Pipeline management assistance device, pipeline management assistance method, and recording medium

Abstract

A pipeline management assistance device (100) is connected with two or more sensors provided at a pipeline. The pipeline management assistance device (100) has a reception section (11) that receives a management condition designated as a condition for managing the pipeline, and a presentation section (12) that presents, as candidates for sensors used for management of the pipeline, one or more sensors that are pre-associated with a use condition in which a degree of similarity to the management condition exceeds a threshold, among use conditions of the sensors that are registered in advance, and presents assistance information showing a list of the candidates.

Description

Technical Field

[0001] This invention relates to an auxiliary device, method, and procedure for assembly line management. Background Technology

[0002] In FA (Factory Automation) settings, various assembly lines, such as production lines, inspection lines, and processing lines, are commonly used. By using sensors installed on such assembly lines, the status of the assembly lines can be monitored and managed (for example, see Patent Document 1).

[0003] Patent Document 1 describes a management system that uses sensors to detect the arrival of workpieces at each stage of a manufacturing line and sensors to detect the removal of workpieces from each stage. This system obtains status information indicating the progress of each stage and detects the occurrence of events based on this status information. In this management system, if any image representing multiple manufacturing lines displayed on a user interface screen is selected, a log of events occurring in that stage is displayed as information related to one or more stages within the selected manufacturing line. Therefore, data obtained from the sensors is hierarchically managed in association with the stage associated with that sensor and the production line containing that stage.

[0004] Patent Document 1: Japanese Patent Application Publication No. 2017-102668 Summary of the Invention

[0005] To improve production line operation, new sensors are sometimes selected and used to manage the production line. For example, consider a scenario where, at the start of a process within the production line, there's a requirement to monitor it using sensors in the same way as other processes. However, it's rare to obtain information directly from sensors that aligns with the requirements for production line management, as in the management system described in Patent Document 1. The sensor readings need to be processed into information useful to the user. Therefore, selecting the appropriate sensor based on the user's desired production line management requires the user's technical expertise. This can lead to the use of potentially inappropriate sensors, resulting in a risk of reduced efficiency in the sensor-based production line management.

[0006] The present invention was made in view of the above circumstances, and its purpose is to help to improve the efficiency of pipeline management using sensors.

[0007] To achieve the above objectives, the assembly line management assistance device of the present invention is connected to two or more sensors installed on the assembly line. The assembly line management assistance device includes: a receiving unit that receives management conditions specified as conditions for managing the assembly line; and a prompting unit that prompts one or more sensors pre-associated with the pre-registered sensor usage conditions whose similarity to the management conditions exceeds a threshold as candidates for sensors used for managing the assembly line, and provides assistance information showing a list of candidates.

[0008] The effects of the invention

[0009] According to the present invention, it is possible to improve the efficiency of production line management using sensors. Attached Figure Description

[0010] Figure 1 This is a diagram showing the structure of the management system involved in Implementation Method 1.

[0011] Figure 2 This is a diagram showing the hardware structure of the assembly line management auxiliary device according to Embodiment 1.

[0012] Figure 3 This is a diagram showing the functional structure of the assembly line management auxiliary device according to Embodiment 1.

[0013] Figure 4 This is a flowchart illustrating the registration process involved in Implementation Method 1.

[0014] Figure 5 This is a diagram showing an example of the assembly line registration screen according to Implementation Method 1.

[0015] Figure 6 This is a diagram showing an example of a process registration screen related to Implementation Method 1.

[0016] Figure 7 This is a diagram showing an example of a target registration screen according to Implementation Method 1.

[0017] Figure 8 This is a diagram illustrating the relationship between the production line information, process information, and destination information involved in Implementation Method 1.

[0018] Figure 9 This is a diagram showing an example of a sensor registration screen according to Embodiment 1.

[0019] Figure 10 This is a diagram showing an example of a sensor group registration screen according to Embodiment 1.

[0020] Figure 11 This is a diagram used to illustrate the computational logic involved in Implementation Method 1.

[0021] Figure 12 This is a diagram illustrating an example of setting sensor information according to Implementation Method 1.

[0022] Figure 13 This is a diagram showing an example of the corresponding sensor registration screen according to Embodiment 1.

[0023] Figure 14 This is a diagram illustrating the relationship between the production line information, process information, destination information, sensor setup information, and corresponding sensor information involved in Implementation Method 1.

[0024] Figure 15 This is a flowchart illustrating the selection process involved in Implementation 1.

[0025] Figure 16 This is a diagram showing an example of a sensor selection screen according to Embodiment 1.

[0026] Figure 17 This is a flowchart illustrating the sensor data processing involved in Implementation Method 1.

[0027] Figure 18 This is a diagram used to illustrate the output information involved in Implementation Method 1.

[0028] Figure 19 This is a flowchart illustrating the registration process involved in Implementation Method 2.

[0029] Figure 20 This is a diagram illustrating the relationship between the target information, sensor setup information, and corresponding sensor information involved in Implementation Method 2.

[0030] Figure 21 This is a flowchart illustrating the selection process involved in Implementation Method 2.

[0031] Figure 22 This is a diagram showing an example of the first setting screen according to Embodiment 2.

[0032] Figure 23 This is a diagram showing the first example of the second setting screen according to Embodiment 2.

[0033] Figure 24 This is a diagram showing a second example of the second setting screen related to Embodiment 2.

[0034] Figure 25 This is a diagram showing a third example of the second setting screen related to Embodiment 2.

[0035] Figure 26 This diagram illustrates the situation where the settings of the sensor and sensor group involved in Embodiment 2 directly become the settings of metadata. Detailed Implementation

[0036] Hereinafter, the assembly line management auxiliary device 100 according to the embodiments of the present invention will be described in detail with reference to the accompanying drawings.

[0037] Implementation Method 1

[0038] The assembly line management assistance device 100 according to this embodiment is a device that assists a user, wherein the user selects sensors for managing the assembly line. Figure 1 As shown, the production line management auxiliary device 100 is connected to the upper-level device 200 via a transmission line and is connected to two or more sensors 401, 402, 403, and 40n via a network 30. Hereinafter, sensors 401, 402, 403, and 40n will be collectively referred to as sensors 40, and the set including all sensors 40 will be referred to as sensor group 400.

