DIFFERENCE EXTRACTION DEVICE

Abstract

Difference extraction device (50) comprising a processor configured to perform the following steps: Collecting initial status information from a first production facility (100) equipped with a first device (110) comprising a first electric motor (120) and a first control device (140) that controls the first device (110); Collecting second state information from a second production facility (200) equipped with a second device (210) comprising a second electric motor (220) and a second control device (240) that controls the second device (210), wherein the second production facility (200) is a copy of the first production facility (100); Extracting a difference between the first and second state information between the first and second production facilities (100, 200); and a display screen set up to show the extracted difference, wherein the first and second state information are collected at the same time when the first and second production facilities are operated synchronously under the same operating program in the first and second control devices.

Description

General state of the art 1. Field of invention

[0001] The present invention relates to a difference extraction device that extracts and displays a difference between two or more production facilities. 2. Description of the state of the art

[0002] When a production facility that uses a device such as a machining fixture or the like is expanded, it is possible that, through the process of reproducing an existing production facility, a new production facility identical to the existing one is built. In this case, achieving a complete reproduction with full conformity between two production facilities, including the type of machining tools, peripheral devices, components, and the like, is often difficult.Therefore, when setting up a new production facility by an operator who has precise knowledge of the production facility, various tests are carried out based on the specification and a comparison is made with the existing production facility in order to prevent the occurrence of anomalies due to the fact that complete reproduction was not possible.

[0003] Utility model patent application JP H02-27 204 U describes an integrated monitoring device that monitors the state of several moving devices incorporated into machine tools, comprising: "an output terminal; a selector switch that sends a switching signal to the output terminal with each actuation by an operator; several selector input terminals, each receiving a selector signal corresponding to a target device selected according to the selector output signal in an external control device; a selector target device indicator that displays the actually selected target device based on the selector signal at the selector input terminals; and at least one information input terminal into which information relating to the individual target devices is entered by the external control device."and includes a display for the associated information, which displays related information in connection with the related information entered into the information input terminal” (page 6, line 11 to page 7, line 4).;

[0004] Document US 2015 / 0323926A1 describes an automation operations and management system that consolidates and analyzes inputs from multiple machines within an automated enterprise to predict failures and provide instructions for countermeasures to prevent failures during machine operation and to identify opportunities for efficiency improvements, including measures to reduce peak power consumption within a facility comprising multiple machines. A machine may include a machine controller and at least one basic controller, the basic controller acting as a low-level controller to directly control the movement of elements communicating with the basic controller according to parameters set by the machine controller.The basic control system collects time data for the elements it controls, compares the time data with the parameters, and triggers an alarm if the time data is outside the tolerance limits defined by the parameters.

[0005] Document US 2010 / 0079488A1 describes a visualization system that uses preconfigured overlay models and data models to create overlay displays that present different views of the same data or a single view of different data. The visualization system allows for the collection and sharing of overlay displays and datasets with other interconnected visualization systems. The overlays can be automatically generated by the visualization system and displayed in various formats, such as three-dimensional or translucent displays. Brief description of the invention

[0006] In the field of the above-described setup of new production facilities by carrying out a reproduction, a device is desired that effectively designs the setup activities by an operator and can prevent the occurrence of anomalies in advance.

[0007] The problem underlying the invention is solved by a difference extraction device with the features of independent claim 1. Advantageous embodiments of the invention are specified in dependent claims 2 to 13. Simple explanation of the drawings

[0008] The tasks, features, and advantages of the present invention will become even clearer from the following explanation of one embodiment in conjunction with the accompanying drawings. In the accompanying drawings is Fig. 1 a view showing the entire setup of a production system comprising a difference extraction device according to one embodiment; is Fig. 2 a functional block diagram of the difference extraction device; is Fig. 3. A first example of displaying a difference in information related to the operating status of the engine between several production facilities; is Fig. 4 a second example of the display of a difference in information relating to the operating status of the engine between several production facilities; is Fig. 5 a third example of displaying a difference in information relating to the operating status of the engine between several production facilities; is Fig. 6. An example of displaying a difference between two production facilities based on images; is Fig. 7. A view explaining an example of extracting a difference when four groups of production facilities are present; and is Fig. 8. A view explaining an example of the extraction of a difference when at least four groups of production facilities are present. Detailed explanation

[0009] An embodiment of the present disclosure is explained below with reference to the accompanying drawings. Corresponding structural elements are identified by common reference numerals throughout all drawings. The scale of these drawings has been arbitrarily changed for ease of understanding. The embodiment shown in the drawings represents an example of the present invention, but the present invention is not limited to the form shown.

