PCT/JP2023/005317
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English (en)
French (fr)
Japanese (ja)
Inventor
剛 山下
幸男 橋口
佳史 斧山
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Yaskawa Electric Corp
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Yaskawa Electric Corp
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Priority to JP2024501413A priority Critical patent/JP7780620B2/ja
Publication of WO2023157889A1 publication Critical patent/WO2023157889A1/ja
Priority to US18/798,829 priority patent/US20240403510A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • G—PHYSICS
    • G06—COMPUTING OR CALCULATING; COUNTING
    • G06F—ELECTRIC DIGITAL DATA PROCESSING
    • G06F30/00—Computer-aided design [CAD]
    • G06F30/10—Geometric CAD
    • G06F30/17—Mechanical parametric or variational design
    • G—PHYSICS
    • G05—CONTROLLING; REGULATING
    • G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
    • G05B19/00—Program-control systems
    • G05B19/02—Program-control systems electric
    • G05B19/418—Total factory control, i.e. centrally controlling a plurality of machines, e.g. direct or distributed numerical control [DNC], flexible manufacturing systems [FMS], integrated manufacturing systems [IMS] or computer integrated manufacturing [CIM]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the present disclosure relates to production systems and production methods.
  • Patent Document 1 discloses a control system that includes a plurality of local controllers that respectively control a plurality of local devices including at least robots, and an environment manager that can communicate with the plurality of local controllers.
  • the environment management unit has an environment information storage unit that stores environment information, and an information update unit that updates the environment information according to operations of the plurality of local devices.
  • Each of the plurality of local controllers includes a condition monitoring unit that monitors whether the environment information stored in the environment information storage unit satisfies a predetermined condition, and a local device to be controlled when the environment information satisfies the predetermined condition. and an operation execution unit that causes the to execute a predetermined operation.
  • the present disclosure provides an effective system for verifying autonomous behavior in real time.
  • a production system includes a production apparatus that produces a product by executing a processing process on a workpiece in real space based on a production instruction transmitted based on a production plan, and a production apparatus that produces a product based on the production instruction.
  • a simulator having a virtual production device that executes, in a virtual space, a virtual processing step corresponding to the processing steps performed by the production device; Prepare.
  • a production method includes: producing a product by executing a processing process on a workpiece in a real space based on a production instruction transmitted based on a production plan; , causing a virtual production device to execute a virtual processing step corresponding to the processing step performed by the production device in a virtual space, and comparing the execution result of the processing step with the execution result of the virtual processing step.
  • FIG. 1 is a schematic diagram illustrating the configuration of a production system
  • FIG. 1 is a schematic diagram illustrating the configuration of a production apparatus
  • FIG. 1 is a schematic diagram illustrating the configuration of a robot
  • FIG. 3 is a block diagram illustrating functional configurations of a higher-level controller and a local controller
  • FIG. 3 is a block diagram illustrating the functional configuration of a virtual production device
  • FIG. It is a block diagram which shows the modification of a production system.
  • FIG. 11 is a block diagram showing another modified example of the production system
  • FIG. 11 is a block diagram showing still another modified example of the production system
  • 3 is a block diagram illustrating hardware configurations of a data collection device, a cell simulator, a host controller, and a local controller;
  • 4 is a sequence chart illustrating a production procedure; 4 is a flow chart illustrating an execution procedure of processing steps; 4 is a flow chart illustrating an execution procedure of processing steps; 4 is a flow chart illustrating an execution procedure of a virtual processing step; 4 is a flow chart illustrating an execution procedure of a virtual processing step; 4 is a flow chart illustrating an unplanned processing procedure; 4 is a flow chart illustrating a service processing procedure;
  • a production system 1 shown in FIG. 1 is a system for producing a product in a physical space.
  • a product may be any tangible object produced by mechanical processing and assembly of one or more parts.
  • Real space is the space in which tangible objects actually exist.
  • a production system 1 makes it possible to verify the autonomous operation of production equipment in real time by utilizing so-called digital twin technology.
  • a production system 1 includes a production device, a simulator, and a comparison section. Based on the production instructions transmitted based on the production plan, the production equipment executes the processing steps on the workpiece in the real space to produce the product.
  • the simulator has a virtual production device that executes, in virtual space, virtual processing steps corresponding to the processing steps performed by the production device based on the production instructions.
  • the comparison unit compares the execution result of the processing step with the execution result of the virtual processing step.
  • the simulator executes virtual processing steps based on the same production instructions as the production equipment is based on.
  • the same production instructions mean that the content of the production instructions is the same and the transmission timing of the production instructions is the same.
  • the simulator receives production instructions after the production instructions are transmitted to the production equipment, and executes virtual processing steps based on the received production instructions.
  • the simulator may execute the virtual processing steps during a period that at least partially overlaps with the period during which the production apparatus executes the processing steps, but the execution timing of the processing steps does not necessarily match the execution timing of the virtual processing steps. It doesn't have to be.
  • the simulator may perform virtual process steps after receiving production instructions and before the production equipment performs the process steps.
  • the execution results of the virtual processing steps according to the situation in which the production equipment executes the processing steps are generated by the simulator as comparison standards, and the execution results of the processing steps are timely displayed based on comparison with the comparison standards. can be monitored. Therefore, it is effective for verifying the autonomous operation of production equipment in real time.
  • the production system 1 includes a production instruction device 2 and one or more cells 3.
  • the production instruction device 2 breaks down a production plan generated by a manufacturing execution system 9 (MES: Manufacturing Execution System) into a production plan for each cell, and issues production instructions based on the production plan for each cell to one or more cells 3. Send to each.
  • MES Manufacturing Execution System
  • the production system 1 may include a plurality of cells 3.
  • the production instruction device 2 transmits production instructions to each of the plurality of cells 3 .
  • the cell 3 has a production device 4 , a data collection device 100 and a cell simulator 200 .
  • the production device 4, the data collection device 100, and the cell simulator 200 mutually transmit and receive information through network communication or the like.
  • the production device 4 executes the processing steps on the workpiece in the real space to produce the product based on the production instructions sent from the production instruction device 2.
  • a work is a tangible object handled by the production apparatus 4 to constitute at least part of the product.
  • the work may be a part to be assembled into a product, an intermediate product formed by assembling parts, or the final product itself.
  • the processing process for the workpiece includes multiple processes. Examples of multiple steps include bringing the base part into the work area, assembling the part to the base part, securing the part to the base part by fastening or welding, etc., and assembling one or more parts to the base part. Carrying out the completed product from the work area, and the like.
  • the production equipment 4 has multiple machines including at least one robot.
  • machines other than robots include, but are not limited to, a conveying device that conveys a work, a device that adjusts the position and orientation of a work to be worked on, and a machine tool that processes a work. It is included in multiple machines if it is possible to execute processes for workpieces.
  • a plurality of steps may include two or more steps to be executed sequentially in series, or may include two or more steps that can be executed concurrently by a plurality of machines.
  • processes executed by robots include work transfer, work assembly, work fixation by fastening, and work loading/unloading to and from peripheral machines such as machine tools.
  • processes executed by a machine tool include opening and closing of doors, chucking of loaded workpieces, rotation/movement of workpieces, tool change, arrangement/movement of tools relative to workpieces, and release of chucks after machining. .
  • the data collection device 100 collects and accumulates data from the production device 4.
  • the data collection device 100 has a history acquisition unit 111 and a database 112 as functional components (hereinafter referred to as “function blocks”).
  • the history acquisition unit 111 collects execution histories of processing steps from the production apparatuses 4 and stores them in the database 112 .
  • the execution history of the processing steps is, for example, the transition of the state of the real space due to the execution of the processing steps.
  • the state of the physical space is, for example, the state of the cell 3 in the physical space, and includes the states of each of a plurality of machines and the state of the work.
  • Examples of the state of the robot include the joint angle of the robot, the type of tool attached to the robot, the operating state of the tool, and the like.
  • Examples of the state of the machine tool include the state of the door, the presence or absence of a workpiece, and the progress of machining.
  • Examples of work status include the placement of work and the progress of processes with respect to work.
  • the state of the physical space may include the state of the workpiece for each of the plurality of products.
  • the production device 4 periodically acquires information representing the state of the physical space.
  • the history acquisition unit 111 sequentially acquires the information acquired by the production apparatus 4 and stores it in the database 112 in association with the time.
  • the database 112 accumulates an execution history that expresses transitions of a plurality of types of information at a common time.
  • the information representing the state of the physical space may include still image data or moving image data of the physical space captured by a camera or the like.
  • the content of processing by the functional block corresponds to the content of processing by the subject having the functional block.
  • the history acquisition unit 111 collecting the execution history of the processing steps and storing them in the database 112 corresponds to the data collection device 100 collecting and storing the execution history of the processing steps. The same applies to the following.
  • the cell simulator 200 is the simulator described above, and has functional blocks including a model storage unit 211, a virtual production device 212, a state matching unit 213, a virtual data collection unit 214, a virtual database 215, a comparison unit 216, and an abnormality detection unit 217 .
