Monitoring device and recording medium for recording a program

Abstract

The present application provides a monitoring device and a recording medium having a program recorded therein, which can more quickly identify the cause of a problem in a production line. The monitoring device monitors the status in a production line having a plurality of processes by dividing the plurality of processes into a plurality of work units, and includes an operation status acquisition unit that acquires the operation status of equipment used in work for each work unit, a determination unit that determines whether the acquired operation status is appropriate based on a set value set in advance, and an output unit that outputs whether the work is appropriate for each work unit based on the determination result.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to a monitoring device and a recording medium recording a program. BACKGROUND

[0002] A monitoring device that monitors a production line constituted by a plurality of production devices such as industrial robot systems is known at present. The monitoring device manages data at the time of product manufacturing in units of manufacturing processes such as products or production lots. In this way, a delivery date management support system that performs management for each manufacturing process has been proposed (for example, refer to Patent Literature 1).

[0003] In a production line, the quality of products is judged, for example, by performing an inspection process after assembly of the products. In this case, even if a problem is detected in the inspection process, there is a time difference from the progress of the manufacturing process (occurrence of the problem) to the inspection process. Therefore, sometimes a product of which the quality is problematic is manufactured during this time difference. In addition, in management in units of manufacturing processes, sometimes time is spent in order to find out in which work included in the manufacturing process the problem has occurred. Therefore, it is more appropriate if the cause of the problem in the production line can be found out more quickly.

[0004] Patent Literature 1: Japanese Patent Application Publication No. 2005-71136 SUMMARY

[0005] (1) The present disclosure relates to a monitoring device that monitors the state of a work constituting a process in a production line provided with a plurality of processes by stages, the monitoring device being provided with: an operation state acquisition section that acquires an operation state at the time of operation of an apparatus used in the work in units of the work; a judgment section that judges whether or not the acquired operation state is appropriate based on a set value set in advance; and an output section that outputs whether or not the work is appropriate in units of the work based on the judgment result.

[0006] (2) In addition, the present disclosure relates to a recording medium recording a program that causes a computer to function as a monitoring device that monitors the state of a work constituting a process in a production line provided with a plurality of processes by dividing into a plurality of units of the work constituting the process, the program causing the computer to function as: an operation state acquisition section that acquires an operation state of an apparatus used in the work in units of the work; a judgment section that judges whether or not the acquired operation state is appropriate based on a set value set in advance; and an output section that outputs whether or not the work is appropriate in units of the work based on the judgment result.

[0007] According to the present disclosure, it is possible to provide a monitoring device that can find out the cause of a problem in a production line more quickly and a recording medium recording a program. BRIEF DESCRIPTION OF DRAWINGS

[0008] Figure 1 is a schematic diagram showing a production line as a monitoring target of a monitoring device of one embodiment of the present disclosure.

[0009] Figure 2 is a schematic diagram showing a relationship between a monitoring device of one embodiment and each device.

[0010] Figure 3 is a block diagram showing a structure of a monitoring device of one embodiment.

[0011] Figure 4 is a table showing action states and preparation information associated by an association section of a monitoring device of one embodiment.

[0012] Figure 5 is a screen diagram showing an output of an output section of a monitoring device of one embodiment.

[0013] Figure 6 is a flowchart showing an operation of a monitoring device of one embodiment.

[0014] Figure 7 is a schematic diagram showing a production line as a monitoring target of a monitoring device of another example.

[0015] Figure 8 is a schematic diagram showing a relationship between a monitoring device of another example and each device.

[0016] Figure 9 is a table showing action states and preparation information associated by an association section of a monitoring device of another example. DETAILED DESCRIPTION

[0017] Hereinafter, a description is given with reference to Figures 1 to 6 A monitoring device 1 and a program of one embodiment of the present disclosure are described.

[0018] First, before a description of the monitoring device 1 of the present embodiment, a description is given with reference to Figure 1 A relationship between processes and jobs of a production line 100 monitored by the monitoring device 1 is described.

