Changeover time estimation system, changeover time estimation method and changeover time estimation device

Abstract

Changeover time estimation system (1) comprising: an industrial machine (10) configured to execute a first step specified by first step information and a second step specified by second step information in this order, wherein in the first step a first workpiece (W1) is to be machined with the industrial machine (10), wherein in the second step a second workpiece (W2) is to be machined with the industrial machine (10); a detection unit (21) configured to detect the first step information and the second step information; an estimation unit (23) configured to determine whether the first step information and the second step information differ and to estimate a changeover time between the first step and the second step based on an operation end time of the first step and an operation start time of the second step when the first step information and the second step information differ, wherein the estimation unit (23) is configured to estimate the changeover time as the time difference between the operation end time of the first step and the operation start time of the second step and / or wherein the estimation unit (25) is configured to calculate the time difference between the operation end time of the first step and the operation start time of the second step multiple times and to estimate the changeover time as an average value, a median value, a maximum value or a minimum value of the multiple-calculated time differences; an advertisement (30); and a display unit (24) configured to control the display (30) and cause the changeover time estimated by the estimation unit (23) to be displayed on the display (30).

Description

Technical area

[0001] The present disclosure relates to a changeover time estimation system, a changeover time estimation method and a changeover time estimation device Technical background

[0002] Non-Patent Document No. 1 proposes understanding and improving changeover times to increase the changeover frequency in small-batch production with industrial machines.

[0003] A changeover occurs when a workpiece is changed or when the machining of a workpiece is modified. Changeover is a setup change operation that involves stopping an industrial machine, and more specifically, a job that involves attaching or removing a tool or mold and adjusting the industrial machine. Changeover time is the time difference between the end time of machining a workpiece at the current time and the start time of subsequent machining of the workpiece.

[0004] In Non-Patent Document No. 1, an operator uses a stopwatch to measure the changeover time. Prior art documentNon-patent document

[0005] Non-Patent Document No. 1: Consultsourcing Corporation, “Toyota Production System: Small-lot production - introduction procedures and examples” [online] [accessed: August 23, 2021] Internet:<URL: https: / / www.consultsourcing.jp / 4194> Summary of the inventionProblem to be solved by the invention

[0006] However, it is tedious for an operator to measure the changeover time with a stopwatch.

[0007] An object of the present disclosure is to provide a changeover time estimation system, a changeover time estimation method, and a changeover time estimation device with which it is possible to easily estimate the changeover time of an industrial machine. This object is achieved by the changeover time estimation system according to claim 1, the changeover time estimation method according to claim 8, and the changeover time estimation device according to claim 9. Further advantageous effects can be achieved by preferred embodiments defined in the appended dependent claims. Means to solve the problem

[0008] A changeover time estimation system according to claim 1 comprises an industrial machine, a detection unit, an estimation unit, a display, and a display unit. The industrial machine is configured to execute a first step specified by first step information and a second step specified by second step information in this order. The detection unit is configured to detect the first step information and the second step information. In the first step, a first workpiece is to be machined with the industrial machine, and in the second step, a second workpiece is to be machined with the industrial machine. The first step information includes an operation end time of the first step, and the second step information includes an operation start time of the second step.The estimation unit is configured to determine whether the first step information and the second step information differ, and to estimate a changeover time between the first step and the second step based on an operation end time of the first step and an operation start time of the second step when the first step information and the second step information differ. The estimation unit is further configured to estimate the changeover time as the time difference between the operation end time of the first step and the operation start time of the second step, and / or to calculate the time difference between the operation end time of the first step and the operation start time of the second step multiple times and estimate the changeover time as an average value, a median value, a maximum value, or a minimum value of the multiple-calculated time differences.The display unit is configured to control the display and cause the changeover time estimated by the estimation unit to be displayed on the display. Effect of the invention

[0009] According to the present disclosure, a changeover time estimation system, a changeover time estimation method, and a changeover time estimation apparatus can be provided, with which a changeover time of an industrial machine can be easily estimated. Brief description of the drawings Fig. 1 is a block diagram showing the configuration of a changeover time estimation system according to an embodiment. Fig. 2 is an example of a table stored by a storage unit according to the embodiment. Fig. 3 is a flowchart showing a changeover time estimation method according to this embodiment. Description of the embodiments (Configuration of the changeover time estimation system 1)

[0010] A configuration of a changeover time estimation system 1 according to the present embodiment will be explained with reference to the drawings. Fig. 1 is a block diagram showing a configuration of the changeover time estimation system 1.