  • the model storage unit 211 stores at least models of a plurality of machines.
  • a model is numerical data representing the arrangement, structure, shape, size, etc. in the real space.
  • the model storage unit 211 may further store models of workpieces.
  • the virtual production equipment 212 executes virtual processing steps in virtual space based on the same production instructions as the production instructions based on the production equipment.
  • a virtual process step includes a plurality of virtual steps having the same content as a plurality of steps included in the process step.
  • the virtual production device 212 operates a plurality of virtual machines in the virtual space based on the production instructions so as to correspond to the operations of the machines based on the production instructions.
  • a plurality of virtual machines are models of a plurality of machines stored in the model storage unit 211, for example.
  • Running multiple virtual machines in a virtual space means calculating numerical data representing the state of multiple machines after operation based on the above model without actually running multiple machines. For example, it can be said that numerical data representing the states of a plurality of machines after operation are a plurality of virtual machines in the virtual space.
  • the virtual space is the coordinates that serve as a reference for numerical data representing the states of multiple machines after operation.
  • the virtual production device 212 may change the state of the virtual work corresponding to the work in the virtual space according to the operation of the virtual machine in the virtual space.
  • Changing the state of the virtual work in the virtual space means calculating numerical data representing the state of the work after operation based on the model without actually operating the machine. For example, it can be said that numerical data representing the state of the work after operation is the virtual work.
  • the state matching unit 213 matches the state of the virtual space with the state of the real space when starting the execution of the processing steps. For example, the state matching unit 213 matches the state of the virtual space with the state of the real space based on information stored in the database 112 of the data collection device 100 .
  • the state of the virtual space is, for example, the state of the virtual cell corresponding to the cell 3 in the virtual space.
  • the state matching unit 213 matches the states of the plurality of virtual machines and works in the virtual space to the states of the plurality of machines and works in the real space.
  • Matching the states of multiple virtual machines and virtual works in the virtual space to the states of the multiple machines and works in the real space is the above-mentioned "numerical data representing the states of multiple machines after operation" and "post-operation It means matching the initial data, which is the basis for calculating "numerical data representing the state of the workpiece", to the states of multiple machines and workpieces in the real space.
  • the state matching unit 213 may match the state of the virtual space with the state of the real space in response to receiving the production instruction.
  • the state matching unit 213 may repeat matching the state of the virtual space with the state of the real space during a period other than the period during which the virtual production device 212 executes the virtual processing steps.
  • the virtual production device 212 executes the virtual processing steps based on the state of the virtual space adjusted to the state of the real space, and the state of the virtual space is changed to the state of the real space immediately before the processing step according to the production instruction is executed. are combined and the virtual production equipment is caused to execute the virtual processing steps, it is possible to generate a comparison standard with higher reliability.
  • the virtual data collection unit 214 collects execution histories of virtual processing steps and stores them in the virtual database 215 .
  • the execution history of the virtual process is, for example, transition of the state of the virtual space due to the execution of the virtual process.
  • the state of the virtual space is, for example, the state of a virtual cell in the virtual space, and includes the state of each of a plurality of virtual machines and the state of virtual work.
  • the virtual production device 212 periodically calculates numerical data representing the state of the virtual space according to the elapsed time while increasing the elapsed time from the start of the virtual processing process. Note that the elapsed time is not the computation time by the virtual production device 212, but the time simulating the elapsed time in the real space.
  • the virtual data collection unit 214 sequentially acquires the numerical data calculated by the virtual production apparatus 212 and stores them in the virtual database 215 in association with the elapsed time. As a result, the virtual database 215 accumulates execution histories in which transitions of a plurality of types of information are represented by a common time.
  • the comparison unit 216 compares the execution result of the processing step and the execution result of the provisional processing step. For example, the comparison unit 216 compares the execution history of processing steps stored in the database 112 and the execution history of virtual processing steps stored in the virtual database 215 . For example, the comparison unit 216 compares the transition timing of the state of the real space based on the start time of the processing step and the transition timing of the state of the virtual space based on the start time of the virtual processing step. Examples of the state transition timing of the physical space/virtual space include the state transition timing of a plurality of machines/virtual machines, the state transition timing of a work/virtual work, and the like. Transition timing means the timing at which the state changes.
  • the comparison between the execution result of the processing step and the execution result of the virtual processing step is not necessarily limited to comparison of transition timing.
  • the comparison unit 216 may compare the states of the plurality of machines and the states of the plurality of virtual machines at the time when the same time has passed since the reference. Examples of comparison between the state of the machine and the state of the virtual machine include comparison between the joint angle of the robot and the joint angle of the virtual robot, and comparison between the joint torque of the robot and the joint torque of the virtual robot.
  • the comparison unit 216 may compare the state of the work and the state of the virtual work at the time when the same time has passed since the reference. Examples of the comparison between the state of the work and the state of the virtual work include the comparison of the arrangement of the work and the arrangement of the virtual work, the comparison of the progress of the process with respect to the work and the progress of the process with respect to the virtual work, and the like.
  • the abnormality detection unit 217 detects an abnormality in the production device 4 based on the comparison result by the comparison unit 216. For example, the abnormality detection unit 217 detects an abnormality in the production apparatus 4 when a deviation satisfying a predetermined condition is detected between the execution result of the processing step and the execution result of the virtual processing step. As an example, the anomaly detection unit 217 detects an anomaly in the production apparatus 4 when the difference between the state transition timing in the real space and the state transition timing in the virtual space exceeds a predetermined threshold.
  • the production device 4 may autonomously execute processing steps according to a predetermined algorithm based on the production instructions and the state of the real space.
  • the virtual production equipment 212 may autonomously execute the virtual processing steps according to the above algorithm based on the production instructions and the state of the virtual space.
  • Autonomously executing a processing step means that at least one of the operation to be executed by each of the plurality of machines and the operation timing of each of the plurality of machines to execute the processing step is determined based on the state of the physical space. It means to decide for yourself.
  • production instructions include instructions on the type and quantity of products to be produced.
  • the production device 4 modifies at least a part of the operations to be executed by each of the plurality of machines for the selected process, based on the state of the real space, so as to avoid collisions with surrounding objects. may autonomously determine at least a portion of the actions to be performed by each of the machines.
  • the virtual production device 212 determines, based on the state of the virtual space, at least a part of the actions to be executed by each of the plurality of virtual machines for the selected virtual process so as to avoid collisions with surrounding objects.
  • a modified algorithm may autonomously determine at least a portion of the actions to be performed by each of the plurality of virtual machines.
  • the production apparatus 4 determines the operation timing of each of the plurality of machines using an algorithm that determines whether or not each operation of the plurality of machines can be executed based on predetermined conditions and the state of the physical space. At least a part may be determined autonomously.
  • the virtual production device 212 determines whether or not each of the virtual machines can perform operations based on predetermined conditions and the state of the virtual space. may autonomously determine at least part of the operation timing of each of the .
  • Autonomously executing a processing step may further include autonomously selecting a step to be executed by each of a plurality of machines from a plurality of steps included in the processing step.
  • the production device 4 identifies the process to be executed by each of the plurality of machines based on the types of processes that can be executed by each of the machines, the status of each of the machines, and the progress of the processes.
  • a process to be executed by each of a plurality of machines may be autonomously selected depending on the algorithm used.
  • the virtual production apparatus 212 is configured to control the plurality of virtual machines based on the types of virtual processes that can be executed by each of the plurality of virtual machines, the state of each of the plurality of virtual machines, and the progress of the plurality of virtual processes.
  • a process to be executed by each of a plurality of virtual machines may be autonomously selected by an algorithm that specifies a virtual process to be executed by each of the virtual machines.
  • FIG. 2 is a schematic diagram illustrating a production device 4 that autonomously executes processing steps.
  • the production apparatus 4 shown in FIG. 2 has a plurality of machines 5 including robots, and a process allocation unit 316 that collects state information in the real space.
  • the robot autonomously executes at least part of the process based on the state information of the real space collected by the process assigning unit 316 .
  • the production device 4 includes a plurality of machines 5 and a host controller 300.
  • Each of the multiple machines 5 includes a machine body 10 and a local controller 400 .
  • the machine body 10 directly performs work on the work W in the physical space. Direct work is work that imparts some kind of energy to the work W, such as thermal energy, kinetic energy, or potential energy.
  • the local controller 400 controls the machine body 10 to perform work.
  • Each of the multiple machines 5 is, for example, an industrial machine.
  • the plurality of machines 5 includes at least robots (at least one machine 5 is a robot).
  • the plurality of machines 5 also includes industrial machines that cooperate with robots. Examples of industrial machines that cooperate with robots include other robots, machine tools, and the like.
  • the plurality of machines 5 shown in FIG. 2 includes a carrier device 5A and robots 5B, 5C, and 5D, but is not limited to this.
  • the number and type of machines 5 can vary, as long as they include at least one robot.
  • the transport device 5A has a device main body 10A (machine main body) and a device controller 400A (local controller).
  • the device main body 10A is driven by, for example, an electric motor or the like, and conveys the work W.