[0039] The transmission line connecting the production line management auxiliary device 100 and the upper-level device 200 can be a communication line, such as a USB (Universal Serial Bus) cable, or it can be part of the network 30. The network 30 can be an industrial network, such as a fieldbus network, or an information network, such as a LAN (Local Area Network).

[0040] Sensors 40, such as data acquisition instruments like barcode readers, distance sensors, pass-through sensors, depth sensors, illuminance sensors, and facial recognition devices, are installed on the production line. Specifically, sensors 401 and 402 are installed in device 51 of the first production line L1, and sensors 403 to 40n are installed in device 52 of the second production line L2. Sensors 40 can output sensing results at a predetermined period, or they can send signals as sensing results when a specific event occurs.

[0041] Production lines L1 and L2 are production lines, inspection lines, and other production lines that perform pre-defined processing on the workpieces. Equipment 51 and 52 are structural elements of the production line that differ from sensor 40 and the workpieces being processed; for example, they are conveyor belts, components supporting the conveyor belts, and FA (Automatic Facilitator) instruments that process the workpieces transported by the conveyor belts. Examples of such FA instruments include actuators and robots.

[0042] In addition, Figure 1In the diagram, one device 51 for the first production line L1 and one device 52 for the second production line L2 are each shown, but there can be multiple devices 51 and 52. Hereinafter, devices 51 and 52 will be collectively referred to as device 50. Typically, multiple devices 50 are used to form a production line.

[0043] The production line management auxiliary device 100, such as a PLC (Programmable Logic Controller), IPC (Industrial Personal Computer), or other information processing device, together with the upper-level device 200, sensor group 400, and multiple devices 50, constitutes a management system 1000 for user-managed production lines. In the management system 1000, the production line management auxiliary device 100 obtains data from the sensor group 400, representing the sensing results of the production line's operating status obtained by each sensor 40, and sends the obtained data to the upper-level device 200.

[0044] The upstream device 200 is an IPC (Integrated Product Control) that uses BI (Business Intelligence) tools to analyze the operation of the production line based on data obtained from the production line management auxiliary device 100 and present the analysis results to the user. The analysis performed by the upstream device 200 includes, for example, anomaly detection and real-time calculation of indicators such as yield, turnover rate, and pass rate.

[0045] In order for efficient analysis to be performed by the upper-level device 200, it is necessary to define the attributes of the data and obtain so-called metadata. Therefore, the pipeline management auxiliary device 100 sends the data obtained from the sensor group 400 with metadata attached to it to the upper-level device 200. The attributes of the data are, for example, the identifier of the sensor 40 that outputs the data, the type of data, or the purpose of the analysis in which the data will be used.

[0046] exist Figure 2 The hardware structure of the production line management auxiliary device 100 is shown in the figure. Figure 2 As shown, the pipeline management auxiliary device 100 includes a processor 101, a main storage unit 102, an auxiliary storage unit 103, an input unit 104, an output unit 105, and a communication unit 106. The main storage unit 102, the auxiliary storage unit 103, the input unit 104, the output unit 105, and the communication unit 106 are all connected to the processor 101 via an internal bus 107.

[0047] The processor 101 includes a CPU (Central Processing Unit) or MPU (Micro Processing Unit) as an integrated circuit. The processor 101 performs the functions described later by executing the program P1 stored in the auxiliary storage unit 103.

[0048] The main storage unit 102 includes RAM (Random Access Memory). Program P1 is loaded into the main storage unit 102 from the auxiliary storage unit 103. Furthermore, the main storage unit 102 is used as the working area of ​​the processor 101.

[0049] The auxiliary storage unit 103 includes non-volatile memory, such as EEPROM (Electrically Erasable Programmable Read-Only Memory). In addition to program P1, the auxiliary storage unit 103 also stores various data used by the processor 101. According to the instructions of the processor 101, the auxiliary storage unit 103 supplies data used by the processor 101 to the processor 101 and stores the data supplied from the processor 101.

[0050] The input unit 104 includes input devices such as input keys and dual in-line packages (DIP) switches. The input unit 104 acquires information input by the user from the pipeline management auxiliary device 100 and notifies the processor 101 of the acquired information.

[0051] The output unit 105 includes output devices such as LED (Light Emitting Diode) and LCD (Liquid Crystal Display). The output unit 105 displays various information to the user according to the instructions of the processor 101.

[0052] The communication unit 106 includes a network interface circuit for communicating with external devices. The communication unit 106 receives signals from the outside and notifies the processor 101 of the information indicated by those signals. Additionally, the communication unit 106 transmits signals indicating information output from the processor 101 to external devices.

[0053] Through the collaboration of the aforementioned hardware, such as Figure 3 As shown, the assembly line management auxiliary device 100 includes, as its function, a receiving unit 11 and a prompting unit 12 serving as a user interface; a registration unit 13 for registering information in the assembly line management auxiliary device 100; a storage unit 14 for storing various types of information; a retrieval unit 15 for retrieving specific information from the information registered in the storage unit 14; an acquisition unit 16 for acquiring data from the sensor group 400; and an output unit 17 for outputting information including metadata to the upper-level device 200 based on the data from each sensor 40.

[0054] The receiving unit 11 is primarily implemented by the input unit 104. However, when the pipeline management auxiliary device 100 receives information input by the user operating the upper-level device 200 via a transmission line, the receiving unit 11 can also be implemented by the communication unit 106 that communicates with the upper-level device 200. Similarly, the prompting unit 12 is primarily implemented by the output unit 105. However, when the pipeline management auxiliary device 100 provides information to the user from the upper-level device 200 via a transmission line, the prompting unit 12 can also be implemented by the communication unit 106 that communicates with the upper-level device 200.

[0055] The registration unit 13 is primarily implemented by the processor 101. The registration unit 13 includes: a production line registration unit 131 for registering the production line; a process registration unit 132 for registering the processes constituting the production line; a destination registration unit 133 for registering the purpose of using the data from the sensor 40; a sensor installation registration unit 134 for registering the sensor 40 installed on the production line; and a corresponding sensor registration unit 135 for registering the sensor 40 that outputs data to achieve the desired purpose in relation to that purpose. The production line registration unit 131, process registration unit 132, destination registration unit 133, sensor installation registration unit 134, and corresponding sensor registration unit 135 all provide information to the prompting unit 12 to prompt the user for input, and store the information in the storage unit 14 based on the input received from the user by the receiving unit 11. Details of the information registration implemented by the registration unit 13 will be described later.

