Detection system and method for automated recording of defects in semi-finished products

Abstract

The invention relates to a detection system (1) for automatically recording defects of a semi-finished product (3), comprising: at least one measuring device (4, 5, 6), which is designed to detect at least one measured value of the semi-finished product (3) processed in a production plant (2); and a data processing device (7) having a first interface (10) connected to the at least one measuring device and receiving the at least one measured value. The data processing device (7) comprises: a database (13) in which database entries (14, 15) for recording defects of the semi-finished product (3) can be stored; a comparison device (11) which is designed to compare the at least one measurement value with a predetermined range limit (13a) and to store the at least one measurement value outside the range limit (13a) in a database entry (14); and a loss detection device (12) which is designed to detect data relating to the degree of loss caused by the defect when the at least one measurement value is outside the range limit (13a) and to store the data in a database entry (14).

Description

Technical Field

[0001] The invention relates to a detection system for automatically recording defects of semi-finished products. In addition, the invention relates to a method for automatically recording defects of semi-finished products. Background Art

[0002] German patent application DE 199 21 748 A1 describes a system and a method for controlling an automated and unmanned logistics, rental and sales system, which provides the possibility of making claims against suppliers. Summary of the invention

[0003] The object of the present invention is to provide a testing system and a method which simplify the documentation of defects in semi-finished products.

[0004] The solution to the proposed task is achieved by a detection system for automatically recording defects of semi-finished products. The detection system comprises at least one measuring device, which is arranged on or in a production facility and is designed to detect at least one measured value of a semi-finished product processed in the production facility, which is characterized by the semi-finished product properties. In addition, the detection system comprises a server- or cloud-based data processing device, which has a first interface, via which the data processing device is connected to the at least one measuring device and receives the at least one measured value from the at least one measuring device. The data processing device comprises: a database, in which database entries for recording defects of the semi-finished product can be stored; a comparison device, which is designed to compare the at least one measured value with a predetermined range limit of an acceptable range, and in the case of the at least one measured value being outside the range limit, the at least one measured value is stored in the database entry created for recording the defect; and a loss detection device, which is designed to detect data about the extent of the loss caused by the defect in the case of the at least one measured value being outside the range limit and store it in the database entry created for recording the defect.

[0005] The detection system according to the invention enables the automatic recording of defects in semi-finished products. When it is concluded from the comparison of the measured values ​​of the semi-finished product with the predetermined range limits that the characteristics of the semi-finished product are outside the range limits, a new database entry is automatically created in which information about the defects of the semi-finished product is summarized. The measured values ​​of the defective semi-finished product are detected in the database entry together with information about the extent of the damage caused by the defect. The information summarized in the database can serve as a basis for constructing a claim against the supplier. The advantage of such a detection system is that the data required for the claim can be saved with little additional effort, thereby facilitating and inexpensive construction of the claim. Another advantage is that, by accurately detecting the extent of the damage, it is possible to prioritize the individual damage situations according to their economic relevance.

[0006] The invention also relates to a method for automatically recording semi-finished product defects in a production device by means of a server- or cloud-based data processing device, the data processing device comprising a database in which database entries for recording semi-finished product defects can be stored, wherein the data processing device is connected to at least one measuring device installed on or in the production device via a first interface. The method comprises the following steps: detecting at least one measurement value characterizing a property of the semi-finished product by means of the at least one measuring device; transmitting the at least one measurement value from the at least one measuring device to the data processing device; and comparing the at least one measurement value with a predetermined range limit of an acceptable range. In addition, the method comprises: storing the at least one measurement value in a database entry created for recording the defect in the case where the at least one measurement value is outside the range limit, and detecting data about the extent of the loss caused by the defect and storing the data in the database entry created for recording the defect.

[0007] Advantageous embodiments and further developments which can be used individually or in combination with one another form the subject matter of the dependent claims and the following description.