[0011] The changeover time estimation system 1 includes an industrial machine 10, a management unit 20, and a display 30. The management unit 20 is a changeover time estimation device according to the present disclosure. (Industrial Machine 10)

[0012] The situation in which the industrial machine 10 is a lathe is in Fig. 1. However, a machine tool other than a lathe, such as a spot welder, a welding robot, a semiconductor-related device, an exposure device, a chemical processing device, a wire bonder, a testing device, an electronic component placement device, a board punching machine, an assembly device, a conveyor device, a press forging machine, a wire saw, a sheet metal processing machine such as a shearing machine, or the like, may serve as an example for the industrial machine 10. For example, a milling machine, a drilling machine, a machining center, a jig boring machine, a drill press, a grinder, an electrical discharge machine, a wireless cutting electrical discharge machine, a punch press, a laser processor, or the like may serve as an example of a machine tool instead of a lathe.

[0013] While in Fig. 1 only one industrial machine 10 is shown, the number of industrial machines 10 can be more than one.

[0014] The industrial machine 10 has a control unit 11. The control unit 11 controls the machining of a workpiece according to a numerical control (NC) program. The control unit 11 is equipped with a communication function. The control unit 11 is connected to the management unit 20 via a network (e.g., the Internet) using the communication function.

[0015] A pallet 12 is used in the industrial machine 10. The pallet 12 delivers a first workpiece W1, a second workpiece W2, and a third workpiece W3 in this order to the industrial machine 10.

[0016] In the present embodiment, the industrial machine 10 processes the first workpiece W1, the second workpiece W2, and the third workpiece W3 in this order. First, the industrial machine 10 performs a first step on the first workpiece W1. In this first step, a first machining operation is carried out according to a first program. Subsequently, the industrial machine 10 performs a second step on the second workpiece W2. In this second step, the second machining operation is carried out according to a second program. Next, the industrial machine 10 performs a third step on the third workpiece W3. In this third step, the third machining operation is carried out according to a third program.

[0017] The control unit 11 transmits to the management unit 20 first step information specifying the first step on the first workpiece W1, second step information specifying the second step on the second workpiece W2, and third step information specifying the third step on the third workpiece W3.

[0018] The first step information includes a first step name "Nx" of the first step, a first part number "Mx" of the first workpiece W1 to be machined in the first step, a first program number "Px" to be used in the first step, and a time. The part number represents a product number, and a design drawing corresponds to a part number. The part number is an identifier for the product drawn in the design drawing and generally consists of numbers, symbols (hyphens, etc.), and letters (letters of the alphabet, etc.).

[0019] A second step name “Ny” of the second step, a second part number “Mx” of the second workpiece W2 to be machined in the second step, a second program number “Py” to be used in the second step, and a time are included in the second step information.

[0020] A third step designation “Nz” of the third step, a third part number “Mz” of the third workpiece W3 to be machined in the third step, a third program number “Pz” to be used in the third step, and a time are included in the third step information.

[0021] To facilitate explanation, in the present embodiment, the first to third step names are different, the part numbers of the first and second workpieces W1 and W2 are the same, the part number of the third workpiece W3 is different from the part numbers of the first and second workpieces W1 and W2, and the first to third program numbers are different. Workpieces with the same part numbers correspond to the same design drawing, and workpieces with different part numbers have different corresponding design drawings.

[0022] The control unit 11 may transmit the step information to the management unit 20 when the processing of each workpiece is completed. Alternatively, the control unit 11 may combine the plurality of step information after the processing of a plurality of workpieces is completed and transmit the plurality of step information to the management unit 20. (Administrative Unit 20)

[0023] The management unit 20 includes a recording unit 21, a storage unit 22, an estimation unit 23, and a display unit 24. The functions of the management unit 20 are executed by means of a server. The server can be a cloud server. The management unit 20 is connected to the control unit 11 and the display 30 via a network. The management unit 20 is a changeover time estimator.

[0024] The acquisition unit 21 acquires the first step information, the second step information, and the third step information from the control unit 11. The acquisition unit 21 is provided with a communication function that enables communication with the control unit 11 via a network, and receives the step information from the control unit 11 by means of the communication.