[0010] Fig. Figure 1 is a view showing the complete setup of a production system 10, which includes a difference extraction device 50 according to one embodiment. As shown in Fig. As shown in Figure 1, the production system 10 comprises two production units 100 and 200, and the difference extraction device is connected to these two production units 100 and 200. For the purposes of this illustration, it is assumed that production unit 100 is an existing production unit and production unit 200 is a unit added by the reproduction process of production unit 100. The difference extraction device 50 of the present embodiment is designed such that an operator can identify the difference between the two production units 100 and 200 by displaying the difference between them on a screen, thereby enabling more efficient performance of the setup activities required for setting up production unit 200.In the following explanation, it is assumed that the production equipment consists of 100 or 200 machining systems, each equipped with a machining tool having an electric motor and a control device that controls this machining tool. However, the present invention is not limited to this example. The production equipment can be various types of systems equipped with a device having an electric motor (such as an assembly device, a testing device, a transport device, or the like) and a control device that controls this device.

[0011] The production facility 100 comprises a machine tool 110, a control device 140 that controls the machine tool 110, and a robot 130 that handles workpieces. The machine tool 110 is designed, by way of example, to have a main spindle drive mechanism 111 that drives a main spindle 112, and a table movement mechanism 115 that moves a table on which a workpiece is arranged. The machine tool 110 has several motors, such as a spindle motor contained in the main axis drive mechanism 111, which drives the main spindle 112, and a motor 120 that drives the table movement mechanism 115, wherein in Fig. Figure 1 shows the motor 120 as a representative example. Various types of machining tools with a different design than the one shown can be used for the machining tool 110.

[0012] The control device 140 is, for example, a CNC (a computer numerical control device) that controls the operation of the machine tool 110 according to operating commands described in a machining program (operating program). The control device 140 can have a general-purpose computer architecture with a CPU, ROM, RAM, storage device, operator panel, display unit, communication interface, input / output interface to an external device, etc. In the production equipment 100, a camera 131 is mounted on a movable section of the robot 130, and by moving the camera 131 with the robot 130, various images can be obtained to monitor the condition of the production equipment 100.The camera 131 is connected to the difference extraction device 50, and the images taken by the camera 131 are supplied to the difference extraction device 50.

[0013] Production facility 200 has the same structure as production facility 100 (that is, a structure that executes the same machining program as production facility 100) and comprises a machining center 210, a control device 240 that controls the machining center 210, and a robot 230 that handles workpieces. The machining center 210 has a main spindle drive mechanism 211 that drives a main spindle 212, a table movement mechanism 215 that moves a table on which a workpiece is arranged, and several motors, such as a spindle motor (not shown) contained in the main axis drive mechanism 211, which drives the main spindle 212, and a motor 220 that drives the table movement mechanism 215.In the following description of the functions of production facility 100, it is assumed that these functions are the same for production facility 200. For example, the difference extraction device 50 is connected to the control devices 140 and 240 via a LAN (local area network) or similar. The difference extraction device 50 may be located at a different location than the plant where production facility 100 and production facility 200 are located. Production facility 100 and production facility 200 may be located in the same plant or in separate plants.

[0014] The control device 140 performs servo control of the individual motors of the machine tool 110. During the execution of the servo control of the individual motors of the machine tool 110, the control device 140 can acquire various pieces of information (current and torque, speed, position, temperature, and the like) and supply information regarding the operating state of these motors (hereinafter referred to as first information) to the differential extraction device 50. Furthermore, a device for detecting physical quantities is provided in the production facility 100, which detects various physical quantities related to the state of the production facility 100.The detection object of the device for detecting physical quantities related to the state of the production equipment can include various types of information that can indicate the state of the production equipment, such as object information obtained from an image (position, shape, size, etc.), vibrations, current (the current of the power source, etc.), humidity, force, the presence of various other objects besides the workpiece and their position, etc. The device for detecting physical quantities is a detection device capable of acquiring this information and can include, for example, various types of sensors such as an image capture device, a vibration detection sensor (an accelerometer), an ammeter, a temperature sensor, a humidity sensor, a force sensor, a proximity sensor, a distance sensor, or the like.The information obtained by the physical quantity detection device (that is, information that differs from the first information) is also referred to as second information. This second information, which the physical quantity detection device detects regarding the state of the production equipment, can include various pieces of information related to the respective location of the production equipment, such as images of the location, its temperature or humidity, or vibrations of the floor at that location. In the example setup of... Fig. In the device for detecting physical quantities, a camera 131 is installed, which detects the state of the production equipment as an image. In addition to instantaneous values, the first and second sets of information can also contain waveform data or time series data of the sensors' response timing (for example, the response timing of the proximity sensor in conjunction with the movement of the workpiece).