[0008] According to an advantageous embodiment, the loss detection device is designed to detect, if the at least one measured value is outside a range limit, which section of the semi-finished product processed in the production plant is defective and to store this information in a database entry created for recording the defect.

[0009] Furthermore, it is advantageous if the loss detection device is designed to detect, for the at least one measured value outside a range limit, how large the defective section of the semi-finished product processed in the production plant is and to store this information in a database entry created for recording the defect.

[0010] Preferably, the detection system includes a position detection device, which is arranged on or in the production equipment and is designed to detect the position of a semi-finished product processed in the production equipment, wherein the data processing device is designed to retrieve the position of the semi-finished product from the position detection device once or repeatedly when at least one measured value is outside the range limit and store it in a database entry created for recording defects.

[0011] Preferably, the loss detection device is designed to detect, for the case where the at least one measured value is outside the range limits, which processing steps have been carried out with the defective semi-finished product and to store this information in a database entry created for recording the defect.

[0012] Advantageously, the damage detection device is designed to determine the damage sum based on the data about the extent of the damage caused by the defect and to store this damage sum in a database entry created for recording the defect.

[0013] Preferably, the database entry stored in the database contains the at least one measured value detected by the at least one measuring device, the data about the extent of the damage caused by the defect and the damage sum.

[0014] Preferably, the data processing device is designed to prioritize the database entries stored in the database according to the level of the loss sum.

[0015] According to a preferred embodiment, the data processing device is designed to automatically request a laboratory test of the defective semi-finished product in the event that the at least one measured value is outside a range limit.

[0016] Preferably, the data processing device has a second interface and is connected to the quality management system via the second interface, and is designed to transmit at least one defect record stored in the database to the quality management system via the second interface.

[0017] Advantageously, the data processing device and the quality management system are designed for automatically creating a claim based on the defect records stored in the database.

[0018] Preferably, the comparison device is designed to detect a trend in the measured value detected by the at least one measuring device and to issue a warning already before a range limit is exceeded or undershot.

[0019] Preferably, the data processing device is designed to derive the range limits of the acceptable range of the measured values ​​detected by the measuring device from the predetermined specification limits of the semi-finished product specification taking into account the measuring accuracy of the respective measuring device.

[0020] Preferably, the data processing device is designed to derive the range limit values ​​of the acceptable range of the measurement values ​​detected by the measuring device by adding a tolerance band reflecting the measurement accuracy of the corresponding measuring device to the predetermined specification limit values ​​of the semi-finished product specification.

[0021] Further preferably, the data processing device is designed to determine a scatter band of a set of measured values ​​detected successively by the measuring device and to determine the tolerance band based on this scatter band by means of statistical methods.

[0022] Further preferably, the data processing device is designed to determine the interquartile range of a group of measurement values ​​detected successively by the measuring device and convert the interquartile range into a tolerance band reflecting the measurement accuracy of the corresponding measuring device by means of a statistical method.

[0023] According to a preferred embodiment, the semi-finished product is a metal sheet and the production plant is a production plant for manufacturing vehicles. The production plant is preferably one of the following: a sheet cutting plant, a forming device, an extrusion line.

[0024] Preferably, the at least one measuring device arranged in or on the production equipment for manufacturing the vehicle is designed to detect at least one measurement value of the semi-finished product, which measurement value characterizes at least one of the following properties of the metal sheet: the thickness of the metal sheet, the tribological properties of the metal sheet, such as the amount of lubricant and / or roughness, the elastic-plastic properties of the metal sheet, the number of welds on the metal sheet, and the chemical properties of the metal sheet.

[0025] Advantageously, the at least one measuring device arranged in or on the production equipment for manufacturing the vehicle is at least one of the following devices: a measuring device for optically detecting the thickness of a metal sheet, a measuring device for optically detecting a weld, a measuring device for inductively detecting a weld, a measuring device for optically detecting the amount of lubricant on a metal sheet, an eddy current sensor for detecting the elastic-plastic properties of a metal sheet. BRIEF DESCRIPTION OF THE DRAWINGS

[0026] Further advantageous embodiments will be described in more detail below with reference to an exemplary embodiment shown in the drawing, without however restricting the invention to this exemplary embodiment.