[0025] The acquisition unit 21 causes the acquired first step information, second step information and third step information to be stored in the storage unit 22 in chronological order.

[0026] Fig. 2 is an example of a table stored by the storage unit 22.

[0027] The storage unit 22 stores the execution dates and times of the steps in conjunction with the step information. Fig. In the example shown in Figure 2, the first step is executed on June 1, 2021, between 0 hours and 00 minutes and 0 hours and 10 minutes, the second step is executed on June 1, 2021, between 0 hours and 10 minutes and 0 hours and 23 minutes, and the third step is executed on June 1, 2021, between 0 hours and 27 minutes and 0 hours and 29 minutes.

[0028] Therefore, the start time of the first step is 0 hours 00 minutes and the end time of the first step is 0 hours 10 minutes, the start time of the second step is 0 hours 10 minutes and the end time of the second step is 0 hours 23 minutes, and the start time of the third step is 0 hours 27 minutes and the end time of the third step is 0 hours 29 minutes.

[0029] The estimation unit 23 estimates a changeover time between the first step and the second step based on the operation end time of the first step and the operation start time of the second step when the first step information and the second step information are different.

[0030] If the first step information and the second step information differ, it means that a retooling is being performed on the industrial machine 10. In the present embodiment, the estimation unit 23 determines that the first step information and the second step information differ when the first step name and the second step name differ, and when the first part number and the second part number differ.

[0031] In the present embodiment, the first part number "Mx" and the second part number "Mx" are the same, but the first step name "Nx" and the second step name "Ny" are different. Subsequently, the estimation unit 23 determines that the first step information and the second step information are different. The estimation unit 23 then estimates the changeover time between the first step and the second step based on 0 hours and 10 minutes, which is the operation end time of the first step, and 0 hours and 17 minutes, which is the operation start time of the second step. The estimation unit 23 estimates the changeover time as "7 minutes," which is the difference between the operation end time of the first step and the operation start time of the second step.

[0032] Similarly, the estimation unit 23 estimates the changeover time between the second step and the third step based on the operation end time of the second step and the operation start time of the third step when the second step information and the third step information are different.

[0033] In the present embodiment, the second part number "My" and the third part number "Mz" are different, and the second step name "Ny" and the third step name "Nz" are different. As a result, the estimation unit 23 determines that the second step information and the third step information are different. The estimation unit 23 then estimates the changeover time between the second step and the third step based on 0 hours and 23 minutes, which is the operation end time of the second step, and 0 hours and 27 minutes, which is the operation start time of the third step. The estimation unit 23 estimates the changeover time as "4 minutes," which is the difference between the operation end time of the second step and the operation start time of the third step.

[0034] In this way, the estimation unit 23 determines that two pieces of step information differ when either the part number or the step name, or both the part number and the step name, are different in one piece of step information and the following step information, and estimates the changeover time. Consequently, the changeover time can be easily estimated by automatically detecting two consecutive steps that require changeover.

[0035] The display unit 24 controls the display 30. The display unit 24 causes the changeover time estimated by the estimation unit 23 to be displayed on the display 30. If the estimation unit 23 has estimated two or more changeover times, the display unit 24 preferably causes the two or more changeover times to be displayed using a priority order.

[0036] For example, the display unit 24 may cause the changeover time to be displayed on the display 30 when the changeover time is equal to or greater than a predetermined time. The predetermined time may be a threshold value that can be set arbitrarily. For example, if the predetermined time is set to five minutes, only the "7 minutes" that is the changeover time between the first step and the second step is displayed. Thus, only one step requiring changeover improvement can be indicated. Alternatively, the predetermined time may be a time required as a standard time ST for the changeover work. The standard time ST is a time during which a worker with a standard qualification performs the changeover work according to standard work procedures or conditions. The standard work time ST can be used for production planning, cost management, and the like.

[0037] Alternatively, the display unit 24 can cause the changeover time to be displayed on the display 30 in order of time lengths. In this case, the display unit 24 causes "7 minutes," i.e., the changeover time between the first step and the second step, to be displayed higher than "4 minutes," i.e., the changeover time between the second step and the third step. This can highlight a step requiring an improvement in the changeover. (Changeover time estimation method)

[0038] A changeover time estimation method according to the present embodiment will be described with reference to Fig. 3 explained. Fig.Figure 3 is a flowchart showing the process of the changeover time estimation procedure. Since the changeover time estimation procedure between the first step and the second step and the changeover time estimation procedure between the second step and the third step are identical, the changeover time estimation procedure between the first step and the second step is explained below.