[0015] In the present embodiment, the difference extraction device 50 extracts and displays the difference between the two production units 100 and 200 with respect to the first set of information relating to the operating state of the motors and the second set of information detected by the physical quantity detection device. Since this setup displays not only the difference in information relating to the operating state of the motors but also a difference relating to the information detected by the physical quantity detection device, useful information can be provided to the operator performing the start-up for the initial operation of the production unit 200.

[0016] Fig. Figure 2 is a functional block diagram of the difference extraction device 50. As shown in Fig. As shown in Figure 2, the difference extraction device 50 comprises a display unit 51, an information collection unit 52, a difference extraction unit 53, and a difference display processing unit 54. The difference extraction unit 50 can be structured as a general-purpose computer with a CPU, ROM, RAM, storage device, operator panel, display unit, communication interface, input / output interface to an external device, etc. Alternatively, the individual functions of the difference extraction device 50 can be implemented by the CPU of the difference extraction device 50 executing a software program.

[0017] The display unit 51 is a display such as a liquid crystal display device. The information gathering unit 52 obtains information from the control device 140 relating to the operating state of the motors of the production equipment 100 and images captured by the camera 131 as information relating to the state of the production equipment 100. The images captured by the camera 131 are, for example, images that include the main spindle 112 of the production equipment 110, the table movement mechanism 115, and a workpiece during (or after) machining. The difference extraction unit 53 compares the information collected by the information gathering unit 52 relating to the state of the production equipment 100 with information relating to the state of the production equipment 200 and extracts the difference.The difference display processing unit 54 processes the difference extracted by the difference extraction unit 53 between production unit 100 and production unit 200 and displays it on the display unit 51. The processing sequence, from the collection of information by the information collection unit 52 to the display of the difference by the difference display processing unit 54, can be started, for example, by the operator issuing a start command via the control unit of the difference extraction unit 50.

[0018] Fig. 3 to Fig. Five examples are of information displayed as a difference between production unit 100 and production unit 200, based on information related to the operating state of an engine obtained by control devices 140 and 240. The examples of Fig. 3 to Fig. 5. Waveform data, which are time series data of signals (torque commands, current values, position information) expressing the operating state of the motors, are used as objects for comparison. Fig. 3 is a signal waveform, 71 is the signal waveform associated with the operation of the motor in the machine tool 110, and 81 is a signal waveform associated with the operation of the motor in the machine tool 210. These signal waveforms 71 and 81 are displayed superimposed (this also applies to those described below). Fig. 4 and Fig. 5) The maximum value (peak) differs between signal waveform 71 and signal waveform 81. The difference extraction device 50 represents the difference range D1 (the hatched area in Fig. 3) these two signal waveforms 71 and 81 are highlighted, thus ensuring that the operator can immediately visually perceive the difference range D1.

[0019] In Fig. Signal waveform 4 is the signal waveform associated with the operation of the motor in the machine tool 110, and signal waveform 82 is the signal waveform associated with the operation of the motor in the machine tool 210. Of both signal waveforms 72 and 82, only signal waveform 72 exhibits a comparatively small protruding wave region (difference region D2), while signal waveform 82 does not exhibit such a protruding region. The difference extraction device 50 represents the difference region D2 (the hatched area in Fig. 4) these two signal waveforms 72 and 82 are highlighted, thus ensuring that the operator can immediately visually perceive the difference range D2.