[0027] In the figure:

[0028] Figure 1 An inspection system for automatically recording defects in semi-finished products is shown.

[0029] Figure 2 The structure of a database entry in a database of a detection system is shown.

[0030] Figure 3 The sequence of the method according to the invention for the automated documentation of defects in semi-finished products is shown. DETAILED DESCRIPTION

[0031] In the following description of preferred embodiments of the present invention, the same reference numerals denote the same or comparable components.

[0032] exist Figure 1 1 shows an inspection system 1 for detecting defects in semi-finished products. Semi-finished products such as metal sheets are usually obtained from different suppliers and processed in production. In order to be able to achieve correct further processing, the properties of these semi-finished products must meet predetermined specifications. If the properties of the semi-finished product exceed the pre-defined specifications, the defective semi-finished product cannot be processed further. In this case, claims are made against the supplier of the semi-finished product, who must then compensate for the resulting losses. The losses caused by the defective semi-finished product also include the entire expenditure incurred when processing the defective semi-finished product. The recording and claiming of such losses is simplified by the inspection system 1 described below.

[0033] exist Figure 1 2 shows a production device 2 designed to process a semi-finished product 3. For example, the production device 2 can be a production device for manufacturing vehicles, such as a slab cutting device, a forming device or an extrusion production line.

[0034] A measuring device for detecting the properties of the semi-finished product 3 is arranged on or in the production device 2. Figure 1 In the example shown, a first measuring device 4, a second measuring device 5 and a third measuring device 6 are arranged on or in the production device 2, which determine different properties of the processed semi-finished product 3. The measured values ​​detected by the measuring devices 4, 5, 6 are transmitted to a data processing device 7 installed on a server 8. For this purpose, the first measuring device 4, the second measuring device 5 and the third measuring device 6 are connected via a first data connection 9 to a first interface 10 of the data processing device 7.

[0035] The data processing device 7 comprises a comparison device 11, a loss detection device 12 and a database 13 for recording defects. In the comparison device 11, the measured values ​​detected by the measuring devices 4, 5, 6 are compared with predetermined range limits 13a of the acceptable range. For example, these range limits 13a of the measured values ​​detected by the measuring devices can be derived from the specification limits of the semi-finished product specifications taking into account the measurement accuracy of the corresponding measuring devices. For example, the range limits 13a can be determined by adding a tolerance band representing the measurement accuracy of the corresponding measuring device to the specification limits of the semi-finished product specifications. For example, the tolerance band can be determined by means of statistical methods. For example, a scatter band of the measured values ​​of a sequence detected successively by a measuring device can be determined. Starting from this scatter band, a tolerance band reflecting the measurement accuracy of the measuring device can then be determined by means of statistical methods. For example, the specifications of different semi-finished products can be stored in a specification database.

[0036] If the comparison performed by the comparison device 11 shows that all measured values ​​are within the range limit 13a, the semi-finished product 3 meets the specifications and there is no motivation for a claim. If at least one of the detected measured values ​​is outside the predetermined range limit 13a, the semi-finished product 3 does not meet the specifications. In this case, the semi-finished product 3 has a defect for which a claim can be made. In the case of the detection of such a violation of the specifications, it can be provided that the data processing device 7 outputs an alarm. In addition, it can be provided, for example, that the data processing device 7 automatically sends an e-mail message to the responsible employee.

[0037] To record the defect, the comparison device 11 generates a new database entry 14 in the database 13, in which an old database entry 15 for the previously occurring defect is already stored. In the new database entry 14, the comparison device 11 first stores an identifier of the process. For example, the identifier may include one or more of the following: a serial number of a workpiece, a part number of a workpiece, a part number of a semi-finished product, an identifier of a production device.