[0056] The storage unit 14 is mainly implemented by the auxiliary storage unit 103. The storage unit 14 stores the following information: the production line information 141 registered by the production line registration unit 131, the process information 142 registered by the process registration unit 132, the destination information 143 registered by the destination registration unit 133, the sensor setting information 144 registered by the sensor setting registration unit 134, and the corresponding sensor information 145 registered by the corresponding sensor registration unit 135, which indicates the correspondence between the destination and the sensor 40.

[0057] The retrieval unit 15 is mainly implemented by the processor 101. The retrieval unit 15 searches the storage unit 14 for the sensor 40 corresponding to usage conditions similar to the management conditions received by the receiving unit 11, and provides the retrieval results to the prompting unit 12. Details of the management conditions and usage conditions will be described later.

[0058] The acquisition unit 16 is mainly implemented by the communication unit 106. The acquisition unit 16 acquires data representing the sensing results from the sensor 40 selected by the user based on the search results of the search unit 15, and outputs the acquired data to the output unit 17.

[0059] The output unit 17 is mainly implemented through the cooperation of the processor 101 and the communication unit 106. Based on the data from the sensor 40, the output unit 17 generates information containing metadata and sends it to the upper-level device 200. The information output from the output unit 17 is used by the upper-level device 200 for pipeline management.

[0060] Next, use Figures 4-18 The processing performed by the assembly line management auxiliary device 100 will be explained.

[0061] exist Figure 4 The diagram shows the registration process for users to register various information in the assembly line management auxiliary device 100. Figure 4 The registration process shown begins, for example, when a user launches a specific application.

[0062] During the registration process, the pipeline registration unit 131 performs pipeline registration processing (step S11) to define the attributes of each pipeline. Specifically, the prompting unit 12, upon receiving instructions from the pipeline registration unit 131, prompts the system to... Figure 5 The pipeline registration screen shown is displayed. On this pipeline registration screen, the user inputs for each pipeline that they want to manage, including the pipeline name as an identifier for identifying the pipeline, the processing objects in the pipeline, the function of the pipeline as the main processing performed in the pipeline, other characteristic attributes related to the pipeline, and a visual image representing an overview of the pipeline.

[0063] The objects processed are, for example, manufactured goods, workpieces, inspection objects, or components. The function of an assembly line includes, for example, machining, assembly, or painting. Figure 5 The example shows a production line with the name "aaa production line" assembling "model [aaa123]". User-implemented input can be a string specified using the keyboard, a selection from a predefined dropdown menu, or information read from a user-specified storage area.

[0064] After receiving information input by the user defining the attributes of the pipeline, the receiving unit 11 stores it in the storage unit 14 as pipeline information 141.

[0065] Next, the process registration unit 132 performs process registration processing (step S12) to define the attributes of one or more processes included in the production line. Specifically, the prompting unit 12, for each of the production lines registered in step S11, provides instructions from the process registration unit 132. Figure 6The process registration screen shown is displayed. On this screen, the user enters the process name (as an identifier for the process) and the name of the equipment used in that process for each process. Figure 6 The example shows Figure 5 The "aaa production line" shown sequentially includes "aa1 process" which uses "aa1x" and "aa1y" as equipment, "aa2 process" which uses "aa2x", and "aa3 process" which uses "aa3x" and "aa3y". After the receiving unit 11 receives the information input by the user defining the attributes of the process, the process registration unit 132 stores it as process information 142 in the storage unit 14.

[0066] Next, the purpose registration unit 133 performs purpose registration processing (step S13) to define the purpose of the user's use of the data from the sensor 40 in association with the production line, process, and equipment. Specifically, the prompting unit 12, for the production line, process, and equipment registered in steps S11 and S12, provides instructions from the purpose registration unit 133. Figure 7 The purpose registration screen shown in the example is displayed. The user enters a string representing the purpose and related remarks on this purpose registration screen.

[0067] exist Figure 7 In the example, for the "aa1 process" using "aa1x" in the "aaa production line", the objectives are input as follows: "aa1 process start time", "aa1 process completion time", "batch start time", "batch completion time", "operating", and "not operating". These objectives are intended to ensure that the information obtained by the user using a certain sensor 40 is equivalent to the content analyzed by the upstream device 200. After the receiving unit 11 receives the information defining the objectives input by the user, the objective registration unit 133 stores it as objective information 143 in the storage unit 14.

[0068] By performing the above steps S11 to S13, as follows Figure 8 As illustrated, the pipeline information 141, process information 142, and destination information 143 are registered in relation to each other in the storage unit 14. Furthermore, in... Figure 8 In the example, some information was omitted. For example, in Figure 8 The pipeline processing objects and functions contained in pipeline information 141 are not shown in the figure, but the pipeline processing objects and functions can be further associated with... Figure 8 The pipeline names are stored in association.

[0069] Next, the sensor registration unit 134 performs a sensor registration process for registering the sensors 40 installed on the production line. Specifically, the prompting unit 12, upon receiving instructions from the sensor registration unit 134, performs a sensor registration process. Figure 9 , 10 The sensor registration screen and sensor group registration screen shown in the example are displayed.

[0070] In the sensor registration screen, the user can specify each sensor 40, such as... Figure 9 As shown, the input includes the sensor name, the category of the sensor 40, the manufacturer's name, and the model number of the sensor 40, which serve as identifiers for identifying the sensor 40. Figure 9 The example shows that sensor 40, which will be classified as an "ultrasonic distance sensor", is registered as "distance sensor 1".

[0071] Additionally, in the sensor group registration screen, such as... Figure 10 As shown, the inputs are: the sensor group name (an identifier used to identify a set of multiple sensors 40, i.e., a sensor group); the individual sensor names of each sensor 40 constituting the sensor group; setting conditions; and computational logic representing the operations performed on the sensor group. Setting conditions include parameters for setting the distance between the sensors 40, the detection sensitivity of each sensor 40, or the sensing period. Figure 10 The example shows that "sensor group z" consists of "distance sensor 1", "distance sensor 2" and "illuminance sensor".