[0019] As shown in FIG. 1, the production line 100 is composed of a plurality of processes. The production line 100 is composed of, for example, a press process 101, an assembly process (arc welding) 102, an assembly process (other) 103, an inspection process 104, and a painting process 105. Each process is composed of a plurality of job units. The assembly process (arc welding) 102 is composed of, for example, three joint sites of weld beads 1 to 3 as job units (see FIG. 2). Figure 1 Figure 4

[0020] ​​The monitoring device 1 in this embodiment is divided into multiple work units constituting the process to monitor the status. The monitoring device 1 directly monitors the operation status of the equipment included in the process and monitors the process in detail, thereby seeking to find out the cause of the problem earlier.

[0021] Next, the monitoring device 1 and procedure of one embodiment of the present disclosure will be described.

[0022] In a production line 100 with multiple processes, the monitoring device 1 is divided into multiple work units constituting the processes to monitor the status. In this embodiment, the monitoring device 1 that monitors the assembly process (arc welding) 102 among the multiple processes will be described as an example.

[0023] The monitoring device 1 is connected to the equipment used in the assembly process (arc welding) 102. For example, as... Figure 2 As shown, the monitoring device 1 is connected to the controller (robot controller) 114. The controller (robot controller) 114 controls the servo welding torch (robot) 111, the positioner 112, and the welding power source 113. The monitoring device 1 obtains the operational status of each device from the robot controller 114 on a work unit basis. Additionally, the monitoring device 1 is connected to the stamping machine 121 included in the stamping process 101, the preceding process to the assembly process (arc welding) 102. Figure 3 As shown, the monitoring device 1 includes an operation status acquisition unit 11, a previous process content acquisition unit 12, a correlation unit 13, an operation status storage unit 14, a value setting unit 15, a judgment unit 16, and an output unit 17.

[0024] For example, the operation status acquisition unit 11 is implemented by the CPU. The operation status acquisition unit 11 acquires the operation status of the equipment used in the operation on a per-work-unit basis. For example, such as... Figure 2 As shown, the equipment used in the operation includes a servo welding torch (robot) 111 for performing arc welding, a positioner 112 for changing the position or orientation of the workpiece (not shown), a welding power source 113 for supplying power for arc welding, and a controller 114 for controlling these devices. For example, as... Figure 4 As shown, the operation status acquisition unit 11 acquires the current value of the welding power source 113 and the welding speed of the servo welding torch (robot) 111 for each work unit, and uses these as the operation status. In addition, the operation status acquisition unit 11 acquires the operation status for each individual product (product X-1 in this embodiment).

[0025] The previous process content acquisition unit 12 is implemented, for example, by an operation performed by the CPU. The previous process content acquisition unit 12 is used to acquire the processing content of the previous process of a process whose operation status has been acquired, as the previous process content. In this embodiment, as... Figure 2As shown, the previous process content acquisition unit 12 acquires the processing content of the stamping machine 121 in the previous process (stamping process 101). Figure 4 As shown, the previous process content acquisition unit 12 acquires metal mold information and stamping waveforms as processing content.

[0026] The association unit 13 is implemented, for example, by the CPU. The association unit 13 associates the acquired operation status with the acquired previous process content. In this embodiment, the association unit 13 associates weld beads 1 to 3 (operation status) with metal mold information and stamping waveform (previous process content).

[0027] The operation status storage unit 14 is, for example, a secondary storage medium such as a hard disk. The operation status storage unit 14 stores the associated operation status and the contents of the previous process.

[0028] The value setting unit 15 is implemented, for example, by the CPU. The value setting unit 15 sets a value that is used to determine an anomaly based on the acquired action status as a set value. The value setting unit 15 may set the difference between the value and the average of a predetermined number of past action statuses (measurement data), a threshold using the maximum and minimum values, or a differential average over a predetermined time period as a set value.

[0029] The judgment unit 16 is implemented, for example, by the CPU. Based on a preset value, the judgment unit 16 determines whether the obtained operating condition is appropriate. For example, regarding fluctuations in current values ​​caused by poor soldering, the judgment unit 16 detects a difference greater than a predetermined value, thereby determining whether the operating condition is appropriate.

[0030] The output unit 17 is implemented, for example, by the CPU. Based on the judgment result, the output unit 17 outputs whether the job is appropriate for each work unit. In addition, the output unit 17 outputs the operation status and related previous process information. For example, such as... Figure 5 As shown, the output unit 17 displays information on a mobile terminal (not shown) or similar device in response to an abnormality (defect). For example, the output unit 17 displays the process, work unit, and product number where the defect occurred. Additionally, the output unit 17 outputs information from the previous process.