[0038] Furthermore, the semi-finished product measurement values ​​detected by the measuring devices 4 , 5 , 6 , which measurement values ​​partially do not meet the required specifications, are stored in a new database entry 14 in order to record the defect.

[0039] In addition to the detected measured values, the extent of the loss due to the defect of the semi-finished product 3 is also recorded. In order to determine the extent of the loss, the loss detection device 12 determines which section of the semi-finished product 3 is defective and how large the defective section is. For example, if the semi-finished product 3 is a metal sheet, it is detected how many meters of the metal sheet unwound from the coil are defective. For this purpose, a position detection device 15a can be provided on the side of the production device 2, which is connected to the first interface 10 of the data processing device 7 via a second data connection 15b and is designed to transmit the corresponding strip position of the semi-finished product to the data processing device 7. Starting from the strip position and ending with the violation of the specification, it can then be determined, for example: how large the defective section of the semi-finished product is. For example, it can be determined: how many meters of the metal sheet unwound from the coil does not meet the specification.

[0040] It can also be provided that the time at which the violation of the specification began and ended and the time at which normal operation was restored are determined. For example, machine downtimes can be derived from these time stamps, which are also a component of quantifiable losses.

[0041] Furthermore, it can be provided that the loss detection device 12 determines which processing steps have been carried out for the defective semi-finished product 3 and which excess costs these processing steps have caused. The costs caused by the defective semi-finished product 3 are compensable and can be billed to the supplier.

[0042] Furthermore, it can be provided that the processing results achieved with defective semi-finished products are recorded. For example, if cracks and creases occur when forming semi-finished products that do not meet specifications, this information can be used to record the extent of the loss.

[0043] The detected data about the extent of the damage caused by the defect are stored in the new database entry 14. It can also be provided that when such a defect occurs, the comparison unit 11 automatically orders a laboratory test of the defective semi-finished product 3.

[0044] The loss detection device 12 may also include a loss assessment unit 16 which determines a loss sum based on the detected data about the extent of the loss caused by the defect. This loss sum is also stored in the new database entry 14. The data processing device 7 may then sort and prioritize the losses thus recorded based on the loss sum.

[0045] The data processing device 7 can also be connected to a quality management system 19 via the second interface 17 and the third data connection 18. The quality management system 19 can access the data processing device 7 via the second interface 17 and read the database entries 14, 15 from the database 13. Depending on the defect records stored in the database entries, the quality management system 19 can create claims against the supplier based on these data completely or partially automatically.

[0046] exist Figure 1 In the solution shown, the data processing device 7 and the database 13 are implemented on a server 8. However, as an alternative thereto, it can also be provided that the data processing device and the database are stored off-site in the cloud.

[0047] exist Figure 2 1 shows the structure of a database entry 14 of a database 13. In a first area 20 of the database entry 14, an identifier of a process is stored. For example, the identifier may include one or more of the following: a serial number of a workpiece, a part number of a workpiece, a part number of a semi-finished product 3, an identifier of a production plant. In a second area 21 of the database entry, measured values ​​of properties of the semi-finished product 3 detected by the measuring devices 4, 5, 6 are stored, which measured values ​​are at least partially outside the predetermined range limits. In a third area 22 of the database entry, information about the extent of the damage is stored, for example, information about which section of the semi-finished product 3 is defective, how large this section is, how long the machine has been down, and which processing steps have been carried out with the defective semi-finished product 3. Finally, in a fourth area 23 of the database entry 14, the sum of the damages determined by the damage assessment unit 16 is stored. This information stored in the database entry 14 enables the quality management system 19 to create claims against the supplier in a fully or partially automated manner.