  • the apparatus controller 400A controls the apparatus main body 10A so that the workpiece W is transported. Examples of the apparatus main body 10A include belt conveyors, roller conveyors, and carousels.
  • the robot 5B has a robot main body 10B and a robot controller 400B
  • the robot 5C has a robot main body 10C and a robot controller 400C
  • the robot 5D has a robot main body 10D and a robot controller 400D.
  • the robot main bodies 10B, 10C, and 10D (machine main bodies) work on the work W conveyed by the apparatus main body 10A.
  • Robot controllers 400B, 400C and 400D local controllers respectively control robot main bodies 10B, 10C and 10D to perform work.
  • Examples of work on the work W include assembling another work W (for example, sub-parts) to the work W (for example, base parts) conveyed by the apparatus main body 10A, fastening parts ( For example, bolting)/joining (for example, welding), loading of the workpiece W into the NC machine tool installed around the apparatus main body 10A, and unloading of the workpiece W from the NC machine tool.
  • fastening parts For example, bolting
  • joining for example, welding
  • the robot main bodies 10B and 10C are 6-axis vertical articulated robots, and as shown in FIG. , tip 18 and actuators 41 , 42 , 43 , 44 , 45 , 46 .
  • the base 11 is installed around the device main body 10A of the transport device 5A.
  • the swivel part 12 is provided on the base part 11 so as to swivel around a vertical axis 21 .
  • the first arm 13 is connected to the swivel portion 12 so as to swing about an axis 22 that intersects (for example, is perpendicular to) the axis 21 .
  • Crossing includes a twisted relationship such as a so-called overpass.
  • the second arm 14 is connected to the tip of the first arm 13 so as to swing about an axis 23 substantially parallel to the axis 22 .
  • the second arm 14 includes a swinging portion 15 and a turning portion 16 .
  • the swinging portion 15 is connected to the tip of the first arm 13 and extends along an axis 24 that intersects (for example, orthogonally) the axis 23 .
  • the swivel portion 16 is connected to the distal end portion of the swing portion 15 so as to swivel around the axis 24 and further extends along the axis 24 .
  • the third arm 17 is connected to the distal end of the turning section 16 so as to swing about an axis 25 intersecting (for example, perpendicular to) the axis 24 .
  • the distal end portion 18 is connected to the distal end portion of the third arm 17 so as to pivot about an axis 26 that intersects (for example, is perpendicular to) the axis 25 .
  • a work tool such as a hand, a suction nozzle, or a welding torch is attached to the tip 18 .
  • the robot bodies 10B and 10C include a joint 31 connecting the base portion 11 and the revolving portion 12, a joint 32 connecting the revolving portion 12 and the first arm 13, the first arm 13 and the second arm 14. a joint 34 connecting the swinging portion 15 and the turning portion 16 in the second arm 14; a joint 35 connecting the turning portion 16 and the third arm 17; It has a joint 36 that connects with the tip 18 .
  • the actuators 41, 42, 43, 44, 45, 46 include, for example, electric motors and speed reducers, and drive the joints 31, 32, 33, 34, 35, 36, respectively.
  • the actuator 41 swings the swivel unit 12 about the axis 21
  • the actuator 42 swings the first arm 13 about the axis 22
  • the actuator 43 swings the second arm 14 about the axis 23
  • the actuator 44 pivots the pivot 16 about the axis 24
  • the actuator 45 pivots the third arm 17 about the axis 25
  • the actuator 46 pivots the tip 18 about the axis 26 .
  • the configuration of the robot main bodies 10B and 10C can be changed as appropriate.
  • the robot main bodies 10B and 10C may be 7-axis redundant robots obtained by adding 1-axis joint to the 6-axis environment sensor vertical articulated robot, or may be a so-called scalar type articulated robot. good.
  • the robot body 10D is a robot that can run independently.
  • the robot main body 10D is a robot similar to the robot main bodies 10B and 10C in which the base portion 11 is self-propelled.
  • An example of the self-propellable base 11 is an electric automatic guided vehicle (AGV: Automated Guided Vehicle).
  • the upper controller 300 performs wired or wireless synchronous communication with the local controllers 400 of the multiple machines 5, and collects state information of the real space. Synchronous communication means that a plurality of machines 5 also communicate with the local controller 400 every cycle in synchronization with a synchronous frame of a certain cycle (the communication cycle described above).
  • the local controller 400 controls the machine body 10 to autonomously execute at least part of the processing steps based on the state information of the real space collected by the host controller 300 .
  • the host controller 300 communicates with the production instruction device 2 by wire or wirelessly, and acquires production instructions. Communication between the host controller 300 and the production instruction device 2 may be synchronous communication or asynchronous communication.
  • the host controller 300 may determine the processing steps to be executed by the multiple machines 5 based on the production instructions.
  • the host controller 300 collects the state information of the plurality of machines 5 in the real space and the state information of the real space including the progress information of the processing steps, and collects the state information of the plurality of machines 5 and the progress information of the processing steps. Based on this, the process to be executed by each of the plurality of machines 5 may be autonomously selected.
  • the local controller 400 may autonomously execute the selected process based on the state information of the plurality of machines 5 in the physical space and the progress information of the processing process.
  • the host controller 300 includes, as functional blocks, a processing process database 311, a production instruction acquisition unit 312, a processing process selection unit 313, an information storage unit 314, an information display unit 315, and a process allocation unit. It has a unit 316 and a command output unit 317 .
  • the processing process database 311 stores multiple types of processing processes corresponding to multiple types of products. Each of the multiple types of processing steps includes multiple tasks (steps). A task is a unit of work that one machine 5 executes. Multiple tasks of one process step may include tasks performed by multiple different machines 5 .
  • the production instruction acquisition unit 312 acquires production instructions from the production instruction device 2.
  • the production instruction includes product types and production quantities for each type.
  • the processing process selection unit 313 selects a processing process for each product based on the production instruction acquired by the production instruction acquisition unit 312 and a plurality of types of processing processes stored in the processing process database 311 .
  • the processing process selection unit 313 causes the information storage unit 314 to store the selection result of the processing process for each product.
  • the information display unit 315 collects state information of the real space and stores it in the information storage unit 314 .
  • the state information of the physical space includes, for example, information about the plurality of machines 5 (hereinafter referred to as "machine information") and information about the work W (hereinafter referred to as "work information").
  • An example of the work information is the position/orientation information of the work W.
  • FIG. An example of the machine information is position/orientation information of each of the plurality of machines 5 .
  • Examples of the position/posture information of the machine 5 include posture information of the robot bodies 10B and 10C and position/posture information of the robot body 10D.
  • the posture information of the robot bodies 10B and 10C may be motion angle information of the joints 31, 32, 33, 34, 35, and 36, or may be position/posture information of the tip portion 18.
  • the position/posture information of the robot body 10D includes, for example, the position/posture information of the base 11 and the posture information of the robot body 10D with the base 11 as a reference.
  • the machine information includes information on control signals generated between the local controller 400 and the machine body 10 (hereinafter referred to as "real control signals").
  • the real control signal may be an internal signal generated by the local controller 400 for controlling the machine main body 10, an output signal output from the local controller 400 to the machine main body 10, or a machine control signal. It may be a feedback signal output from the main body 10 to the local controller 400 .
  • An example of the internal signal is a position/orientation command value of the machine body 10 .
  • Examples of the output signal include an output current value to the actuator of the machine body 10 and the like. Specific examples of the feedback signal include detected values of the position/orientation, velocity, force, etc. of the machine body 10 in the real space.
  • the information display unit 315 updates the state information of the physical space according to the operations of the multiple machines 5.
  • the information posting unit 315 acquires status information of the machine body 10 in the physical space from each of the plurality of local controllers 400, and updates the machine information based on the status information.
  • the information posting unit 315 may further update the work information based on the status information of multiple machines 5 .
  • the information posting unit 315 may identify the work performed on the work W based on the status information of the plurality of machines 5, and update the work information based on the identified work.
  • the information posting unit 315 may update the environment information further based on the detection results of the environment sensor 6 provided separately from the plurality of machines 5 .
  • the environment sensor 6 detects the state of the work environment of multiple machines 5 .
  • An example of the environment sensor 6 is a camera that captures the work environment of a plurality of machines 5, for example. If the environment sensor 6 is a camera, the information posting unit 315 performs image processing on the image captured by the environment sensor 6, and updates the state information of the physical space based on the image processing result.
  • the environment sensor 6 may be a sensor that detects the presence or absence of the work W at a predetermined position using a laser beam or the like, or may be a sensor that detects the size of the work W or the like.
  • the production equipment 4 may comprise multiple environment sensors 6 .
  • the information display unit 315 may further collect progress information of processing steps (processing steps stored by the information storage unit 314 for each product) and store the progress information in the information storage unit 314 in association with the processing steps. For example, the information display unit 315 may collect progress information of the processing steps based on the status state and store the information in the information storage unit 314 .
  • the progress information indicates, for example, whether each of the plurality of tasks included in the processing step is unexecuted, being executed, or completed.