[0072] like Figure 11 As shown, computational logic refers to the pre-defined operations performed on multiple data output from the sensors 40 constituting the sensor group in order to obtain the desired output. Computational logic can be, for example, a combination of logical OR and logical AND operations, operations or statistical processing that treats time-series data as objects, such as moving average, or the addition of pre-defined correction values, the addition or subtraction of sensing results.

[0073] Furthermore, when monitoring the production status of products flowing along the production line using a small number of distance sensors, omissions may occur due to operator shadows and timing discrepancies. To prevent these omissions, multiple distance sensors can be positioned at different locations along the flow direction. These multiple distance sensors can repeatedly transmit data indicating the detection results for the same product to the production line management auxiliary device 100. Therefore, the calculation logic that removes duplicate data from the data transmitted by multiple distance sensors based on the product speed, the distance between the distance sensors, and the data acquisition time is effective.

[0074] In addition, in the sensor group registration screen, calculation logic can be omitted, and the sensor group can be registered simply to make it easier for users to manage a set of sensors 40.

[0075] After receiving information input by the user defining the sensor 40 and sensor group in the sensor registration screen and sensor group registration screen, the receiving unit 11 sets the sensor registration unit 134 and stores it in the storage unit 14 as sensor setting information 144. Sensor setting information 144 is... Figure 12 The information specified for each of the registered sensors 40 and sensor groups is illustrated as follows. Hereinafter, the sensor group specified by the sensor setting information 144 will be referred to as sensor 40.

[0076] Return to Figure 4 After step S14, the corresponding sensor registration unit 135 performs corresponding sensor registration processing (step S15). This corresponding sensor registration processing is used to define the sensor 40 registered in step S14 in accordance with the information registered in steps S11 to S13. Specifically, the prompting unit 12 displays a corresponding sensor registration screen, which is as follows: Figure 13 As illustrated, the system includes input fields for specifying the usage conditions of sensor 40 based on the information registered in steps S11 to S13, and input fields for specifying the corresponding sensor among the sensors 40 registered in step S14 that corresponds to the aforementioned usage conditions. The user inputs usage conditions, including the production line, process, equipment, and purpose, in the input fields for usage conditions within the corresponding sensor registration screen. Figure 13 In the example, the production line name, process name, equipment name, and purpose were entered as usage conditions.

[0077] Additionally, in the corresponding sensor registration screen, the user enters the intended data acquisition method, the sensor 40 that meets the usage conditions, and the effects and disadvantages / risks in the corresponding sensor input field. The intended data acquisition method refers to the unit used to acquire data corresponding to the intended purpose, and is used as an identifier to identify the sensor 40 that meets the usage conditions. Figure 13 In the example, the input as the means of acquiring the target data included labels such as "using a distance sensor", "using a depth sensor", and "using both an illuminance sensor and an ultrasonic distance sensor".

[0078] Additionally, in the "Sensor / Sensor Group" field, the user inputs a sensor 40 deemed suitable for achieving the intended purpose in relation to the "Sensor Usage Conditions" input. "Effects and Disadvantages / Risks" refers to the effects, disadvantages, or risks of utilizing the sensor 40 as input by the user, considering the usage conditions. Examples of "Effects and Disadvantages / Risks" include, for instance, the ability to suppress detection omissions and remove noise through the combination of sensors. Figure 13 In this context, based on the usage conditions of determining the "start time of process aa1" according to the "aa1x" set in the "aa1 process" of the "aaa production line", three types of sensors 40 are input as appropriate. By having the user select the "register" button on the screen, the receiving unit 11 receives the input content, and then the corresponding sensor registration unit 135 stores it in the storage unit 14 as corresponding sensor information 145.

[0079] exist Figure 14 The diagram shows the relationship between production line information 141, process information 142, destination information 143, and sensor setting information 144 and corresponding sensor information 145. For example... Figure 14 As shown by the lines in the diagram, the corresponding sensor information 145 specifies the correspondence between each item of the production line information 141, process information 142, and destination information 143 and each item of the sensor information 144.

[0080] In addition, the information on "effects and disadvantages / risks" can also be registered by the sensor registration unit 134 associated with the sensor 40, instead of the corresponding sensor registration unit 135.

[0081] Return to Figure 4 If step S15 ends, the registration process ends. By executing steps S11 to S15 of the registration process, information used in the selection process for users to select sensors that meet their requirements is registered in the storage unit 14.

[0082] The process can be initiated, for example, by launching a specific application. Figure 15 As shown, in the selection process, the receiving unit 11 receives the management conditions specified for managing the production line (step S21). Specifically, the prompting unit 12 provides information on the conditions specified for managing the production line. Figure 16 The sensor selection screen displays the input field for management conditions as shown, prompting the user to input the management conditions. Here, the management conditions correspond to the user's requirements, which specify the purpose of using the data from sensor 40 by determining the production line, process, and equipment. That is, the management conditions are based on... Figure 13The input is in the same form as the usage conditions shown, including the purpose of sensor utilization. The receiving unit 11 is equivalent to an example of a receiving unit in the assembly line management auxiliary device 100, which receives management conditions specified as conditions for managing the assembly line.

[0083] Next, the retrieval unit 15 retrieves sensors 40 associated with usage conditions whose similarity to the specified management conditions exceeds a threshold from the storage unit 14 (step S22). Specifically, the retrieval unit 15 treats each item that matches the items included in the management conditions as one item, and retrieves usage conditions from the storage unit 14 whose total number of items exceeds a predetermined threshold. For example, regarding... Figure 16 Regarding the management conditions shown, due to Figure 13 The usage conditions shown are consistent with "Production Line Name", "Process Name", and "Purpose", therefore the total number of sensors 40 associated with these usage conditions is 3. Here, if the threshold is 2, then after inputting... Figure 16 Under such management conditions, Figure 13 When such a usage condition is met, the corresponding sensor associated with that usage condition is output as the search result.