[0048] exist Figure 1In the example shown, the properties of the processed metal sheet detected by the measuring devices 4, 5, 6 can be, for example, at least one of the following: the thickness of the metal sheet, the tribological properties of the metal sheet (for example, the amount of lubricant located on the metal sheet or the roughness of the metal sheet), the elastic-plastic properties of the metal sheet, the number of welds on the metal sheet, the chemical properties of the metal sheet. In order to detect one or more of these properties, a suitable measuring device can be provided, preferably a non-contact measuring device. For example, the thickness of the metal sheet can be determined by means of two laser beams aimed at the upper and lower sides of the metal sheet. The oil layer attached to the surface of the metal sheet can also be measured using optical measurement methods. Eddy current sensors can be used to detect the elastic-plastic properties of the metal sheet. Welds that must be marked by the supplier with individual markings can be detected and counted by detecting these markings, for example, by means of gratings. Alternatively or additionally, the welds can be detected by means of inductive measurement methods.

[0049] Figure 3 The sequence of the method according to the invention for automatically recording defects of a semi-finished product 3 is schematically shown. In a first step 24, the measured values ​​are detected by the measuring devices 4, 5, 6 installed on or in the production plant and transmitted to the data processing device 7. In a second step 25, these measured values ​​are compared with the predetermined range limit 13a. In a third step 26, it is queried whether the measured value is within the range limit 13a. If the case is "yes", there is no reason to claim and the method jumps back to the first step 24.

[0050] However, if at least one measured value is outside the range limit 13a, a new database entry 14 is created in a fourth step 27 to record the defect. In addition, it can be provided that a laboratory test is automatically requested. In a fifth step 28, an identifier of the process is stored in the new database entry 14. In addition, the detected measured values ​​are also stored in the new database entry 14.

[0051] The sixth, seventh and eighth steps 29, 30, 31 serve to record the extent of the losses caused by the defect. In the sixth step 29 it is determined how large the defective section of the semi-finished product 3 is. In the seventh step 30 further data about the extent of the losses caused by the defective semi-finished product are detected. For example, this can be data about machine downtimes, data about processing steps performed with the defective semi-finished product 3 and / or data about processing results obtained with the defective semi-finished product 3. In the eighth step 31 the losses are evaluated and the sum of the losses is determined.

[0052] In a ninth step 32, the database entries 14, 15 stored in the database 13 are sorted or prioritized according to the total loss. In a tenth step 33, the data contained in the database entries 14, 15 are transmitted to the quality management system 19, which automatically generates one or more claims therefrom.

[0053] The features disclosed in the above description, the claims and the drawings can be essential for realizing the invention in its various embodiments both individually and in any combination.