  • the progress information may include reservation information indicating which of the plurality of machines 5 is assigned to the unexecuted task. Assignment of one of the plurality of machines 5 to an unexecuted task may be performed by autonomous task selection of each of the plurality of machines 5, or may be performed by the host controller 300 (for example, a process assignment unit 316 described later). ) may be performed by
  • the information posting unit 315 may be configured to prohibit assignment of other machines 5 to a task to which one of the plurality of machines 5 is assigned in the reservation information. For example, the information posting unit 315 may reject the request when the reservation information requests assignment of another machine 5 to a task to which any one of the plurality of machines 5 is assigned. In addition, the information posting unit 315 may preliminarily exclude a task to which any one of the plurality of machines 5 is assigned from targets to which other machines 5 can be assigned.
  • the process allocation unit 316 allocates an unexecuted task in the processing process to one of the machines 5 based on the progress information. For example, the process allocation unit 316 uses an algorithm for specifying processes to be executed by each of the plurality of machines 5 based on the types of processes that can be executed by each of the plurality of machines 5, machine information, and progress information. A task for execution is assigned to one of a plurality of machines 5. Thereby, a task to be executed by each of the plurality of machines 5 is autonomously selected. The process allocation unit 316 updates the reservation information stored in the information storage unit 314 based on the allocation result.
  • the command output unit 317 outputs an execution command for an unexecuted task to the local controller 400 based on the progress information of the processing steps. For example, the command output unit 317 specifies an unexecuted task to be executed next for each product, and issues an execution command of the specified task to the local controller 400 of the machine 5 assigned to the specified task based on the reservation information. to output
  • the command output unit 317 determines the tasks for each product based on the progress information of each of the plurality of processing steps. You may output an execution command. In this case, multiple execution commands corresponding to multiple processing steps can be output to the same local controller 400 . For example, in the information storage unit 314, when a first process is assigned to a first product and a second process is assigned to a second product, a task execution command in the first process and a second process are assigned. Instructions for executing tasks in two processing steps can be output to the same local controller 400 .
  • the command output unit 317 may output a task execution command in response to a request from the local controller 400 in the synchronous communication, or may output a task execution command regardless of the presence or absence of a request from the local controller 400. good.
  • the upper controller 300 may further have a display section 318 .
  • the display unit 318 displays information collected by the information display unit 315 (information stored in the information storage unit 314) on the monitor.
  • the monitor may be possessed by the host controller 300 itself, or may be possessed by another device capable of communicating with the host controller 300 (for example, the data collection device 100).
  • the display unit 318 may display information collected by the information display unit 315 on a display device of the user interface 195 (described later) of the data collection device 100 .
  • the local controller 400 has a command buffer 411, a task program storage section 412, a selection section 413, a control section 416, and a status output section 417 as functional blocks.
  • the command buffer 411 stores execution commands output by the command output unit 317 of the host controller 300 . As described above, multiple execution commands corresponding to multiple processing steps can be output to the same local controller 400, so multiple execution commands can be stored in the command buffer 411 at the same time.
  • the task program storage unit 412 stores two or more task programs 420 that respectively define operations in two or more tasks executable by the machine body 10 .
  • Each of the two or more task programs 420 includes an operating program 421 and conditional headers 422 .
  • the operating program 421 represents the operation of the machine body 10 .
  • the operation program 421 includes a plurality of operation instructions arranged in chronological order so as to cause the machine body 10 to execute a group of operations.
  • the action command in the action program 421 includes the target position/target orientation of the tip portion 18 and the distance from the current position/current orientation to the target position/target orientation. and a target displacement velocity.
  • the target position/orientation of the distal end portion 18 may be represented by the target angles of the joints 31, 32, 33, 34, 35, and 36, and the target displacement speeds of the joints 31, 32, 33, 34, 35, It may be represented by 36 target rotational speeds.
  • the condition header 422 represents execution conditions of the operating program 421 .
  • the execution condition is a condition for determining the execution timing of the operation program 421 (the operation timing of the machine body 10).
  • the execution condition includes an execution enable/disable condition for determining whether or not the operation program 421 can be executed, and the priority of the operation program 421 .
  • the priority indicates the order of priority among the plurality of task programs 420 stored in the task program storage unit 412 . If the priority is a numerical value representing the priority itself, the lower the value, the higher the priority.
  • Examples of execution enable/disable conditions include the following.
  • Example 1) There are no obstacles to the movement of the machine body 10 within the movement range of the machine body 10 .
  • Example 2) The work W to be the task target (hereinafter simply referred to as "work W") is at a predetermined position.
  • Example 3) There is no other work W at the place where the work W is carried.
  • Example 4) The destination of the workpiece W is open.
  • Examples of obstacles include other machine bodies 10, workpieces W held by other machine bodies 10, and people.
  • An NC machine tool which is an example of another machine main body 10, is given as an example of a destination to which the work W is carried.
  • a specific example of the fact that the delivery destination is open is that the door of the NC machine tool is open.
  • the selection unit 413 selects an execution command stored in the command buffer 411 based on the execution conditions (condition headers 422) of the plurality of tasks in the task program storage unit 412 and the state of the physical space stored in the information storage unit 314. select one of the tasks corresponding to (hereinafter referred to as "corresponding task"). For example, the selection unit 413 checks whether each corresponding task can be executed. For example, the selection unit 413 checks whether the state information of the physical space satisfies the executability condition for each of one or more corresponding tasks. If two or more corresponding tasks are executable, the selection unit 413 selects one of the two or more executable corresponding tasks based on the priority. For example, the selection unit 413 selects the corresponding task with the highest priority.
  • the control unit 416 controls the machine body 10 to execute the corresponding task selected by the selection unit 413 .
  • the corresponding task corresponds to a task execution command autonomously selected by the process allocation unit 316 based on the state information of the physical space and the progress information.
  • Selection of the corresponding task by the selection unit 413 is autonomous based on the execution conditions (condition header 422) of each of the plurality of tasks in the task program storage unit 412 and the state of the real space in the information storage unit 314. It is done. Therefore, executing the corresponding task selected by the selection unit 413 is an example of autonomously executing at least a part of the processing steps based on the state information of the physical space and the progress information. This is also an example of autonomously executing the process assigned by the assigning unit 316 based on the state information of the physical space.
  • the corresponding task execution command is output to the local controller 400 of the machine 5 assigned to the corresponding task by the reservation information. Therefore, executing the corresponding task selected by the selection unit 413 is also an example of executing the task assigned in the reservation information.
  • the control unit 416 corrects the motion from the current position/current attitude of the machine body 10 to the first target position/target attitude of the corresponding task so as to avoid collisions with surrounding objects based on the state of the real space.
  • the algorithm may autonomously determine the first action in the corresponding task.
  • the status output unit 417 outputs the above status information of the machine body 10 to the host controller 300 .
  • the status information includes at least position/orientation information of the machine body 10 .
  • the status output unit 417 may include a task completion notification in the status information and output it upon completion of execution of the task program 420 .
  • the status output unit 417 may output status information in response to a request from the host controller 300 in the synchronous communication, or may output status information regardless of the presence or absence of a request from the host controller 300 .
  • the local controller 400 may further have an interlock section 414.
  • the machine main body 10 controlled by the local controller 400 will be referred to as the "corresponding machine main body 10”
  • the machine main body 10 controlled by the local controller 400 in the other machine 5 will be referred to as the "other machine main body 10”.
  • the interlock unit 414 sets an entry-prohibited area for the corresponding machine body 10 in the physical space based on the progress of the tasks executed by the other machine bodies 10 . For example, the interlock unit 414 sets a no-entry area for the corresponding machine body 10 based on the operating range when the other machine body 10 executes the task assigned in the reservation information.
  • the interlock unit 414 may set the operation range itself when the other machine main body 10 executes the task assigned in the reservation information as the no-entry area, and the range obtained by adding a predetermined margin to the operation range may be the no-entry area. may be
  • the execution enable/disable condition of the condition header 422 is that the no-entry area set by the interlock unit 414 and the corresponding operating range of the machine body 10 do not overlap.
  • the selection unit 413 selects a corresponding task in which the entry-inhibited area and the operating range of the corresponding machine body 10 do not overlap.
  • the local controller 400 may further have a parameter holding unit 415.
  • the parameter holding unit 415 stores one or more control parameters for controlling the machine body 10 . Specific examples of one or more control parameters include position control gain, speed control gain, and current control gain. If the local controller 400 has a parameter storage unit 415 , the control unit 416 controls the machine body 10 based on one or more control parameters stored in the parameter storage unit 415 .
  • FIG. 5 is a schematic diagram illustrating a virtual production device 212 that autonomously executes virtual processing steps.
  • the virtual production apparatus 212 shown in FIG. 5 has a plurality of virtual machines 600 including virtual robots corresponding to robots, and a process allocation unit 516 that collects virtual space state information.
  • the virtual robot autonomously executes at least part of the virtual processing process based on the state information of the virtual space collected by the process allocation unit 516 .
  • the virtual production equipment 212 includes a virtual upper controller 500, a plurality of virtual machines 600, and a space simulator 700.