[0020] In Fig. 5 is a signal waveform, 73 is the signal waveform associated with the operation of the motor in the machine tool 110, and 83 is a signal waveform associated with the operation of the motor in the machine tool 210. A time offset (difference range D3) occurs in a portion of the signal waveforms 73 and 83. The difference extraction device 50 defines the difference range D3 in which the time offset between signal waveform 73 and signal waveform 83 occurs (the hatched area in Fig. 5) highlighted, thus ensuring that the operator can immediately visually perceive the difference area D3.

[0021] As in Fig. 3 to Fig. The five differences shown in the waveforms, which represent the operation of the motors, can arise from various factors such as differences in the attached tools, differences in the assembly components, differences in the arrangement of the workpieces, and the like. By displaying information regarding, for example, the motor (the spindle) as an assembly component where a difference occurs, along with a description as shown in Fig. 3 to Fig. The difference in signal waveforms shown in Figure 5 makes it possible for the operator to quickly identify the work object to be set up based on this information.

[0022] Fig. Figure 6 is a view to explain an example where the difference extraction device 50 represents a difference between two production facilities based on images. An image M1 in Fig. Figure 6 shows an image taken by camera 131 at production unit 100, containing the main spindle 112 and the table movement mechanism 115 of the machining center 110. Image M2 shows an image taken by camera 231 at production unit 200, containing the main spindle 212 and the table movement mechanism 115 of the machining center 210. Images M1 and M2 are taken at the same time during synchronized operation of both production units 100 and 200. Robot 130 and robot 230 are operated such that cameras 131 and 231 capture images M1 and M2 of the same position and at the same angle. Fig. 6 is an image M3, an image displayed by the difference extraction device 50 on the display unit 51, which represents the difference between image M1 and image M2. Since in the example of Fig. 6. Since the position of the tip end of the main spindle (or tool) differs between image M1 and image M2, a difference area D4 is highlighted in image M3 at the tip end of the main spindle (or tool). The difference area D4 between the two images M1 and M2 can be obtained, for example, by calculating the difference in the image data of the two images M1 and M2.

[0023] The difference extraction device 50 shows how in Fig. 3 to Fig. 5. Information shown in connection with the difference in the signal waveforms of the motors and how in Fig. The information shown in 6, related to the difference in the images, is simultaneously displayed on the display unit 51. This enables the operator to determine the object to be adjusted even more quickly and precisely. For example, if there is a difference in the current waveform (or torque waveform) of the motor driving the main spindle, and a difference as shown in Fig. The difference shown in image 6 makes it immediately clear that the tool attached to the main spindle is not the correct one.

[0024] It is possible that the same processing program is executed at production facilities 100 and 200 with different timings. In such a case, the information gathering unit 52 can collect the status information from each of the two production facilities 100 and 200 with different timings. The difference extraction unit 52 then extracts the difference after aligning the timing on the timeline for the status information collected by each production facility 100 and 200. This enables a correct comparison.

[0025] If the differential extraction unit 50 extracts a difference between two production units 100 and 200, the respective machining programs in the control devices 140 and 240 of the two production units 100 and 200 can be executed synchronously. In this case, the machining programs in the two control devices 140 and 240 are started after precise timing coordination between them. Alternatively, the other control device is operated in sync with an operating signal from the first. This configuration enables the differential extraction unit 50 to collect status information in real time and display the difference.

[0026] The difference extraction device 50 can, for example, also be designed to extract the difference by comparing previous state information recorded during the operation of production facility 100 with state information collected during the operation of production facility 200. To obtain even more stable information than the state information from production facility 200, the difference extraction device 50 can also be operated multiple times, using state information representing average values ​​as the object for comparison.

[0027] It is also possible to gather information related to the state of production facility 200 by controlling the processing machine 210 of production facility 200 via the control device 140 of production facility 100. Since production facility 100 is an existing facility, it can be assumed in this case that the control device is operating normally. If a difference is then found between the information representing the state of production facility 200 and the information representing the state of production facility 100, it can be assumed that some anomaly exists in production facility 200, not in the control system but in the mechanical system. This means that when specifying the anomaly in the new facility, a clear distinction can be made in advance between an anomaly of the control system and an anomaly of the mechanical system.

[0028] In this case, operating commands based on the machining program are generated in control device 140 and output via the network to control device 240, and the machining center 110 is controlled by control device 240. Control device 240 sends feedback data from machining center 110 back to control device 140, and control of machining center 210 by control device 140 is thus mediated.