[0054] Reference numerals list

[0055] 1. Detection system

[0056] 2Production Equipment

[0057] 3 Semi-finished products

[0058] 4. First measuring device

[0059] 5 Second measuring device

[0060] 6Third measuring device

[0061] 7 Data processing device

[0062] 8 Servers

[0063] 9First Data Connection

[0064] 10 First Interface

[0065] 11 Comparison device

[0066] 12 Loss Detection Device

[0067] 13 Database

[0068] 13a Range Limits

[0069] 14 New database entries

[0070] 15 Old database entries

[0071] 15a Position detection device

[0072] 15b Second data connection

[0073] 16 Damage Assessment Unit

[0074] 17 Second interface

[0075] 18 Third data connection

[0076] 19 Quality Management System

[0077] 20 First field of database entry

[0078] 21 Second area of ​​database entry

[0079] 22 Third area of ​​database entry

[0080] 23 Fourth area of ​​database entry

[0081] 24 First Step

[0082] 25 Step 2

[0083] 26 Step 3

[0084] 27 Step 4

[0085] 28 Step 5

[0086] 29 Step 6

[0087] 30 Step 7

[0088] 31 Step 8

[0089] 32 Step 9

[0090] 33 Step 10

Claims

1. A detection system (1) for automatically recording defects of a semi-finished product (3), the detection system comprising: at least one measuring device (4, 5, 6) which is arranged on or in the production plant (2) and is designed to detect at least one measured value of a semi-finished product (3) processed in the production plant (2), the at least one measured value being characteristic of a property of the semi-finished product (3); A server- or cloud-based data processing device (7) having a first interface (10), via which the data processing device is connected to the at least one measuring device (4, 5, 6) and receives the at least one measured value from the at least one measuring device (4, 5, 6), wherein: The data processing device (7) comprises: a database (13) in which database entries (14, 15) for recording defects of the semi-finished product (3) can be stored; Comparison means (11) designed to compare the at least one measured value with predetermined range limits (13a) of an acceptable range and, in the event that the at least one measured value is outside the range limits (13a), to store the at least one measured value in a database entry (14) created for recording a defect; and A loss detection device (12) is designed to detect data about the extent of the loss caused by the defect for the case where the at least one measured value is outside the range limit (13a) and to store the data in a database entry (14) created for recording the defect.

2. The detection system (1) according to claim 1, characterized in that: The loss detection device (12) is designed to detect which section of the semi-finished product (3) processed in the production device (2) is defective when at least one measured value is outside the range limit (13a) and to store this information in a database entry (14) created for recording the defect.

3. The detection system (1) according to claim 1 or claim 2, characterized in that: The loss detection device (12) is designed to detect the size of a defective section of a semi-finished product (3) processed in a production plant (2) in the event that at least one measured value is outside a range limit (13a) and to store this information in a database entry (14) created for recording the defect.

4. The detection system (1) according to one of the preceding claims, characterized in that The loss detection device (12) is designed to detect, in the event that the at least one measured value is outside a range limit (13a), which processing steps have been carried out with the defective semi-finished product (3) and to store this information in a database entry (14) created for recording the defect.

5. The detection system (1) according to one of the preceding claims, characterized in that The damage detection device (12) is designed to determine the damage sum based on the data about the extent of the damage caused by the defect and to store the damage sum in a database entry (14) created for recording the defect.

6. Detection system (1) according to one of the preceding claims, characterized in that The database entry (14) stored in the database (13) contains the at least one measured value detected by the at least one measuring device (4, 5, 6), the data on the extent of the damage caused by the defect and the damage sum.

7. The detection system (1) according to claim 5 or claim 6, characterized in that: The data processing device (7) is designed to prioritize the database entries (14, 15) stored in the database according to the magnitude of the loss sum.

8. The detection system (1) according to one of the preceding claims, characterized in that The data processing device (7) has a second interface (17) and is connected to a quality management system (19) via the second interface (17), and is designed to transmit at least one defect record stored in the database (13) to the quality management system (19) via the second interface (17).

9. The detection system (1) according to one of the preceding claims, characterized in that The data processing device (7) is designed to derive the range limit values ​​(13a) of the acceptable range of the measurement values ​​detected by the measuring devices (4, 5, 6) by adding a tolerance band reflecting the measurement accuracy of the corresponding measuring devices (4, 5, 6) to the predetermined specification limit values ​​of the semi-finished product (3) specifications.

10. The detection system (1) according to claim 9, characterized in that The data processing device (7) is designed to determine a scatter band of a set of measured values ​​detected successively by the measuring devices (4, 5, 6) and to determine a tolerance band based on the scatter band by means of a statistical method.

11. A method for automatically recording defects of semi-finished products (3) in a production plant (2) by means of a server- or cloud-based data processing device (7), the data processing device comprising a database (13) in which database entries (14, 15) for recording defects of semi-finished products (3) can be stored, the data processing device (7) being connected via a first interface (10) to at least one measuring device (4, 5, 6) installed on or in the production plant (2), in, The method comprises the following steps: detecting at least one measured value characterizing a property of the semi-finished product (3) by means of the at least one measuring device (4, 5, 6); transmitting the at least one measured value from the at least one measuring device (4, 5, 6) to a data processing device (7); comparing the at least one measured value with predetermined range limits (13a) of an acceptable range; In the event that the at least one measured value is outside the range limit (13a), storing the at least one measured value in a database entry (14) created for recording a defect; In the event that the at least one measured value is outside the range limits (13a), data on the extent of the damage caused by the defect are detected and stored in a database entry (14) created for recording the defect.

Images