[0031] Next, refer to Figure 6 The flowchart below explains the operation of the monitoring device 1 in this embodiment.

[0032] First, the previous process content acquisition unit 12 acquires the previous process content (step S1). Next, the operation status acquisition unit 11 acquires the operation status (step S2). Next, the association unit 13 associates the operation status with the previous process content (step S3). The association unit 13 saves the associated operation status and the previous process content in the operation status storage unit 14.

[0033] Next, the judgment unit 16 determines whether the obtained operation status is appropriate (step S4). Specifically, the judgment unit 16 compares the preset setting value with the value of the operation status to determine whether the operation status is appropriate. When the operation status is abnormal (step S4: "Yes"), the process proceeds to step S5. On the other hand, if the operation status is not abnormal (step S4: No), the process proceeds to step S6.

[0034] In step S5, the output unit 17 outputs a signal indicating an abnormality in the work unit corresponding to the abnormal operating condition. Additionally, the output unit 17 outputs the abnormal operating condition and the previous process details. Thus, the process ends.

[0035] In step S6, it is determined whether the job has ended. If the job has ended (step S6: "Yes"), the process ends. On the other hand, if the job continues (if there is a next job unit, step S6: "No"), the process proceeds to step S2.

[0036] Next, the procedures disclosed herein will be explained.

[0037] The various structures included in the monitoring device 1 can be implemented individually through hardware, software, or a combination thereof. Here, implementation through software means implementing it by having a computer read and execute a program.

[0038] Programs can be stored and provided to a computer using various types of non-transitory computer-readable media. Non-transitory computer-readable media include various types of tangible storage media. Examples of non-transitory computer-readable media include magnetic recording media (e.g., floppy disks, magnetic tapes, hard disks), optical-magnetic recording media (e.g., optical discs), CD-ROMs (Read Only Memory), CD-Rs, CD-R / Ws, and semiconductor memories (e.g., mask ROMs, PROMs (Programmable ROMs), EPROMs (Erasable PROMs), flash memory ROMs, and RAMs (Random Access Memory)). Additionally, display programs can also be provided to a computer using various types of transitory computer-readable media. Examples of transitory computer-readable media include electrical signals, optical signals, and electromagnetic waves. Transitory computer-readable media can provide programs to a computer via wired communication paths such as wires and optical fibers, or via wireless communication paths.

[0039] The monitoring device 1 and the program according to the above embodiment achieve the following effects.

[0040] (1) A monitoring device 1, which monitors the status of a production line 100 having multiple processes by dividing it into multiple work units constituting the processes, the monitoring device 1 comprising: an operation status acquisition unit 11, which acquires the operation status of the equipment used in the operation for each work unit; a judgment unit 16, which judges the appropriateness of the acquired operation status based on a preset set value; and an output unit 17, which outputs the appropriateness of the operation for each work unit based on the judgment result.

[0041] Another program enables a computer to function as a monitoring device 1, which monitors the status of a production line 100 having multiple processes, which is divided into multiple work units constituting the processes. The program enables the computer to function as the following units: an operation status acquisition unit 11, which acquires the operation status of the equipment used in the operation for each work unit; a judgment unit 16, which judges the appropriateness of the acquired operation status based on preset settings; and an output unit 17, which outputs the appropriateness of the operation for each work unit based on the judgment result.

[0042] Therefore, compared to judging the suitability of a product through the post-assembly inspection process 104 in production line 100, product abnormalities can be judged at the manufacturing stage. This allows for faster detection of abnormalities. Furthermore, compared to monitoring each process individually, monitoring each work unit makes it easier to determine in which work unit the abnormality occurred. Therefore, the cause of problems in production line 100 can be identified more quickly. Especially in this embodiment, the operation status acquisition unit 11 acquires the equipment operation status for each joint, thus enabling more rapid identification of joints where poor connection has occurred.

[0043] (2) The monitoring device 1 further includes: a previous process content acquisition unit 12, which acquires the processing content of the previous process for which the operation status has been acquired, and uses it as the previous process content; and a correlation unit 13, which correlates the acquired operation status with the acquired previous process content, and an output unit 17 outputs the correlated previous process content and the operation status together. Thus, the operation status can be output in conjunction with the processing content executed in the previous process. Therefore, it can assist in identifying the cause of an anomaly.

