Production system, control method for production system, and control program for production system

Abstract

To provide a technique to support in factor specifying of an event that occurs in a production system.SOLUTION: A production system comprises: a display unit, a machine tool, and a control unit. The control unit performs: a process of acquiring a database that specifies a classification of each of a plurality of objects related to processing by the machine tool; a process of counting a generation amount of a first event occurring for each of the plurality of objects by the classification; and a process to display ranking information according to the generation amount of the first event on a display unit, whereas: the ranking information represents information for indicating the classification, the generation amount of the first event, and information for identifying a factor in which the first event occurred by classification and by the generation amount of the first event.SELECTED DRAWING: Figure 11

Description

[Technical field]

[0001] The present disclosure relates to a production system, a control method for a production system, and a control program for a production system. [Background technology]

[0002] Japanese Patent No. 7001854 (Patent Document 1) discloses a tool transport system that automatically transports tools used in machining to a machine tool. The tool transport system has a tool storage unit that can store multiple tools, and transports a specified tool to the machine tool. The tool transport system also removes unnecessary tools from the machine tool. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 7001854 Summary of the Invention [Problem to be solved by the invention]

[0004] In a production system such as a tool transport system, various events occur. When an event occurs in a production system, it is necessary to identify the cause of the event. The present invention has been made to solve such problems, and its purpose is to provide a technology for supporting the identification of the cause of an event that occurs in a production system. Note that the tool management system disclosed in Patent Document 1 does not relate to such technology. [Means for solving the problem]

[0005] In one example of the present disclosure, a production system includes a display unit, a machine tool, and a control unit. The control unit executes a process of acquiring a database that specifies the classification of each of a plurality of objects related to machining by the machine tool, a process of counting the occurrence amount of a first event that occurred for each of the plurality of objects by the classification, and a process of displaying ranking information according to the occurrence amount of the first event on the display unit. The ranking information represents, by classification and in order of the occurrence amount of the first event, information indicating the classification, the occurrence amount of the first event, and information for identifying the cause of the occurrence of the first event.

[0006] In one example of the present disclosure, the plurality of targets include a plurality of tools. The production system further includes a transport device for transporting a designated tool of the plurality of tools to the machine tool. The database defines a classification of each of the plurality of tools. In the counting process, an occurrence amount of the first event occurring for each of the plurality of tools is counted by the classification.

[0007] In one example of the present disclosure, the control unit further executes a process of counting an occurrence amount of a second event that has occurred for each of the plurality of tools by the classification. The second event is different from the first event. The ranking information further indicates an occurrence amount of the second event by the classification.

[0008] In one example of the present disclosure, the control unit further executes a process of accepting a selection operation of either the first event or the second event, and the displaying process includes updating the ranking information according to the order of occurrence of the events selected by the selection operation.

[0009] In one example of the present disclosure, the first event is an event indicating that the transport device has transported a tool to the machine tool.

[0010] In one example of the present disclosure, the first event is an event indicating that the machine tool has run out of a tool.

[0011] In one example of the present disclosure, the first event is an event indicating that the tool has become disabled.

[0012] In another example of the present disclosure, a method for controlling a production system is provided. The production system includes a display unit and a machine tool. The control method includes a step of acquiring a database that specifies the classification of each of a plurality of objects related to machining by the machine tool, a step of counting the occurrence amount of a first event that has occurred for each of the plurality of objects by the classification, and a step of displaying ranking information according to the occurrence amount of the first event on the display unit. The ranking information represents, by the classification and in order of the occurrence amount of the first event, information indicating the classification, the occurrence amount of the first event, and information for identifying a cause of the occurrence of the first event.

[0013] In another example of the present disclosure, a control program for a production system is provided. The production system includes a display unit and a machine tool. The control program causes the production system to execute the steps of acquiring a database that defines the classification of each of a plurality of objects related to machining by the machine tool, counting the occurrence amount of a first event that has occurred for each of the plurality of objects by the classification, and displaying ranking information according to the occurrence amount of the first event on the display unit. The ranking information represents, by classification and in order of the occurrence amount of the first event, information indicating the classification, the occurrence amount of the first event, and information for identifying a cause of the occurrence of the first event.