[0029] Next, with reference to Fig. 7 and Fig. Eight examples of extracting a difference when three or more groups of production facilities are explained. Fig. Figure 7 shows a schematic example of the structure of a production system 10A, which contains four groups of production facilities 301 to 304. Fig. For ease of explanation, the production equipment 301 to 304 of the four groups are designated as Device A, Device B, Device C, and Device D, respectively. In this case, each device comprises, for example, a processing machine and a control device. In the setup example of Fig. 7. It is assumed that the individual devices A to D are newly manufactured by reproduction, and it is assumed that a difference extraction device is connected to the individual devices A to D via a network. In this setup, the difference extraction device obtains information from the individual devices A to D relating to the state of the manufacturing equipment. In this case, the difference extraction device can perform the extraction and display of the difference as follows. Operational example A1

[0030] As a first operational example, the difference extraction device displays a warning indicating that an anomaly exists in the device in question when the information from three devices (for example, devices A to C) of the four devices A to D is identical, and the information from one device (for example, device D) differs. This warning, along with the difference in the device (device D) from which the differing information was obtained, is based on the assumption that a majority of several manufactured devices output the same information. This operation is based on the premise that if multiple devices output the same information, it can be assumed that these devices are operating normally.As a more concrete operational example, the difference extraction device collects state information (time series information) from each of the four devices A to D when the four devices A to D are executing the same operating program, and compares this information after aligning the operating timing of this state information on the time axis. If the state information of three devices (for example, devices A to C) of the four devices A to D is the same, and the information of one device (for example, device D) differs, information related to the difference and a warning message are displayed for device D. Information related to the difference can include, along with the information mentioned above, the following: Fig. 3 to Fig. The information described in section 6, for example, information regarding the structural component that is the cause of the difference, and / or information regarding the timing of the occurrence of the difference (for example, the time, the time elapsed since the start of the operating program, the point in time where the difference occurred in the operating program), is displayed. Operational example A2

[0031] As a second operational example, the difference extraction device can also display a warning for all devices A to D together with the difference if the information of device A and device B is the same and the information of device A and device B differs from the information of device C and device D.

[0032] Fig. Figure 8 shows a schematic example of the structure of a production system 10B that contains more than four groups of production facilities. Fig. Figure 8 represents four groups, for easier explanation, which constitute part of the several production facilities. These groups are designated with reference numbers 401 to 404 and are called Device A, Device B, Device C, and Device D. Each device comprises, for example, a processing machine and a control device. In the setup example of Fig.8. It is assumed that the individual devices are newly manufactured through reproduction, and it is assumed that a difference extraction device is connected to the multiple production devices via a network. In this setup, the difference extraction device obtains information from the individual devices relating to the state of the production device. In this case, the difference extraction device can perform the extraction and display of the difference as follows. Company example B1

[0033] As a first operational example, if the information collected for a subset of the total production facilities contained in production system 10B is identical, and no other identical information exists for the individual production facilities, it is assumed that the group of production facilities possessing the same information operates normally. In this case, the difference extraction device for the production facilities with differing information indicates the difference and issues a warning. Company example B2

[0034] The second operation is a procedure for determining which device should receive a warning, based on indices that indicate fluctuations in the information of all production units within production system 10B. For example, based on the standard deviation of the information from all production units, it is assumed that a production unit whose information value exceeds the standard deviation has an anomaly. Alternatively, an example can be given where a device whose deviation from an average value (as status information) is greater than a deviation that includes 80% of all devices is considered abnormal. In this case, the difference extraction device displays the difference for the device identified as abnormal, and consequently, a warning.

[0035] The designs described above allow useful information for determining setting targets to be displayed to the operator once a production facility has been reproduced, and the occurrence of anomalies can be prevented in advance.

[0036] In the foregoing, one embodiment of the present disclosure has been explained, but a person skilled in the art will understand that various improvements and modifications can be made without deviating from the scope of disclosure set forth in the following patent claims.

[0037] In the embodiment described above, the device for detecting physical quantities was described as a camera installed at each of two production facilities; however, the device for detecting physical quantities can also be provided as a single, movable device. In this case, the single device for detecting physical quantities can be moved between several production facilities and acquire information (for example, images) related to the production facilities.