[0084] Furthermore, the items constituting the management conditions and usage conditions are not limited to... Figure 13 , 16 As shown, for example, it may also include Figure 5 The "pipeline function" is shown. Furthermore, the number of items for each item is not limited to one; different weights can be preset for each item. Additionally, the search unit 15 can search for a predetermined number of usage conditions in descending order of the total number of items as a similarity score. However, to avoid concluding that no suitable usage condition exists when the total number of items is low for any usage condition, it is preferable that the search unit 15 searches for usage conditions with a total number of items higher than a threshold. Furthermore, usage conditions consistent with management conditions are more likely to be hit as the usage condition with the highest similarity score during the search performed by the search unit 15.

[0085] Next, the prompting unit 12 selects the sensor 40 detected in step S22 as a candidate and provides auxiliary information to the list of candidates (step S23). Specifically, as follows... Figure 16As illustrated, the prompting unit 12 provides a summary of the target data acquisition means, sensor / sensor group, and effects and disadvantages / risks corresponding to the usage conditions. Here, the user can select the sensor / sensor group based on the effects and disadvantages / risks. The prompting unit 12 is an example of a prompting unit in the production line management auxiliary device 100 that pre-associates one or more sensors with usage conditions that indicate a similarity exceeding a threshold between the pre-registered usage conditions and the management conditions as candidates for sensors used in production line management, and provides auxiliary information showing a list of candidates.

[0086] Next, the receiving unit 11 receives the selection made by the user from the list (step S24). Specifically, this is done when the user presses, clicks, or taps... Figure 16 When any of the selection buttons B1, B2, and B3 shown are used to select candidates, the receiving unit 11 receives the selection of the candidate corresponding to the pressed button. Thus, based on the input management conditions, a setting is made using the sensor 40 of the selected candidate.

[0087] Next, the pipeline management auxiliary device 100 begins sensor data processing (step S25) and ends the selection process. Alternatively, the management conditions entered in the selection process and the selected candidates can be registered in the storage unit 14 as new usage conditions and the corresponding sensor 40. When a combination of management conditions and candidates is registered as a new combination of usage conditions and sensor 40, adding information indicating that it has been selected by the user facilitates the assignment of metadata in the sensor data processing described later.

[0088] Sensor data processing involves processing the data actually output from sensor 40 before sending it to the higher-level device 200. Sensor data processing begins by launching a specific application.

[0089] In sensor data processing, such as Figure 17 As shown, the acquisition unit 16 acquires data representing the sensing result from the sensor 40 selected in the selection process (step S31). For example, in Figure 16 When button B3 is pressed, the acquisition unit 16 receives data from each of the sensors 40 constituting the sensor group z. For example... Figure 12As shown, sensor group z includes "distance sensor 1", "distance sensor 2" and "illuminance sensor", so acquisition unit 16 acquires data from these sensors 40. Acquisition unit 16 is equivalent to an example of an acquisition unit in the production line management auxiliary device 100, which acquires data output from one or more sensors, which are candidates selected from a list.

[0090] Next, based on the data obtained in step S31, the output unit 17 outputs output information including condition information related to at least one of the usage conditions and management conditions of the selected sensor 40 (step S32). Specifically, as Figure 18 As shown, the output unit 17 obtains the sensor output value D1 output from the sensor 40 from the acquisition unit 16, and outputs the output information D30 to the upper-level device 200. The output information D30 is information that adds condition information D20 as metadata to the output value D10 which is equal to the sensor output value D1.

[0091] Condition information represents some or all of the multiple items that constitute each of the usage conditions and management conditions. For example, Figure 18 The condition information D20 shown includes information about the production line, process, equipment, and purpose contained in the management conditions, as well as information about the selected candidate, namely sensor 40. However, the condition information is not limited to this, and some of it may be omitted. That is, the condition information D20 may include at least one of the following: information related to the production line, information related to the process constituting the production line, information related to the selected candidate, namely one or more sensors, and information indicating the purpose of using the sensor. If the user registers the usage conditions through the registration process, the condition information representing the usage conditions or similar management conditions will be appended as metadata to the output value D10 simply by selecting sensor 20 in the selection process. Therefore, the workload of creating metadata by the user can be saved, which can help to improve the efficiency of production line management. In addition, the registration unit 13 is equivalent to an example of a registration unit for registering usage conditions.

[0092] Furthermore, when calculation logic is set for the sensor group, the output unit 17 appends condition information D20 to the output value D10, which represents the result of the calculation logic applied to the sensor output value D1. The output unit 17 is an example of an output unit in the pipeline management assist device 100 that outputs output information based on data acquired by the acquisition unit. This output information includes condition information related to at least one of the usage conditions and management conditions associated with the selected candidate, i.e., one or more sensors. If step S32 ends, the pipeline management assist device 100 repeats step S31 and subsequent processing.

[0093] As explained above, in the assembly line management auxiliary device 100 according to this embodiment, the registration unit 13 registers assembly line information 141, process information 142, destination information 143, sensor setup information 144, and corresponding sensor information 145 in the storage unit 14. Therefore, the assembly line management auxiliary device 100 organizes and manages the sensor information, which includes the configuration of each sensor 40 on multiple assembly lines and the correspondence between the purpose of data utilization and the sensors 40 required for that purpose. Thus, the know-how and knowledge used to obtain data consistent with the user's purpose through the sensors 40 can be accumulated in the storage unit 14 and updated as needed.

[0094] Furthermore, the prompting unit 12 provides auxiliary information by displaying a list of sensors 40 that are associated with conditions similar to the user's request and are used as candidates to meet that request. Additionally, the output unit 17 outputs information that assigns request-related information to the data output from the sensors 40 or the result of operations performed on that data. Thus, after registration processing is complete, the user can select any candidate from the list simply by inputting a request, and output information including metadata can be provided to the upper-level device 200. Therefore, this contributes to the efficiency of pipeline management using sensors.

[0095] Furthermore, to facilitate understanding, examples of sequentially performing registration, selection, and sensor data processing have been provided, but the process is not limited to these. For example, registration can be performed midway through the selection process, or it can be performed during repeated sensor data processing. Specifically, during the selection process, the user can confirm the auxiliary information displayed by inputting management conditions. If a sensor matching the management conditions is identified from the candidate list included in the auxiliary information, the information can be registered in a way that associates such a sensor with usage conditions equivalent to the input management conditions.