[0014] The above and other objects, features, aspects and advantages of the present invention will become apparent from the following detailed description of the invention taken in conjunction with the accompanying drawings. [Brief description of the drawings]

[0015] [Figure 1] FIG. 1 is a diagram showing the external appearance of a production system. [Diagram 2] FIG. 2 is a diagram illustrating a configuration example of a drive mechanism of a production system. [Diagram 3] FIG. 13 is a diagram illustrating an outline of the flow of a ranking information display function. [Figure 4] FIG. 2 is a diagram illustrating an example of a functional configuration of a production system. [Diagram 5] FIG. 13 is a diagram showing an example of processing settings. [Figure 6] FIG. 13 illustrates an example of a work database. [Figure 7] FIG. 11 is a diagram showing an example of a transport schedule. [Figure 8] FIG. 13 is a diagram illustrating an example of a tool database. [Figure 9] FIG. 11 is a diagram showing storage information as an example. [Figure 10] FIG. 13 is a diagram showing ranking information as an example of an output result from an output unit. [Figure 11] FIG. 13 is a diagram showing ranking information according to a modified example. [Figure 12] 11 is a diagram illustrating a flow of a process of carrying a tool from a work station to a tool storage section. FIG. [Figure 13] 10 is a diagram illustrating a flow of a process for carrying a tool from a tool storage unit to a machine tool. FIG. [Figure 14] 1 is a diagram illustrating a flow of a process for carrying out a tool from a machine tool to a work station. FIG. [Figure 15] FIG. 2 illustrates an example of a hardware configuration of a management apparatus. [Figure 16] FIG. 1 is a diagram illustrating an example of a hardware configuration of a PLC (Programmable Logic Controller). [Figure 17] FIG. 2 illustrates an example of a hardware configuration of an operation terminal. [Figure 18] FIG. 2 is a diagram illustrating an example of a hardware configuration of a machine tool. [Figure 19] FIG. 11 is a flowchart showing a process of updating a tool database. [Figure 20] FIG. 11 is a flowchart showing a process for displaying ranking information. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0016] Hereinafter, each embodiment according to the present invention will be described with reference to the drawings. In the following description, the same parts and components are denoted by the same reference numerals. Their names and functions are also the same. Therefore, detailed descriptions thereof will not be repeated. Note that each embodiment and each modification described below may be selectively combined as appropriate.

[0017] <A. Appearance of Production System 10> First, with reference to FIG. 1, a production system 10 according to an embodiment will be described. FIG. 1 is a diagram showing the appearance of the production system 10.

[0018] As shown in FIG. 1, the production system 10 includes a work station 200, a tool storage unit 250, a transfer device 300, and a machine tool 400.

[0019] The work station 200 is a place where an operator performs work on tools. For example, the operator performs tool setting work or tool collection work at the work station 200.

[0020] The work station 200 includes an operation terminal 200A. The operation terminal 200A receives various operations on the production system 10.

[0021] A plurality of tools can be stored in the tool storage unit 250. The tool storage unit 250 functions as a temporary storage place for tools.

[0022] The transfer device 300 transfers tools from a designated transfer source to a designated transfer destination. Examples of the transfer source of the tool include the work station 200, the tool storage unit 250, or the machine tool 400. Examples of the transfer destination of the tool include the work station 200, the tool storage unit 250, or the machine tool 400.

[0023] In the following, the transport mode in which the transport device 300 transports a tool from the work station 200 to the tool storage unit 250 or the machine tool 400, or the transport mode in which the transport device 300 transports a tool from the tool storage unit 250 to the machine tool 400, is also referred to as “loading”.

[0024] In addition, the transport mode in which the transport device 300 transports a tool from the tool storage unit 250 or the machine tool 400 to the work station 200, or the transport mode in which the transport device 300 transports a tool from the machine tool 400 to the tool storage unit 250, is also referred to as "transporting."