  • a virtual upper controller 500 corresponds to the upper controller 300 .
  • a plurality of virtual machines 600 correspond to a plurality of machines 5, respectively.
  • Each of the multiple virtual machines 600 is configured similarly to the local controller 400 .
  • the space simulator 700 calculates numerical values representing the state of the machine body 10 after operation without operating the machine body 10 in the real space based on the processing executed by each of the plurality of virtual machines 600 in the same manner as the local controller 400. Calculate the data.
  • the space simulator 700 calculates numerical data representing the state of the machine body 10 after operation based on the processing of each of the plurality of virtual machines 600, which causes the machine body 10 to operate in the virtual space. This is an example of simulating the operation of the main body 10).
  • the virtual upper controller 500 is configured in the same manner as the upper controller 300, and includes functional blocks such as a task database 511, a production instruction acquisition unit 512, a process selection unit 513, an information storage unit 514, and a virtual information display unit. 515 , a process allocation unit 516 , and a command output unit 517 .
  • the task database 511 stores a plurality of types of processing steps respectively corresponding to a plurality of types of products.
  • the production instruction acquisition unit 512 acquires production instructions from the production instruction device 2 .
  • the processing process selection unit 513 selects a processing process for each product based on the production instructions acquired by the production instruction acquisition unit 512 and a plurality of types of processing processes stored in the task database 511, and stores them in the information storage unit 514. Memorize.
  • the virtual information posting unit 515 collects virtual space state information and stores it in the information storage unit 514 .
  • the state information of the virtual space includes, for example, information about the plurality of virtual machines 600 (hereinafter referred to as "virtual machine information") and information about the virtual work (hereinafter referred to as "virtual work information"). .) and including.
  • An example of the virtual work information is the position/orientation information of the virtual work in the virtual space.
  • An example of the virtual machine information is position/orientation information of a plurality of virtual machines 600 in the virtual space.
  • the virtual machine information includes information on control signals generated between the plurality of virtual machines 600 and the space simulator 700 (hereinafter referred to as "virtual control signals").
  • the virtual control signal may be an internal signal generated by the virtual machine 600 for controlling the machine body 10 or a feedback signal output from the space simulator 700 to the virtual machine 600 .
  • An example of the internal signal is a position/orientation command value of the machine body 10 .
  • Specific examples of the feedback signal include calculation results of the position/orientation, speed, force, etc. of the machine body 10 in the virtual space.
  • the virtual information posting unit 515 updates the state information of the virtual space according to the operations of the multiple virtual machines 600 .
  • the virtual information posting unit 515 acquires status information of the machine body 10 in the virtual space from each of the plurality of virtual machines 600, and updates the virtual machine information based on the status information.
  • the virtual information posting unit 515 may further update the virtual work information based on the status information of the multiple virtual machines 600 .
  • the virtual information posting unit 515 may identify the work performed on the virtual work based on the status information of the plurality of virtual machines 600, and update the virtual work information based on the identified work.
  • the virtual information posting unit 515 may further collect progress information of virtual processing steps (virtual processing steps stored by the information storage unit 514 for each product) and store the progress information in the information storage unit 514 in association with the virtual processing steps. good.
  • the virtual information posting unit 515 may collect progress information of the virtual processing steps based on the status state, and store the information in the information storage unit 514 .
  • the progress information indicates, for example, whether each of the plurality of tasks included in the virtual processing step is unexecuted, being executed, or already executed.
  • the progress information of the virtual processing step may include reservation information indicating which of the plurality of virtual machines 600 is assigned to the unexecuted task. Assignment of one of the plurality of virtual machines 600 to an unexecuted task may be performed by autonomous task selection of each of the plurality of virtual machines 600, or may be performed by the virtual upper controller 500 (for example, a process described later). allocation unit 516).
  • the virtual information posting unit 515 may be configured to prohibit assignment of another virtual machine 600 to a task to which one of the plurality of virtual machines 600 has been assigned in the reservation information. For example, the virtual information posting unit 515 may reject the request when the reservation information requests assignment of another virtual machine 600 to a task to which one of the plurality of virtual machines 600 is assigned. . In addition, the virtual information posting unit 515 may exclude in advance a task to which any one of the plurality of virtual machines 600 is assigned from targets to which other virtual machines 600 can be assigned.
  • the process allocation unit 516 allocates an unexecuted task in the virtual process to one of the plurality of virtual machines 600 based on the progress information of the virtual process. For example, the process allocation unit 516 causes each of the plurality of virtual machines 600 to execute a process based on the type of process executable by each of the plurality of virtual machines 600, the virtual machine information, and the progress information of the virtual processing process. allocates an unexecuted task to one of the plurality of virtual machines 600 by an algorithm that identifies . Thereby, a task to be executed by each of the plurality of virtual machines 600 is autonomously selected. The process allocation unit 516 updates the reservation information stored in the information storage unit 514 based on the allocation result.
  • the instruction output unit 517 outputs an execution instruction for an unexecuted task to the virtual machine 600 based on the progress information of the virtual processing steps. For example, the command output unit 517 identifies an unexecuted task to be executed next for each product, and outputs an execution command for the identified task to the virtual machine 600 assigned by reservation information to the identified task. .
  • the virtual upper controller 500 may further have a display unit 518 .
  • the display unit 518 displays information collected by the virtual information display unit 515 (information stored in the information storage unit 514) on the monitor.
  • the monitor may be possessed by the cell simulator 200 itself having the virtual upper controller 500 or may be possessed by another device capable of communicating with the cell simulator 200 .
  • the display unit 518 may display information collected by the virtual information display unit 515 on a display device of the user interface 295 (described later) of the cell simulator 200 .
  • the virtual machine 600 has a command buffer 611, a task program storage unit 612, a selection unit 613, a control unit 616, and a status output unit 617 as functional blocks.
  • the command buffer 611 stores execution commands output by the command output unit 517 of the virtual upper controller 500 .
  • the task program storage unit 612 stores two or more task programs 420 in the same manner as the task program storage unit 412 .
  • the selection unit 613 selects an execution command stored in the command buffer 611 based on the execution conditions (condition headers 422) of the plurality of tasks in the task program storage unit 612 and the state of the virtual space stored in the information storage unit 514. select one of the tasks corresponding to (hereinafter referred to as "corresponding task"). For example, the selection unit 613 confirms whether or not each corresponding task can be executed. For example, the selection unit 613 checks whether the state information of the virtual space satisfies the executability conditions for each of one or more corresponding tasks. If two or more corresponding tasks are executable, the selection unit 613 selects one of the two or more executable corresponding tasks based on the priority. For example, the selection unit 613 selects the corresponding task with the highest priority.
  • the control unit 616 outputs to the space simulator 700 a control signal for controlling the machine body 10 to execute the corresponding task selected by the selection unit 613 .
  • the space simulator 700 causes the machine body 10 to execute corresponding tasks in the virtual space based on the control signal and the model stored in the model storage unit 211 . For example, the space simulator 700 calculates changes in the position and orientation of the machine body 10 during execution of the corresponding task without actually operating the machine body 10 .
  • the status output unit 617 outputs the above status information of the machine body 10 in the virtual space to the virtual upper controller 500 .
  • the status information includes at least position/orientation information of the machine body 10 in the virtual space.
  • the status output unit 617 may include a task completion notification in the status information and output it upon completion of execution of the task program 420 .
  • the virtual machine 600 may further have an interlock section 614 .
  • the interlock unit 614 sets an entry-prohibited area for the corresponding machine body 10 in the virtual space based on the progress of tasks executed by other machine bodies 10 .
  • the selection unit 613 selects a corresponding task in which the no-entry area and the operating range of the corresponding machine body 10 do not overlap.
  • the virtual machine 600 may further have a parameter holding unit 615.
  • the parameter holding unit 615 stores one or more simulation parameters for operating the machine body 10 in the virtual space. Examples of one or more simulation parameters include position control gain, speed control gain, current control gain, and the like.
  • the parameter holding unit 615 may store a waiting time from the output of the control signal to the completion of the operation of the machine body 10 as a simulation parameter. If the virtual machine 600 has a parameter storage unit 615 , the control unit 616 controls the machine body 10 based on one or more control parameters stored in the parameter storage unit 615 .
  • the production apparatus 4 determines how to allocate processing steps according to production instructions from the host controller 300 to the plurality of machines 5 and at what timing the plurality of machines 5 are to execute the allocated processing steps. determines autonomously and operates autonomously based on the determination result, the production system 1 can be operated flexibly. Even under such flexible operation, a more reliable comparison standard is generated by executing the virtual processing process with the same algorithm as that of the production equipment 4 based on the same production instructions as the production instructions for the production equipment 4. Then, the autonomous operation of the production equipment 4 can be verified in real time.
  • the comparison unit 216 may further compare the task executed by each of the plurality of machines 5 and the task executed by each of the plurality of virtual machines 600 .
  • the cell simulator 200 may further have a service section 221 .
  • the service unit 221 causes the virtual production device 212 to execute a specific simulation in response to a request from the production device 4 and returns response information based on the results of the specific simulation to the production device 4 .