[0039] In step S1, the industrial machine 10 uses the pallet 12 to perform the first step and the second step in this order.

[0040] In step S2, the acquisition unit 21 acquires the first step information and the second step information from the industrial machine 10.

[0041] In step S3, the estimation unit 23 determines whether the first part number and the second part number differ. The routine proceeds to step S4 if the first part number and the second part number do not differ. The routine proceeds to step S5 if the first part number and the second part number differ.

[0042] In step S4, the estimation unit 23 determines whether the first step label and the second step label differ. The routine ends if the first step label and the second step label do not differ. The routine proceeds to step S5 if the first step label and the second step label differ.

[0043] In step S5, the estimation unit 23 estimates the changeover time between the first step and the second step based on the operation end time of the first step and the operation start time of the second step.

[0044] In step S6, the display unit 24 causes the changeover time between the first step and the second step to be displayed on the display 30. (Modified Examples of the Embodiment)[Modified Example 1]

[0045] In the above embodiment, the estimation unit 23 is configured to estimate the time difference between the operation end time of the first step and the operation start time of the second step as the changeover time between the first step and the second step. However, if the estimation unit 23 has calculated the time difference between the first step and the second step multiple times, the estimation unit 23 may estimate an average value, a median value, a maximum value, or a minimum value of the multiple difference times as the changeover time between the first step and the second step.

[0046] Accordingly, when the estimation unit 23 has calculated the time difference between the second step and the third step multiple times, the estimation unit 23 can estimate an average value, a median value, a maximum value, or a minimum value of the multiple difference times as the changeover time between the second step and the third step. [Modified Example 2]

[0047] In the above embodiment, the estimation unit 23 is configured to determine that the first step information and the second step information differ when the first step name and the second step name differ, and when the first part number and the second part number differ. However, the estimation unit 23 may also determine that the first step information and the second step information differ when the first program number used in the first step and the second program number used in the second step differ.

[0048] Accordingly, the estimation unit 23 can also determine that the second step information and the third step information are different when the second program number and the third program number are different.

[0049] When determining whether the first step information and the second step information are different or not based on the program numbers, the step names and part numbers do not need to be included in the step information. [Modified Example 3]

[0050] While the program numbers are included in the step information in the above embodiment, the program numbers may not be included in the step information as long as the determination of whether the first step information and the second step information are different or not is made based on the step names and the part numbers. [Modified Example 4]

[0051] While one pallet 12 is used in the industrial machine 10 in the above embodiment, two or more pallets may be used. For example, the pallets 12a, 12b, and 12c each deliver the first workpiece W1, the second workpiece W2, and the third workpiece W3 to the industrial machine 10 in this order. Even when two or more pallets are used, the changeover is performed for each pallet individually, and therefore the estimation method of the changeover time is the same as that explained in the above embodiment. [Modified Example 5]

[0052] Although the management unit 20 is configured as a server that communicates with the industrial machine 10 via a network in the above embodiment, the management unit 20 may also be mounted on the industrial machine 10 or on the control unit 11 of the industrial machine 10. The changeover time estimation system 1 may be integrated into the industrial machine 10. List of reference numbers 1 Changeover time estimation system 10 industrial machines 11 Control unit 12 pallets 20 Management unit (changeover time estimation device) 21 Recording unit 22 storage unit 23 Estimation Unit 24 display unit