[0096] Implementation Method 2

[0097] Next, Embodiment 2 will be described focusing on its differences from Embodiment 1 described above. Furthermore, structures that are the same as or equivalent to those in Embodiment 1 will be referred to using the same reference numerals. The difference between Embodiment 2 and Embodiment 1 is that the registration process (including combinations of processes) involving a series of data acquisition steps such as purpose registration, sensor setup registration, and corresponding sensor registration is considered as the purpose of acquiring data (the intention to acquire data), and is defined as metadata used to identify the acquired data.

[0098] exist Figure 19 The registration process involved in this embodiment is shown in the diagram. This registration process is different from the one that omits... Figure 4 The processing after steps S11 and S12 in the registration process shown is equivalent. However, in the destination registration process, the destination is registered without being associated with a production line, process, or equipment. Figure 20 The example illustrates information registered in storage unit 14 through registration processing. For example... Figure 20 As shown, the purpose, the sensor category or group of sensor categories used to achieve that purpose is defined in association. The sensor setting information 144 registered in the registration process only shows the sensor category, and its details are added in the process described later. A sensor category group refers to a collection of sensors from multiple categories. Hereinafter, the sensor categories and sensor category groups registered in the registration process will be appropriately abbreviated as sensor categories.

[0099] exist Figure 21 The flowchart of the selection process involved in this embodiment is shown. In this selection process, the receiving unit 11 receives the management conditions specified by the user (step S21). Specifically, the prompting unit 12... Figure 22 The first setting screen, as shown, is displayed for users to configure sensor types that match their requirements. The first setting screen includes a problem setting list 61, a solution / effect list 62, and a sensor setting screen 63.

[0100] Task setting list 61 is a list of purposes for which users utilize data in pipeline management. Users select purposes that match their requirements from task setting list 61 as tasks.

[0101] Return to Figure 21 After step S21, step S22, the same as in Embodiment 1, is performed. However, in step S22, the retrieval unit 15 may also retrieve the sensor category corresponding to the usage conditions that are consistent with the purpose of the management conditions received in step S21. Here, usage conditions refer to, for example, Figure 20 The purpose registered is shown. Alternatively, the search unit 15 can also search for purposes specified using a string similar to the string indicating the purpose as a management condition.

[0102] Next, the prompting unit 12 provides auxiliary information on the list of candidates including sensor categories (step S23). Specifically, the prompting unit 12 provides... Figure 22 In the solution and effect list 62 shown, as information corresponding to the objective selected through the task setting list 61, a summary is displayed of the sensor categories retrieved in step S22 and the combination of effects when using those sensor categories. Here, the prompt unit 12 may also simultaneously display the sensor categories that constitute the sensor category group.

[0103] Next, the receiving unit 11 receives the user's selection (step S24). Specifically, the user considers the effects included in the solution and effect list 62 and selects any sensor category displayed as a candidate, and the receiving unit 11 receives the user's selection.

[0104] Next, the receiving unit 11 receives details of the sensor 40 (step S241). Specifically, it receives information from the prompting unit 12, such as... Figure 22 The sensor settings screen 63 shown in the first settings screen configures the details of sensor 40, which belongs to the sensor category selected by the user. Therefore, for... Figure 12 The sensor information 144 is registered as shown.

[0105] Next, the receiving unit 11 receives the user's configuration settings for the sensor 40 (step S242). This step S242 corresponds to the registration of the production line and process performed by the production line registration unit 131 and the process registration unit 132 in Embodiment 1. Specifically, the prompting unit 12... Figure 23 The second setup screen, as shown, displays the configured sensor 40 and the assembly line for configuring the sensor 40. On the second setup screen, the user can drag and drop objects corresponding to the sensors onto the image of the assembly line. Furthermore, when configuring a sensor group, objects of the sensor group can be configured by drag and drop while maintaining the relative positional relationship of the sensors 40 constituting the sensor group.

[0106] Additionally, if the configuration of the sensor 40 on the production line is complete on the second setting screen, the prompt unit 12 prompts the user to set the data acquisition area. The data acquisition area represents the range on the production line where the sensor 40 acquires data. For example, the user... Figure 24 The data acquisition area is set as shown in the box with a medium-thick dashed line.

[0107] like Figure 25 As shown, users can also set multiple data acquisition areas on the production line, or set data acquisition areas that overlap with other areas. The production line management auxiliary device 100 can manage the sensors 40 hierarchically by using overlapping areas. For example, by setting areas corresponding to processes within areas corresponding to the production line, the production line, the processes contained in the production line, and the sensors 40 corresponding to the processes can be managed hierarchically.

[0108] Furthermore, users can assign attributes, represented by names, to the designated areas. Attribute assignment and... Figure 5 , 6The settings for the production line name and process name are shown. The attributes assigned to a region are used as metadata to assign to the data obtained from sensor 40 in that region.

[0109] Return to Figure 21 After step S242, the production line management auxiliary device 100 performs the same step S25 as in Embodiment 1, and ends the selection process.

[0110] As explained above, the same effect as in Implementation 1 is achieved when a list of candidate sensor categories corresponding to the purpose received from the user is displayed. Specifically, the user selects the sensor category by inputting the purpose, and if the sensor details and configuration are set, information with metadata is provided to the upper-level device 200, thus enabling easy execution of pipeline management.

[0111] In addition, for the higher-level device to analyze the data output from sensor 40, it is necessary to define the attributes of the data. That is, it is necessary to assign metadata to the data output from the sensor. However, attaching metadata to the data each time is a tedious task. In contrast, the pipeline management auxiliary device 100 directly assigns the content of the steps taken when acquiring the data as metadata. Thus, metadata can be assigned to the data without the user being aware of the metadata appending operation.

[0112] That is, regarding the ability to assign metadata to data without the user being aware of the append operation, we will explain further below.

[0113] Figure 22 The first setting screen is shown. This first setting screen is used to set up a sensor group corresponding to the purpose of start-to-complete management, for example, when managing the start and completion of an operator's work on a production line (start-to-complete management). The first setting screen is used to set up the first data group described later. In addition, the first setting screen corresponds to the purpose registration unit 133 and the sensor setting registration unit 134 in Embodiment 1, as well as the corresponding purpose information 143 and sensor setting information 144.