  • a specific simulation is a simulation specified by a request from the production device 4 .
  • An example of a specific simulation is a simulation for generating a return action for restarting the stopped action when the production device 4 stops abnormally.
  • the service unit 221 adjusts the state of the virtual space to the state of the real space in response to a request from the production device 4, and tentatively generates a return action.
  • the service unit 221 causes the virtual production apparatus 212 to execute a return action in the virtual space, and corrects the return action based on the result of the return action in the virtual space, and the result of the return action satisfies a predetermined condition.
  • a return motion is generated, and the generated return motion is returned to the production device 4 as response information.
  • the predetermined condition is that objects do not collide with each other due to the return motion.
  • Another example of a specific simulation is a simulation for correcting a corresponding task so that it satisfies the executability condition when the corresponding task does not satisfy the executability condition.
  • the state of the virtual cell changes along with the state of the cell. Therefore, a specific simulation in response to a request from the production equipment can be quickly executed based on the state of the virtual cell that has changed along with the state of the cell, and response information can be returned to the production equipment in a short waiting time.
  • the cell simulator 200 may further have a simulator correction section 222 .
  • the simulator correction unit 222 makes the virtual production apparatus 212 execute virtual processing steps so as to reduce the deviation between the execution result of the processing steps and the execution result of the virtual processing steps.
  • Change simulation parameters For example, as described above, the waiting time from the output of the control signal to the completion of the operation of the machine body 10 is stored as a simulation parameter. If there is a deviation from the execution result, the simulator correction unit 222 changes the waiting time so as to reduce the deviation.
  • the cell simulator 200 may further have a factor identification unit 223.
  • the comparison result by the comparison unit 216 includes a deviation between the execution result of at least part of the processing steps by the robot and the execution result of at least part of the virtual processing steps by the virtual robot, the robot that causes the deviation Identify virtual machines other than
  • the simulator correction unit 222 corrects the simulation parameters for causing the virtual machine that causes the deviation to execute at least a part of the virtual processing steps. .
  • the factor identification unit 223 identifies the cause of the deviation. Identify the machine tool as a virtual machine that becomes The simulator correction unit 222 corrects the waiting time for door opening/closing stored as a simulation parameter of the machine tool that causes the deviation.
  • the upper controller 300 may further have a parameter changer 321.
  • the parameter changing unit 321 sets control parameters for causing the production apparatus 4 to execute the processing steps so as to reduce the deviation between the execution results of the processing steps and the execution results of the virtual processing steps. to change
  • the parameter changing unit 321 changes the control parameters of the parameter holding unit 415 so as to reduce the deviation between the execution result of the processing step and the execution result of the virtual processing step (see FIG. 4).
  • the parameter changing unit 321 may be included in the host controller 300 or may be included in the local controller 400 .
  • the production instruction device 2 may further have a plan change unit 811.
  • a plan changing unit 811 changes the production plan based on the comparison result by the comparing unit 216 . For example, when the deviation between the execution result of the processing step and the execution result of the virtual processing step exceeds a predetermined level in one cell 3, the plan change unit 811 changes the production plan assigned to the cell 3 to another cell. Change the production plan to run in cell 3.
  • the cell simulator 200 may further have an API 224 and a command conversion section 225.
  • the API 224 is an API (Application Programming Interface) that operates the virtual production equipment based on the simulation instructions.
  • the instruction conversion unit 225 receives the production instruction, converts it into a simulation instruction, and passes it to the API 224 .
  • FIG. 9 is a block diagram illustrating hardware configurations of the data collection device 100, the cell simulator 200, the host controller 300, and the local controller 400.
  • local controller 400 includes circuitry 490 .
  • Circuitry 490 includes processor 491 , memory 492 , storage 493 , driver circuitry 494 and communication port 495 .
  • the storage 493 is composed of one or more non-volatile memory devices such as flash memory or hard disk. The storage 493 stores programs for causing the local controller 400 to configure the functional blocks described above.
  • the memory 492 is composed of one or more volatile memory devices such as random access memory. Memory 492 temporarily stores programs loaded from storage 493 .
  • the processor 491 is composed of one or more computing devices such as a CPU (Central Processing Unit) or a GPU (Graphics Processing Unit). The processor 491 executes a program loaded in the memory 492 to configure each functional block described above in the local controller 400 . A calculation result by the processor 491 is temporarily stored in the memory 492 .
  • the driver circuit 494 operates the machine body 10 according to requests from the processor 491 .
  • the communication port 495 communicates with the host controller 300 via the communication network NW1 for control in response to requests from the processor 491 .
  • the upper controller 300 has a circuit 390.
  • Circuit 390 has processor 391 , memory 392 , storage 393 , input/output port 394 , communication port 395 and communication port 396 .
  • the storage 393 is composed of one or more non-volatile memory devices such as flash memory or hard disk. The storage 393 stores a program for configuring the upper controller 300 with the functional blocks described above.
  • the memory 392 is composed of one or more volatile memory devices such as random access memory. Memory 392 temporarily stores programs loaded from storage 393 .
  • the processor 391 is composed of one or more computing devices such as CPU or GPU. The processor 391 executes a program loaded in the memory 392 to configure each functional block described above in the host controller 300 . A calculation result by the processor 391 is temporarily stored in the memory 392 .
  • the input/output port 394 exchanges information with the environment sensor 6 in response to requests from the processor 391 .
  • Communication port 395 communicates with local controller 400 via communication network NW1 in response to requests from processor 391 .
  • the communication port 396 communicates with the data collection device 100, the cell simulator 200, and the production instruction device 2 via the communication network NW2 in response to requests from the processor 391.
  • the communication network NW2 may be a network different from the communication network NW1, or may be the same network as the communication network NW1.
  • the data collection device 100 has a circuit 190.
  • Circuitry 190 includes processor 191 , memory 192 , storage 193 , communication port 194 and user interface 195 .
  • the storage 193 is composed of one or more non-volatile memory devices such as flash memory or hard disk.
  • the storage 193 stores a program for configuring the data collection device 100 with the functional blocks described above.
  • the memory 192 is composed of one or more volatile memory devices such as random access memory. Memory 192 temporarily stores programs loaded from storage 193 .
  • the processor 191 is composed of one or more arithmetic devices such as CPU or GPU. The processor 191 executes the program loaded in the memory 192 to configure the data collection device 100 with each functional block described above. A calculation result by the processor 191 is temporarily stored in the memory 192 .
  • the communication port 194 communicates with the cell simulator 200 and the upper controller 300 via the communication network NW2 in response to requests from the processor 191.
  • a user interface 195 inputs and outputs information to and from an operator in response to requests from the processor 191 .
  • the user interface 195 has a display device such as a liquid crystal monitor or an organic EL (Electro-Luminescence) monitor and an input device such as a keyboard or mouse.
  • the input device may be integrated with the display device as a touch panel.
  • the cell simulator 200 has a circuit 290.
  • Circuitry 290 includes processor 291 , memory 292 , storage 293 , communication port 294 and user interface 295 .
  • the storage 293 is composed of one or more non-volatile memory devices such as flash memory or hard disk. Storage 293 stores a program for configuring cell simulator 200 with the functional blocks described above.
  • the memory 292 is composed of one or more volatile memory devices such as random access memory. Memory 292 temporarily stores programs loaded from storage 293 .
  • the processor 291 is composed of one or more arithmetic devices such as CPU or GPU. The processor 291 executes the program loaded in the memory 292 to configure the above functional blocks in the cell simulator 200 . A calculation result by the processor 291 is temporarily stored in the memory 292 .
  • the communication port 294 communicates with the data collection device 100, the host controller 300, and the production instruction device 2 via the communication network NW2 in response to requests from the processor 291.
  • a user interface 295 inputs and outputs information to and from an operator in response to requests from the processor 291 .
  • the user interface 295 has a display device such as a liquid crystal monitor or an organic EL (Electro-Luminescence) monitor and an input device such as a keyboard or mouse.
  • the input device may be integrated with the display device as a touch panel.
  • cell simulator 200 may be incorporated in data collection device 100 .
  • the cell simulator 200 and the data collection device 100 may be incorporated in the host controller 300 .
  • [Production procedure] As an example of the production method, the execution procedure of the processing steps and the virtual processing steps by the production system 1 will be illustrated. This procedure is based on the production instructions sent based on the production plan, executing the processing processes for the workpiece in the real space to produce the product, and the processing processes performed by the production equipment based on the production instructions. It includes causing a corresponding virtual process step to be executed by a virtual production device in a virtual space, and comparing the execution result of the process step with the execution result of the virtual process step.
  • the production instruction device 2 executes step S11.
  • step S ⁇ b>11 the production instruction device 2 transmits production instructions based on the cell-by-cell production plan to the host controller 300 and the cell simulator 200 .
  • step S21 In response to receiving the production instruction transmitted from the production instruction device 2, the host controller 300 executes the process in step S21. In parallel with execution of processing steps by the host controller 300, the data collection device 100 executes step S31. In step S ⁇ b>31 , the history acquisition unit 111 collects execution histories of processing steps and stores them in the database 112 .