[0025] In addition, the term "transportation device" in this specification is a concept that includes various devices having a function of transporting tools. In the following, a 4- to 7-axis driven articulated robot will be described as an example of the transportation device 300, but the transportation device 300 is not limited to an articulated robot. As an example, the transportation device 300 may be a 2- to 3-axis driven Cartesian robot (autoloader). Alternatively, the transportation device 300 may be a self-propelled robot.

[0026] Conveyance device 300 includes, for example, arm robot 330, rail 331, and dolly 332. Arm robot 330 is fixed onto dolly 332. Dolly 332 is configured to be able to run on rail 331 (conveyance path). Tool storage unit 250 and machine tool 400 are disposed parallel to and on either side of rail 331 along rail 331.

[0027] Machine tool 400 is one of the destinations of tools transferred by transfer device 300. Although six machine tools 400A-400F are shown as machine tools 400 in Fig. 1, the number of machine tools 400 constituting production system 10 may be two or more. Machine tool 400 machines a workpiece using a designated tool according to a pre-designed machining program.

[0028] As used herein, the "machine tool" is a concept encompassing various devices having a function of processing workpieces. The machine tool 400 may be a horizontal machining center, or may be a vertical machining center. Alternatively, the machine tool 400 may be a lathe, an additional processing machine, or other cutting or grinding machines.

[0029] Note that in the above description, an example in which the production system 10 includes the work station 200 has been described, but the production system 10 may not include the work station 200.

[0030] <B. Drive Mechanisms of Production System 10> Next, with reference to FIG. 2, various drive mechanisms in the production system 10 will be described. FIG. 2 is a diagram showing a configuration example of the drive mechanisms of the production system 10.

[0031] As shown in FIG. 2, the production system 10 includes a control unit 50, remote I / O (Input / Output) units 71 to 73, a work station 200, a transfer device 300, and a machine tool 400.

[0032] As used herein, the "control unit" means a device that controls the production system 10. The device configuration of the control unit 50 is arbitrary. The control unit 50 may be composed of a single control unit or a plurality of control units. In the example of FIG. 2, the control unit 50 is composed of a management device 100, a PLC 150, and the above-described operation terminal 200A. Further, the control unit 50 may include a CNC (Computer Numerical Control) 401.

[0033] The management device 100 is a main computer that manages the production system 10. The management device 100 may be composed of one computer or a plurality of computers. The PLC 150 is configured to be communicable with various industrial devices for automating the processing steps and controls the industrial devices. The operation terminal 200A is a terminal for receiving various operations related to the loading and unloading of tools.

[0034] The management device 100, the PLC 150, and the operation terminal 200A may be connected to a network NW1. The management device 100, the PLC 150, and the operation terminal 200A may be connected for communication by wire or wirelessly. EtherNET (registered trademark) or the like is adopted for the network NW1. The management device 100 and the operation terminal 200A send control commands to the PLC 150 via the network NW1. The control commands specify the tool to be transported, the destination of the tool, start / stop of transport of the tool, and the like.

[0035] The remote I / O units 71 to 73 and the PLC 150 are connected to a network NW2. It is preferable to use a field network that performs periodic communication and guarantees the arrival time of data for the network NW2. As a field network that performs such periodic communication, EtherCAT (registered trademark), EtherNet / IP (registered trademark), CC-Link (registered trademark), CompoNet (registered trademark), or the like is used.

[0036] The work station 200 includes one or more motor drivers 234 and one or more motors 235. In the example of Figure 2, two motor drivers 234A, 234B and two motors 235A, 235B are shown.

[0037] A remote I / O unit 71 is installed in or near the work station 200. The remote I / O unit 71 mediates data exchange between various drive units (e.g., motor driver 234) in the work station 200 and the PLC 150. As an example, the motor driver 234 receives a control command from the PLC 150 via the remote I / O unit 71 at regular intervals, and controls the drive of the motor 235 in accordance with the control command.