[0114] The first data group refers to data acquired in relation to one or more sensors that correspond to the purpose of data acquisition (the purpose of solving the problem). The settings in the purpose registration unit 133 and the sensor registration unit 134 in Embodiment 1 are equivalent to the settings of the first data group. In addition, the settings in the first setting screen in Embodiment 2 are equivalent to the settings of the first data group.

[0115] The first setting screen consists of a problem setting list 61, a solution and effect list 62, and a sensor setting screen 63. Furthermore, information from these lists and setting screens can be pre-registered, for example, using the method shown in Embodiment 1.

[0116] In the task setting list 61, a list of items registered by the user as tasks (objectives) in the start / end management is displayed, such as batch start / end, job start / completion, and operation / non-operation. Next, in the solution and effect list 62, for each item of the task selected through the task setting list 61, the sensors that become solutions, examples of sensor structures, and the effects (advantages / disadvantages) brought about by these solutions are displayed. The sensor structure, for example, refers to a structure composed of multiple sets of notification sensors. As an effect, it is recorded that the combination of notification sensors can suppress detection omissions and remove noise.

[0117] The user selects the desired problem (objective) in the problem setting list 61, and confirms the sensor structure and effects in the solution and effect list 62 displayed corresponding to the selection. This allows the user to select the desired sensor / sensor group to achieve the problem (objective). Furthermore, the setting of the first data group is completed during this selection stage.

[0118] Sensor setting screen 63 is a screen for setting up at least one of the sensors and sensor groups, such as the one in embodiment 1. Figure 9 , 10 The sensor setting screen 63 corresponds to the sensor registration unit 134 and sensor information setting 144 in Embodiment 1. Furthermore, in the sensor setting screen 63, data acquisition settings for the sensors and sensor groups are performed to obtain the accuracy of the target data (production data). When performing these data acquisition settings, for example, the distance between sensors, detection sensitivity, or data acquisition interval are set. Additionally, calculation logic is created to exclude duplicate production data acquired from multiple sensors based on this setting information. In Embodiment 1, as described above, if the distance between sensors and the product (workpiece) movement time are known, calculation logic can be created to extrapolate duplicate data between production data.

[0119] Next, after the user completes the setting of the sensor / sensor group through operation, the production line management auxiliary device 100, as follows: Figure 23 As shown, a second setup screen is displayed, revealing the configured sensors / sensor groups and the production line for configuring the sensors / sensor groups. In this second setup screen, users configure sensors / sensor groups in the production line diagram, for example, by dragging and dropping. Furthermore, when configuring sensor groups, the relevant positions of the sensor groups can be maintained during dragging and dropping.

[0120] Next, after the sensors / sensor groups are configured to the production line, the assembly line management auxiliary device 100, such as... Figure 24 As shown, the system prompts the user to set the data acquisition area for the sensor / sensor group, indicating which area of ​​the production line it covers. The assembly line management auxiliary device 100, if... Figure 24 By setting the data acquisition area as shown by the dashed box, the area for acquiring production data (the configuration area for sensors / sensor groups) will be set as the second data group. For example... Figure 25 As shown, the production line management auxiliary device 100 can set the acquisition area (sensor / sensor group configuration area) of production data to other areas of the production line, and can also set acquisition areas (configuration areas) overlappingly for the already set acquisition areas (configuration areas). By setting acquisition areas (configuration areas) overlappingly, the production line management auxiliary device 100 can manage production data (destination data) in a hierarchical manner. The second data group mentioned above is a data group managed by acquisition areas (configuration areas) as described above.

[0121] like Figure 24 , 25 As shown, the production line management auxiliary device 100 can attach a name to the production data (destination data) determined by the acquisition area (configuration area) through user operation. That is, the production line management auxiliary device 100 attaches metadata to the production data (destination data).

[0122] Furthermore, as described above, the management of the second data group, which sets the acquisition area (configuration area) for production data (target data), and the management of the additional names attached to the acquisition area (configuration area) in the assembly line management auxiliary device 100, are specifically performed by attaching area information and name information used in the second data group to each production data in the first data group managed by the storage unit 14, represented by the database. In addition, the second setting screen in the assembly line management auxiliary device 100 corresponds to the assembly line registration unit 131 and the process registration unit 132, as well as the corresponding assembly line information 141 and process information 142, in Embodiment 1. Furthermore, the area setting of the upper level of the process registration unit 132 corresponds to that of the assembly line registration unit 131.

[0123] exist Figure 26 The relationship between the first and second data groups is shown in the diagram. Within this data group, the necessary information is systematically stored for data analysis by the higher-level system. The structure of this data group is configured by the user according to the first and second setting screens.

[0124] That is, the production line management auxiliary device 100 obtains production data (target data) from the production line based on the setting information set in the first setting screen and the second setting screen, and processes the obtained production data based on the above setting information (deleting duplicate data or adding metadata, etc.), thereby obtaining so-called meaningful data that is easy to analyze.

[0125] Furthermore, it is conceivable to apply the assembly line management auxiliary device 100 of the present invention to various businesses, but as one application example, it is conceivable to introduce an auxiliary system for managing the start time and completion time of each manufacturing process by automatically obtaining the start time and completion time of each manufacturing process using sensors or the like.

[0126] Furthermore, performance data regarding the start and finish times of each manufacturing process is crucial for operations management, cost management, and manufacturing site improvement. Previously, this performance data was typically obtained manually using methods such as stopwatch measurements, but this method is time-consuming. Therefore, many manufacturing companies intend to introduce systems that automatically and continuously acquire this performance data using sensors for daily management. However, the aforementioned difficulties exist in introducing such a system to automatically acquire this performance data. Therefore, the assembly line management auxiliary device 100 of this invention is considered for effective application in order to assist in system implementation.

[0127] The embodiments of the present invention have been described above, but the present invention is not limited to the above embodiments.

[0128] For example, the production line management auxiliary device 100 may also output the output information to a built-in storage device or recording medium for subsequent verification without outputting the output information to the upper-level device 200.

[0129] In addition, the assembly line management auxiliary device 100 searches for usage conditions that are similar to the management conditions to some extent, but it can also exclude usage conditions that are different from the management conditions and search for usage conditions that are consistent with the management conditions.

[0130] Furthermore, the example of the production line management auxiliary device 100 being a PLC has been used as the focus of the explanation, but it is not limited to this. The production line management auxiliary device 100 may also be other FA devices, or it may be a dedicated device for managing the sensor group 400.