  • step S ⁇ b>41 the state matching unit 213 acquires the state information of the physical space from the database 112 .
  • step S42 the state matching unit 213 matches the state of the virtual space with the state of the real space based on the information acquired in step S41.
  • step S43 the cell simulator 200 executes step S43.
  • the virtual production device 212 executes a virtual processing step in the virtual space.
  • the virtual data collection unit 214 collects execution histories of the virtual processing steps and stores them in the virtual database 215 in parallel with the execution of the virtual processing steps.
  • step S44 the comparison unit 216 acquires from the database 112 the execution history of the processing steps collected by the history acquisition unit 111 in step S31 as the execution result of the processing steps.
  • step S45 the comparison unit 216 compares the execution result of the processing step with the execution result of the virtual processing step.
  • the comparison unit 216 compares the execution history of the processing steps acquired in step S44 with the execution history of the virtual processing steps collected by the virtual data collection unit 214 and stored in the virtual database 215 in step S43.
  • step S ⁇ b>45 the abnormality detection section 217 may detect abnormality of the production apparatus 4 based on the comparison result by the comparison section 216 .
  • the cell simulator 200 may further execute step S46 based on the comparison result by the comparison unit 216.
  • the simulator correction unit 222 changes the simulation parameters for causing the virtual production apparatus 212 to execute the virtual process so as to reduce the deviation between the execution result of the process and the execution result of the virtual process.
  • the host controller 300 may further execute step S22.
  • the parameter changing section 321 changes the control parameters for causing the production apparatus 4 to execute the processing steps so as to reduce the deviation between the execution results of the processing steps and the execution results of the virtual processing steps.
  • the production instruction device 2 may further execute step S12.
  • step S ⁇ b>12 the plan changing unit 811 changes the production plan based on the comparison result by the comparing unit 216 .
  • FIG. 11 is a flow chart illustrating the processing executed by the host controller 300 in the above processing steps.
  • the host controller 300 first executes steps S211 and S212.
  • step S211 the production instruction acquisition unit 312 waits for acquisition of production instructions.
  • step S212 the processing process selection unit 313 selects a processing process for each product based on the production instruction acquired by the production instruction acquisition unit 312 and the multiple types of processing processes stored in the processing process database 311.
  • FIG. 11 is a flow chart illustrating the processing executed by the host controller 300 in the above processing steps.
  • the host controller 300 first executes steps S211 and S212.
  • the production instruction acquisition unit 312 waits for acquisition of production instructions.
  • step S212 the processing process selection unit 313 selects a processing process for each product based on the production instruction acquired by the production instruction acquisition unit 312 and the multiple types of processing processes stored in the processing process database 311.
  • step S213 the process allocation unit 316 allocates the unexecuted task in the process to one of the plurality of machines 5 based on the progress information of the process.
  • step S214 the command output unit 317 outputs an execution command for the unexecuted task to the local controller 400 based on the progress information of the processing steps.
  • step S ⁇ b>215 the information display unit 315 collects the state information of the physical space and the progress information of the processing steps, and stores them in the information storage unit 314 .
  • step S216 the display unit 318 displays the information stored in the information storage unit 314 on the monitor.
  • step S217 the command output unit 317 confirms whether or not the processing steps selected by the processing step selection unit 313 for each product have been completed. If it is determined in step S217 that at least part of the processing steps have not been executed, the host controller 300 returns the process to step S213. After that, the output of execution commands and the updating of information are repeated until the processing steps for each product are completed. If it is determined in step S217 that the processing steps have been completed, the host controller 300 terminates the processing.
  • FIG. 12 is a flowchart illustrating processing executed by the local controller 400 in the above processing steps.
  • the local controller 400 first executes step S221.
  • the selection unit 413 waits for the execution command to be stored in the command buffer 411 .
  • step S ⁇ b>222 the interlock unit 414 sets an entry prohibited area for the corresponding machine body 10 in the physical space based on the progress of the task executed by the other machine body 10 .
  • the selection unit 413 selects the command buffer 411 based on the execution conditions (condition headers 422) of the plurality of tasks in the task program storage unit 412 and the state of the physical space stored in the information storage unit 314. It is checked whether any of the tasks (corresponding tasks) corresponding to the stored execution commands are executable. If it is determined in step S223 that there is no executable corresponding task, the local controller 400 returns the process to step S221.
  • step S224 the selection unit 413 selects an executable corresponding task. If two or more corresponding tasks are executable, the selection unit 413 selects the corresponding task with the highest priority.
  • step S ⁇ b>225 the control unit 416 starts controlling the machine body 10 to execute the corresponding task selected by the selection unit 413 .
  • step S ⁇ b>226 the status output unit 417 transmits the status information of the machine body 10 to the host controller 300 .
  • step S227 the status output unit 417 confirms whether or not execution of the corresponding task has been completed. If the local controller 400 determines that execution of the corresponding task has not been completed, the process returns to step S226. Thereafter, the transmission of the status information of the machine main body 10 to the host controller 300 is repeated until the execution of the corresponding task is completed.
  • step S227 When it is determined in step S227 that the execution of the corresponding task has been completed, the status output unit 417 executes step S228.
  • step S ⁇ b>228 the status output unit 417 transmits the notification of completion of the corresponding task to the host controller 300 while including it in the status information.
  • the local controller 400 After that, the local controller 400 returns the process to step S221.
  • the local controller 400 repeatedly executes the above processing at a predetermined control cycle.
  • FIG. 13 is a flow chart illustrating the processing executed by the virtual upper controller 500 in the above virtual processing steps.
  • the virtual upper controller 500 first executes steps S411 and S412.
  • step S411 the production instruction acquisition unit 512 waits for acquisition of production instructions.
  • step S412 the process selection unit 513 selects a virtual process for each product based on the production instructions acquired by the production instruction acquisition unit 512 and the multiple types of processes stored in the task database 511.
  • step S413 the process allocation unit 516 allocates the unexecuted task in the process to one of the plurality of virtual machines 600 based on the progress information of the process.
  • step S414 the command output unit 517 outputs an execution command for the unexecuted task to the virtual machine 600 based on the progress information of the processing steps.
  • step S415 the virtual upper controller 500 executes steps S415 and S416.
  • step S ⁇ b>415 the virtual information posting unit 515 collects state information of the virtual space and progress information of the virtual processing steps, and stores them in the information storage unit 514 .
  • step S416 the display unit 518 displays the information stored in the information storage unit 514 on the monitor.
  • step S417 the command output unit 517 confirms whether or not the virtual processing steps selected by the processing step selection unit 513 for each product have been completed. If it is determined in step S417 that at least part of the virtual processing steps have not been executed, the virtual upper controller 500 returns the process to step S413. After that, until the virtual processing steps for each product are completed, the output of the execution command and the updating of the information are repeated. If it is determined in step S417 that the virtual processing step has been completed, the virtual upper controller 500 ends the processing.
  • FIG. 14 is a flowchart illustrating processing executed by the virtual machine 600 in the virtual processing steps.
  • the virtual machine 600 first executes step S421.
  • the selection unit 613 waits for the execution command to be stored in the command buffer 611 .
  • step S422 the interlock unit 614 sets an entry prohibited area for the corresponding machine body 10 in the virtual space based on the progress of the task executed by the other machine body 10.
  • step S423 the selection unit 613 selects the command buffer 611 based on the execution conditions (condition headers 422) of the plurality of tasks in the task program storage unit 612 and the state of the virtual space stored by the interlock unit 614. It is checked whether any of the tasks (corresponding tasks) corresponding to the stored execution commands are executable. If it is determined in step S423 that there is no executable corresponding task, the virtual machine 600 returns the process to step S421.
  • step S423 If it is determined in step S423 that there is an executable corresponding task, the virtual machine 600 executes step S424.
  • step S424 the selection unit 613 selects an executable corresponding task. If two or more corresponding tasks are executable, the selection unit 613 selects the corresponding task with the highest priority.
  • step S425 the control unit 616 starts causing the machine body 10 to execute the corresponding task selected by the selection unit 613 in the virtual space.
  • step S ⁇ b>426 the status output unit 617 transmits the status information of the machine body 10 in the virtual space to the virtual upper controller 500 .
  • step S427 the status output unit 617 confirms whether or not execution of the corresponding task has been completed.
  • step S426 the virtual machine 600 returns the process to step S426. Thereafter, until the execution of the corresponding task is completed, the transmission of the status information of the machine body 10 in the virtual space to the virtual upper controller 500 is repeated.
  • step S427 If it is determined in step S427 that the execution of the corresponding task has been completed, the status output unit 617 executes step S428.
  • step S ⁇ b>428 the status output unit 617 transmits the notification of completion of the corresponding task to the virtual upper controller 500 while including it in the status information. After that, the virtual machine 600 returns the processing to step S421. The virtual machine 600 repeatedly executes the above processing.
  • FIG. 15 is a flowchart illustrating an unplanned processing procedure by the production system 1.