Claims

[1] Changeover time estimation system (1) which has: an industrial machine (10) configured to execute a first step specified by first step information and a second step specified by second step information in this order, wherein in the first step a first workpiece (W1) is to be machined with the industrial machine (10), wherein in the second step a second workpiece (W2) is to be machined with the industrial machine (10); a detection unit (21) configured to detect the first step information and the second step information; an estimation unit (23) configured to determine whether the first step information and the second step information differ and to estimate a changeover time between the first step and the second step based on an operation end time of the first step and an operation start time of the second step when the first step information and the second step information differ, wherein the estimation unit (23) is configured to estimate the changeover time as the time difference between the operation end time of the first step and the operation start time of the second step and / or wherein the estimation unit (25) is configured to calculate the time difference between the operation end time of the first step and the operation start time of the second step multiple times and to estimate the changeover time as an average value, a median value, a maximum value or a minimum value of the multiple-calculated time differences; an advertisement (30); and a display unit (24) configured to control the display (30) and cause the changeover time estimated by the estimation unit (23) to be displayed on the display (30). [2] Changeover time estimation system (1) according to claim 1, wherein the first step information contains a first step name of the first step in chronological order, the second step information contains a second step designation of the second step in chronological order, and the estimation unit (23) is configured to determine that the first step information and the second step information differ when the first step label and the second step label differ. [3] Changeover time estimation system (1) according to claim 1, wherein the first step information contains a first part number of the first workpiece (W1), in chronological order, the second step information contains a second part number of the second workpiece (W2), in chronological order, and the estimation unit (23) is configured to determine that the first step information and the second step information differ when the first part number and the second part number differ. [4] Changeover time estimation system (1) according to claim 1, wherein the first step information contains a first program number that is used in the first step, the second step information contains a second program number used in the second step, and the estimation unit (23) is configured to determine that the first step information and the second step information differ when the first program number and the second program number differ. [5] The changeover time estimation system (1) according to any one of claims 1 to 4, wherein the display unit (24) is configured to cause the changeover time to be displayed on the display (30) when the changeover time between the first step and the second step is equal to or greater than a predetermined time. [6] Changeover time estimation system (1) according to one of claims 1 to 4, wherein the industrial machine (10) is configured to execute a third step after the second step, which is specified by third step information, the acquisition unit (21) is configured to acquire the third step information, the estimation unit (23) is configured to estimate a changeover time between the second step and the third step based on an operation end time of the second step and an operation start time of the third step when the second step information and the third step information are different, and the display unit (24) is configured to cause the changeover time between the first step and the second step and the changeover time between the second step and the third step to be displayed on the display (30) in order of time duration. [7] Changeover time estimation system (1) according to one of claims 1 to 6, wherein the changeover time estimation system (1) is integrated into the industrial machine (10). [8] Changeover time estimation method that has: Executing (S 1) a first step specified by first step information and a second step specified by second step information, in an industrial machine (10) in this order wherein in the first step a first workpiece (W1) is machined with the industrial machine (10), wherein in the second step a second workpiece (W2) is machined with the industrial machine (10); Acquiring (S2) the first step information and the second step information; determining (S3, S4) whether the first step information and the second step information differ; Estimating (S5), with an estimation unit (23), a changeover time between the first step and the second step based on an operation end time of the first step and an operation start time of the second step when the first step information and the second step information differ, wherein the changeover time is estimated as the time difference between the operation end time of the first step and the operation start time of the second step and / or wherein the time difference between the operation end time of the first step and the operation start time of the second step is calculated multiple times and the changeover time is estimated as an average value, a median value, a maximum value or a minimum value of the multiple-calculated time differences; and Causing (S6), with a display unit (24), that the estimated changeover time is displayed on a display (30). [9] Changeover time estimation device (20) that can communicate with an industrial machine (10), the changeover time estimation device (20) comprising: a detection unit (21) configured to detect first step information specifying a first step of the industrial machine (10) and second step information from the industrial machine (10) by means of communication, which specify a second step of the industrial machine (10), which is a step which follows the first step wherein in the first step a first workpiece (W1) is to be machined with the industrial machine (10), wherein in the second step a second workpiece (W2) is to be machined with the industrial machine (10); a storage unit (22) configured to store the acquired first step information and the acquired second step information in chronological order in association with the date and time of execution of the steps; an estimation unit (23) configured to determine whether the first step information and the second step information differ and to estimate a changeover time between the first step and the second step based on an operation end time of the first step and an operation start time of the second step when the stored first step information and the second step information differ, wherein the estimation unit (23) is configured to estimate the changeover time as the time difference between the operation end time of the first step and the operation start time of the second step and / or wherein the estimation unit (25) is configured to calculate the time difference between the operation end time of the first step and the operation start time of the second step multiple times and to estimate the changeover time as an average value, a median value, a maximum value, or a minimum value of the multiple-calculated time differences; and a display unit (24) configured to communicate with a display (30) and to control the display (30) and to cause the changeover time estimated by the estimation unit (23) to be displayed on the display (30). [10] Changeover time estimating device (20) according to claim 9, wherein the changeover time estimating device (20) is mounted on the industrial machine (10).

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