[0131] In addition, a method for calculating similarity based on the number of items in the usage conditions that are consistent with the management conditions is explained, but the calculation of similarity is not limited to this and can be performed by any method.

[0132] Furthermore, the functions of the assembly line management auxiliary device 100 can be implemented either through dedicated hardware or through a conventional computer system.

[0133] For example, by storing the program P1 executed by the processor 101 in a computer-readable, non-transitory recording medium and distributing it, and then installing the program P1 into a computer, an apparatus for performing the above-described processing can be constructed. Examples of such recording media include floppy disks, CD-ROMs (Compact Disc Read-Only Memory), DVDs (Digital Versatile Discs), and MOs (Magneto-Optical Discs).

[0134] Alternatively, the program P1 can be pre-stored on a disk device of a server device on a communication network such as the Internet, and then downloaded to a computer by superimposing it onto a carrier wave.

[0135] Alternatively, the above processing can also be achieved by transmitting program P1 via a communication network while starting execution.

[0136] Furthermore, by executing all or part of program P1 on a server device, the computer can also send and receive information related to the processing and execute the program via a communication network, thereby achieving the aforementioned processing.

[0137] Furthermore, when the above functions are implemented by the OS (Operating System) or through the coordinated action of the OS and applications, only the parts outside the OS can be stored on the medium for distribution, or they can be downloaded to a computer.

[0138] Furthermore, the means of realizing the functions of the diagnostic device 10 are not limited to software; some or all of them can also be realized through dedicated hardware containing circuitry.

[0139] This invention can be implemented and modified in various ways without departing from the broad spirit and scope of the invention. Furthermore, the above-described embodiments are for illustrative purposes only and are not intended to limit the scope of the invention. That is, the scope of the invention is defined not by the embodiments, but by the claims. Moreover, various modifications implemented within the scope of the claims and their equivalents are considered to fall within the scope of the invention.

[0140] Industrial applicability

[0141] This invention is suitable for managing production lines that use sensors.

[0142] Explanation of the label

[0143] 1000 Management System, 100 Production Line Management Auxiliary Device, 101 Processor, 102 Main Storage Unit, 103 Auxiliary Storage Unit, 104 Input Unit, 105 Output Unit, 106 Communication Unit, 107 Internal Bus, 11 Receiving Unit, 12 Prompt Unit, 13 Registration Unit, 131 Production Line Registration Unit, 132 Process Registration Unit, 133 Destination Registration Unit, 134 Sensor Registration Unit, 135 Corresponding Sensor Registration Unit, 14 Storage Unit, 141 Production Line Information, 142 Process Information, 143 Destination Information, 144 Setting... 145 Sensor Information, 15 Retrieval Unit, 16 Acquisition Unit, 17 Output Unit, 200 Upper-Level Device, 30 Network, 40, 401, 402, 403, 40n Sensors, 400 Sensor Group, 50-52 Devices, 61 Problem Setting List, 62 Solution and Effect List, 63 Sensor Setting Screen, B1-B3 Selection Buttons, D1 Sensor Output Value, D10 Output Value, D20 Condition Information, D30 Output Information, L1 First Pipeline, L2 Second Pipeline, P1 Program.

Claims

1. A production line management auxiliary device, which is connected to an upstream device and two or more sensors installed on the production line. in, This assembly line management auxiliary device has the following features: The registration unit registers the installed sensor and the conditions under which the sensor is used in association; A receiving unit that receives management conditions specified as conditions for managing the production line; The prompting unit prompts one or more of the sensors associated with the registered usage conditions whose similarity to the management conditions exceeds a threshold as candidates for the sensors used in the management of the production line, and provides auxiliary information showing the list of candidates. An acquisition unit acquires data output by one or more of the sensors selected as candidates from the list; as well as The output unit outputs condition information, which assigns condition information to the data or the result of a pre-defined operation on the data, as metadata output information to the upper-level device. This condition information represents the usage conditions associated with one or more of the selected candidates sensors.

2. The assembly line management auxiliary device according to claim 1, wherein, The output unit outputs the output information that assigns the condition information to the result of a pre-defined operation performed on the data.

3. The assembly line management auxiliary device according to claim 1, wherein, The condition information includes at least one of the following: information related to the production line, information related to the process constituting the production line, information related to one or more of the selected candidates sensors, and information indicating the purpose of using the sensors.

4. The assembly line management auxiliary device according to claim 2, wherein, The condition information includes at least one of the following: information related to the production line, information related to the process constituting the production line, information related to one or more of the selected candidates sensors, and information indicating the purpose of using the sensors.

5. The assembly line management auxiliary device according to any one of claims 1 to 4, wherein, The management conditions include the intended use of the sensor.

6. A method for assisting production line management, executed by a production line management assisting device, the production line management assisting device being connected to a higher-level device and two or more sensors installed on the production line. This assembly line management aid includes: The registration unit registers the installed sensor and its usage conditions in association. The receiving unit receives the management conditions specified as conditions for managing the production line. The prompting unit identifies one or more sensors associated with the registered usage conditions whose similarity to the management conditions exceeds a threshold as candidates for the sensors used in the management of the production line, and provides auxiliary information displaying the list of candidates. The acquisition unit acquires data output by one or more of the sensors selected as candidates from the list. The output unit outputs condition information as metadata to the upper-level device, which is assigned to the data or the result of a pre-defined operation on the data. This condition information represents the usage conditions associated with one or more of the selected candidates sensors.

7. A recording medium containing a program that causes a production line management auxiliary device connected to a higher-level device and two or more sensors installed on the production line to function as a unit: The registration unit registers the installed sensor and the conditions under which the sensor is used in association; A receiving unit that receives management conditions specified as conditions for managing the production line; The prompting unit prompts one or more of the sensors associated with the registered usage conditions whose similarity to the management conditions exceeds a threshold as candidates for the sensors used in the management of the production line, and provides auxiliary information showing the list of candidates. An acquisition unit acquires data output by one or more of the sensors selected as candidates from the list; as well as The output unit outputs condition information, which assigns condition information to the data or the result of a pre-defined operation on the data, as metadata output information to the upper-level device. This condition information represents the usage conditions associated with one or more of the selected candidates sensors.

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