[0038] The processing sequence, from the collection of information by the information collection unit 52 to the display of the difference by the difference display processing unit 54, can also be executed periodically according to schedule information predefined in the difference extraction device 50. In this case, anomalies can be detected not only at the time of setting up a production facility but also during ongoing operation.

[0039] In the embodiment described above, the difference extraction device is described as an independent device connected to the individual production units via a network; however, the present invention is not limited to such an embodiment. For example, the difference extraction device can be implemented as an associated device in any of the production units. Or the difference extraction device can be implemented as part of the functions of the control device of any of the production units. In this case, the difference extraction device or the control device that has the function as a difference extraction device can be designed such that it can indicate the result of the difference extraction by sending the result of the difference extraction to the control devices of the other production units at each production unit.

Claims

[1] Difference extraction device (50) comprising a processor configured to perform the following steps: Collecting initial status information from a first production facility (100) equipped with a first device (110) comprising a first electric motor (120) and a first control device (140) that controls the first device (110); Collecting second state information from a second production facility (200) equipped with a second device (210) comprising a second electric motor (220) and a second control device (240) that controls the second device (210), wherein the second production facility (200) is a copy of the first production facility (100); Extracting a difference between the first and second state information between the first and second production facilities (100, 200); and a display screen set up to show the extracted difference, wherein the first and second state information are collected at the same time when the first and second production facilities are operated synchronously under the same operating program in the first and second control devices. [2] Difference extraction device (50) according to claim 1, wherein the display screen is configured to display, together with the difference, information regarding at least one assembly component of the first or second device (110, 210) that is the cause of the difference, or regarding the timing of the occurrence of the difference. [3] Difference extraction device (50) according to claim 1 or 2, wherein the first state information comprises first information indicating the operating state of the first electric motor at the first production device as detected by a first physical quantity detector, and the second state information comprises second information that is different from the first information and that detects the operating state of the second devices (231) by a second physical quantity detector, wherein the processor is further configured to extract a first difference of the first information between the first and second production devices and to extract a second difference of the second information between the first and second production devices, and the display screen is configured to display the extracted first difference and second difference. [4] Difference extraction device (50) according to claim 3, wherein the first information is waveform data of a signal indicating the operating state of the electric motor, and the display screen is configured to display the waveform data of the first and second production devices superimposed and to highlight a first difference as a difference between the waveform data of the first and second production devices. [5] Difference extraction device (50) according to any one of claims 1 to 4, wherein the processor is configured to belong to any one of the first and second production facilities. [6] Difference extraction device (50) according to any one of claims 1 to 5, wherein the processor is connected via a network to each of the first and second control devices of the first and second production facilities (100, 200). [7] Difference extraction device (50) according to one of claims 1 to 6, wherein the first and second state information is time series data indicating the state of the first and second production facilities (100, 200) during the execution of an identical operating program in the first and second control devices (140, 240) of the first and second production facilities (100, 200). [8] Difference extraction device (50) according to any one of claims 1 to 6, wherein the processor is configured to collect first state information relating to the second production device (200), while the second device of the second production device (200) is controlled by the first control device (140) of the first production device (100). [9] Difference extraction device (50) according to any one of claims 1 to 6, wherein the processor is configured to perform the extraction of the difference for at least one production unit of the first and second production units (100, 200) using recorded prior first and second state information. [10] Difference extraction device (50) according to claim 3 or 4, wherein the device for detecting physical quantities (131, 231) as information related to the respective setup location of the first and second production facilities (100, 200) detects physical quantities which include at least one of images, the temperature, the humidity and vibrations of the floor of the setup location. [11] Difference extraction device (50) according to any one of claims 1 to 10, wherein the processor is configured to collect the first and second state information, extract the differences and display the differences on the display screen according to pre-defined schedule information. [12] Difference extraction device (50) according to one of the preceding claims, wherein the display screen is configured to represent the difference by highlighting it as a hatched area between first waveform data of the first state information of the first production device (100) and second waveform data of the second state information of the second production device (200). [13] Difference extraction device (50) according to one of the preceding claims, wherein the first state information records a first position in the first production unit at a first angle and the second state information records a second position in the wider production unit at a second angle, wherein the first and second angles are equal and the first and second positions are equal.

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