[0044] The preferred embodiments of the monitoring device and program of this disclosure have been described above, but this disclosure is not limited to the above embodiments and can be appropriately modified.

[0045] For example, the above embodiment describes an example of monitoring assembly process (arc welding) 102, but is not limited thereto. The monitoring device 1 can also monitor multiple processes of the production line 200. As an example of monitoring other processes, such as... Figure 7 As shown, monitoring device 1 can also monitor assembly process (sealant application) 202 included in production line 200. For example... Figure 8 As shown, the monitoring device 1 is connected to the controller (robot controller) 214 and the sealant application equipment control device 215. The controller 214 controls the pump (motor) 211, robot 212, sealant (heater) 213, and sealant application equipment control device 215. The monitoring device 1 obtains the operating status of each piece of equipment (pump motor 211, robot 212, sealant (heater) 213, controller 214, and sealant application equipment control device 215) from the controller 214 and the sealant application equipment control device 215 for each work unit (each processing part). Furthermore, the monitoring device 1 is connected to the injection molding machine 301 and the stamping machine 302 included in the stamping / forming process 201, which is the preceding process to the assembly process (sealant application) 202. Figure 9 As shown, the monitoring device 1 takes the three joints of coating path 1 to coating path 3 as work units to obtain their respective operation status.

[0046] Alternatively, in the above embodiment, the previous process content acquisition unit 12 can also directly acquire the previous process processing content from the stamping machine 121. Alternatively, the previous process content acquisition unit 12 can also acquire the previous process processing content from a server (not shown) or the like that stores the previous process processing content.

[0047] Furthermore, in the above embodiments, each joint is described as a line segment such as a weld bead and a coating path, but it is not limited to this. For example, it may be a point-shaped joint such as each weld point (dot), each coating point, or a combination thereof.

[0048] Furthermore, while arc welding and sealant application are cited as examples of operations in the above embodiments, the methods are not limited to these. The operation can be, for example, mechanical joints such as laser welding, resistance welding, friction stir bonding, ultrasonic bonding, riveting, and bolt tightening, as well as adhesive bonding. It can also be tapping or drilling, or roughing, finishing, and post-processing performed by machining or laser. Therefore, in the case of these processes, the unit for obtaining the operational status can be each processing location. In this case, according to the present invention, the processing location where a defect has occurred can be identified more quickly.

[0049] Explanation of reference numerals in the attached figures

[0050] 1: Monitoring device; 11: Operation status acquisition unit; 12: Previous process content acquisition unit; 13: Connection unit; 16: Judgment unit; 17: Output unit; 100: Production line.

Claims

1. A monitoring device that monitors a situation in a production line having a plurality of processes by dividing into a plurality of work units that constitute the processes, characterized by comprising: an operation situation acquisition section that acquires an operation situation of equipment used in the work for each of the work units; a determination section that determines propriety of the acquired operation situation based on a set value set in advance; an output section that outputs propriety of the work for each of the work units based on a result of the determination; a preceding process content acquisition section that acquires a processing content of a preceding process of the process for which the operation situation has been acquired as a preceding process content; and a correlation section that correlates the acquired operation situation and the acquired preceding process content, wherein the output section outputs the correlated preceding process content together with the operation situation, and as a result, detects an abnormality of a product at a manufacturing stage before a defect of the product is ascertained through an inspection process after assembly in the production line.

2. The monitoring device according to claim 1, characterized in that the operation situation acquisition section acquires the operation situation of the equipment used in the work for each of processing sites.

3. A recording medium that records a program that causes a computer to function as a monitoring device that monitors a situation in a production line having a plurality of processes by dividing into a plurality of work units that constitute the processes, characterized in that the program causes the computer to function as: an operation situation acquisition section that acquires an operation situation of equipment used in the work for each of the work units; a determination section that determines propriety of the acquired operation situation based on a set value set in advance; an output section that outputs propriety of the work for each of the work units based on a result of the determination; a preceding process content acquisition section that acquires a processing content of a preceding process of the process for which the operation situation has been acquired as a preceding process content; and a correlation section that correlates the acquired operation situation and the acquired preceding process content, wherein the output section outputs the correlated preceding process content together with the operation situation, and as a result, detects an abnormality of a product at a manufacturing stage before a defect of the product is ascertained through an inspection process after assembly in the production line. ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​ ​

Images