  • the host controller 300 first executes step S231.
  • the host controller 300 waits for unscheduled processing. Examples of unplanned processing include the return operation described above. For example, when the operation of a plurality of machines 5 is stopped due to the occurrence of an abnormality, the host controller 300 determines that a recovery operation is necessary.
  • step S232 upper controller 300 requests cell simulator 200 for a service for executing unplanned processing.
  • the host controller 300 requests the cell simulator 200 to generate unplanned processing to be executed by at least one of the plurality of machines 5 .
  • the cell simulator 200 executes steps S431 and S432.
  • step S ⁇ b>431 the state matching unit 213 acquires the state information of the physical space from the database 112 .
  • step S432 the state matching unit 213 matches the state of the virtual space with the state of the real space based on the information acquired in step S41.
  • the cell simulator 200 executes steps S433 and S434.
  • the service unit 221 causes the virtual production device 212 to execute the specific simulation, and executes service processing for generating response information based on the result of the specific simulation.
  • the service section 221 transmits the service processing result to the host controller 300 as response information.
  • step S233 the host controller 300 causes at least one of the plurality of machines 5 to execute unplanned processing based on the response information. Thus, the unplanned processing procedure by the production system 1 is completed.
  • FIG. 16 is a flowchart illustrating the procedure of service processing in step S221.
  • the cell simulator 200 first executes steps S451 and S452.
  • the service unit 221 provisionally generates an unplanned process.
  • the service unit 221 causes the virtual production device 212 to execute unplanned processing in the virtual space.
  • step S453 it is checked whether the operation result of the virtual production device 212 in the virtual space satisfies a predetermined condition.
  • step S454 the service unit 221 corrects the unplanned processing based on the operation result of the virtual production device 212 in the virtual space. After that, the cell simulator 200 returns the processing to step S452.
  • step S453 the operation result of the virtual production device 212 in the virtual space satisfies the predetermined condition.
  • a production device 4 that executes a processing process on a workpiece in real space to produce a product based on a production instruction transmitted based on a production plan, and a process performed by the production device 4 based on the production instruction.
  • a production system comprising a simulator 200 having a virtual production device 212 that executes a virtual process corresponding to the process in a virtual space, and a comparator 216 that compares the execution result of the process with the execution result of the virtual process. 1.
  • the virtual production apparatus 212 is caused to execute the virtual processing steps in the virtual space, and the execution results of the virtual processing steps are compared according to the situation in which the production apparatus 4 executes the processing steps.
  • a reference can be generated and the results of the execution of the process steps can be monitored based on comparison with the comparison reference.
  • the simulator 200 further has a state matching unit 213 that matches the state of the virtual space with the state of the real space when starting the execution of the processing steps.
  • the production system 1 according to (1) which executes virtual processing steps based on the state of the virtual space obtained. After matching the state of the virtual space with the state of the real space immediately before the processing steps according to the production instruction are executed, the virtual production device 212 is caused to execute the virtual processing steps, thereby establishing a more reliable comparison standard. can be generated.
  • the history acquisition unit 111 collects the execution history of the processing steps from the production apparatus 4 and stores it in the database 112.
  • the state matching unit 213 acquires the state of the virtual space based on the information stored in the database 112. to the state of the real space, the production system 1 according to (2).
  • After matching the state of the virtual space with the state of the real space it is possible to easily construct a system that causes the virtual production device 212 to execute the virtual processing steps.
  • the production device 4 autonomously executes processing steps according to a predetermined algorithm.
  • the production system 1 according to any one of (1) to (3), which autonomously executes the virtual processing steps with an algorithm based on. By executing the virtual processing steps with the same algorithm as the algorithm of the production apparatus 4 based on the same production instruction as the production instruction for the production apparatus 4, a more reliable comparison standard can be generated.
  • the production device 4 has a plurality of machines 5 including robots 5B, 5C, and 5D, and an information display unit 315 that collects state information of the real space.
  • the production system 1 according to (4), which autonomously executes at least part of the processing steps based on the state information of the physical space collected by the unit 315 .
  • the robots 5B, 5C, and 5D are caused to perform autonomous operations based on production instructions and cell state information, it is even more difficult to specify the virtual processing steps to be executed by the virtual production device 212 in order to generate a comparison target. be. For this reason, comparisons with comparisons generated by simulations based on production orders are even more useful.
  • the information display unit 315 further collects progress information of the processing steps, and the robots 5B, 5C, and 5D autonomously perform at least a part of the processing steps based on the state information of the real space and the progress information.
  • the production system 1 according to (5), which executes When the robots 5B, 5C, and 5D are caused to perform autonomous operations based on the progress information in addition to the production instructions and the cell status information, the virtual processing to be executed by the virtual production device 212 in order to generate a comparison target. Process identification is even more difficult. For this reason, comparisons with comparisons generated by simulations based on production orders are even more useful.
  • a process allocation unit 316 for allocating unexecuted processes in the processing process to one of the plurality of machines 5 based on the progress information, and the robots 5B, 5C, and 5D are allocated by the process allocation unit 316.
  • the robots 5B, 5C and 5D set a no-entry area for the robots 5B, 5C and 5D based on the progress of the process executed by any of the machines 5 other than the robots 5B, 5C and 5D.
  • the production system 1 according to (6) or (7), which has an interlock part 414 . Based on the progress of the processes executed by the machines 5 other than the robots 5B, 5C, and 5D, the no-entry areas for the robots 5B, 5C, and 5D are dynamically generated. There is no need to set a 5D prohibited area in advance. Therefore, the production system 1 can be easily constructed. If the no-entry area is set more autonomously, it becomes more difficult to specify the virtual processing steps to be executed by the virtual production device 212 to generate the comparison target. For this reason, comparisons with comparisons generated by simulations based on production orders are even more useful.
  • the progress information includes reservation information indicating which of the plurality of machines 5 is assigned to the unexecuted process, and the information display unit 315 displays which of the plurality of machines 5 is assigned in the reservation information.
  • the no-entry area can be set more timely.
  • each autonomous operation of the plurality of machines 5 can be executed in a more timely manner.
  • the production system 1 according to any one of (5) to (9), further comprising a display section 318 for displaying information collected by the information display section 315 on a monitor. It is possible for the operator to easily comprehend what state the robots 5B, 5C, and 5D operate autonomously based on.
  • the virtual production device 212 has a plurality of virtual machines 600 including virtual robots corresponding to the robots 5B, 5C, and 5D, and a virtual information display unit 515 that collects virtual space state information.
  • the production system 1 according to any one of (5) to (10), which autonomously executes at least part of the virtual processing steps based on the state information of the virtual space collected by the virtual information posting unit 515. By matching the configuration of the virtual production device 212 to the configuration of the production device 4, a more reliable comparison target can be generated.
  • the comparison result by the comparison unit 216 includes a deviation between the execution result of at least part of the processing steps by the robots 5B, 5C, and 5D and the execution result of at least part of the virtual processing steps by the virtual robot.
  • a factor identification unit 223 for identifying the virtual machines 600 other than the robots 5B, 5C, and 5D that cause the deviation; and simulation parameters for causing the virtual machine 600 that causes the deviation to execute at least part of the virtual process
  • the comparison unit 216 compares the transition timing of the state of the real space according to the progress of the processing steps with the transition timing of the state of the virtual space according to the progress of the virtual processing steps. ). It is possible to improve the ease of utilization of the result of comparison between the execution result of the processing step and the execution result of the virtual processing step.
  • the simulator 200 further has a service section 221 that causes the virtual production device 212 to execute a specific simulation in response to a request from the production device 4 and returns response information based on the result of the specific simulation to the production device 4. , (1) to (13).
  • the state of the virtual cell changes along with the state of the cell. Therefore, a specific simulation in response to a request from the production device 4 can be quickly executed based on the state of the virtual cell that has changed together with the state of the cell, and response information can be returned to the production device 4 in a short waiting time.
  • Simulation parameters for causing the virtual production device 212 to execute the virtual processing steps are set so as to reduce the deviation between the execution results of the processing steps and the execution results of the virtual processing steps, based on the comparison result by the comparison unit 216.
  • the production system 1 according to any one of (1) to (15), further comprising a simulator correction section 222 that changes.
  • the comparison result by the comparison unit 216 can be used for adjusting the simulation parameters.
  • the production system 1 according to any one of (1) to (16), further comprising a plan changing section 811 that changes the production plan based on the comparison result of the comparing section 216.
  • the comparison result by the comparison unit 216 can be used for adjusting the production plan.
  • the simulator 200 further includes an API 224 that operates the virtual production device 212 based on a simulation instruction, and a command conversion unit 225 that receives a production instruction and converts it into a simulation instruction. 1.
  • a production system 1 according to any of the preceding claims. It is possible to easily construct the simulator 200 that causes the virtual production device 212 to execute a virtual process based on the same production instruction as the production instruction for the production device 4 .
  • a production method comprising causing a virtual production device 212 to execute a corresponding virtual processing step in a virtual space, and comparing the execution result of the processing step with the execution result of the virtual processing step.

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