[0038] The motor 235A, for example, controls the driving of a magazine M1 (see FIG. 12) in the work station 200, which will be described later. The motor 235B, for example, controls the driving of an ATC (Automatic Train Control) 238 (see FIG. 12) in the work station 200, which will be described later.

[0039] The motor driver 234 may be, for example, a driver for a servo motor or a driver for a stepping motor, and the motor 235 may be a servo motor or a stepping motor.

[0040] The transport device 300 includes one or more motor drivers 334 and one or more motors 335. In the example of Fig. 2, two motor drivers 334A and 334B and two motors 335A and 335B are shown.

[0041] A remote I / O unit 72 is installed in or near the transport device 300. The remote I / O unit 72 mediates data exchange between various drive units (e.g., motor driver 334) in the transport device 300 and the PLC 150. As an example, the motor driver 334 receives a control command from the PLC 150 via the remote I / O unit 72 at regular intervals, and controls the drive of the motor 335 according to the control command.

[0042] The motor 335A, for example, controls the driving of the above-mentioned cart 332 (see FIG. 1). The motor 335B, for example, controls the driving of the arm robot 330 (see FIG. 1). The motors 335B are provided according to the number of joints of the arm robot 330.

[0043] The motor driver 334 may be, for example, a driver for a servo motor or a driver for a stepping motor, and the motor 335 may be a servo motor or a stepping motor.

[0044] Inside or around the machine tool 400, a remote I / O unit 73 is installed. The machine tool 400 includes a CNC 401. The remote I / O unit 73 mediates the data exchange between the PLC 150 and the CNC 401. The CNC 401 controls various drive mechanisms inside the machine tool 400 according to a pre-designed machining program, for example, based on receiving a machining start command from the PLC 150.

[0045] <Overview of the display function of C. ranking information> Next, with reference to FIG. 3, a function for assisting an operator in preparing tools will be described.

[0046] The production system 10 stores spare tools of the same type in case of occurrence of tool life, tool damage, etc., or when using the same type of tools simultaneously in the machine tool 400. Among the spare tools, there are spare tools with low usage frequency and spare tools with high usage frequency. If a large number of spare tools with low usage frequency are stored in the production system 10, the tool storage space is wasted. On the other hand, if the spare tools with high usage frequency are insufficient, the machining stops and the machining efficiency decreases. Therefore, the production system 10 displays the occurrence amount of events generated for various tools as ranking information in order to appropriately determine the spare tools that the operator should prepare and the spare tools that do not need to be prepared.

[0047] The "occurrence amount of events" mentioned here is a concept including the occurrence times of events, the length of the occurrence time of events, and the occurrence frequency of events. Hereinafter, as an example of the "occurrence amount of events", the "occurrence times of events" will be taken as an example for explanation.

[0048] In preparation for setting a spare tool in the production system 10, the worker first registers tool information in the production system 10. The contents input in the registration work include, for example, attribute information of the tool. The attribute information is information indicating the characteristics of the tool, such as the tool shape or the tool condition. As an example, the attribute information includes the tool diameter, tool length, and tool life. The worker sets the tool for which the registration work has been completed in the work station 200. In this way, the tool is stored in the production system 10.

[0049] 3 is a diagram showing an outline of the flow of the ranking information display function. In step S10, the control unit 50 of the production system 10 acquires the tool database 130 that specifies information about each tool. The tool database 130 specifies information about each tool in the production system 10. The information includes, for example, the tool classification to which each tool belongs.

[0050] In step S12, the control unit 50 counts the number of occurrences of predetermined events that occur for each tool in the production system 10 by tool classification. Hereinafter, the events are also referred to as "tool events." The number of occurrences of the tool events is an index for determining which tools an operator should prepare and which tools do not need to prepare, and is an index that correlates with a shortage of tools.

[0051] In step S14, control unit 50 outputs ranking information 80 according to the number of times a tool event has occurred. In the example of Fig. 3, ranking information 80 is displayed on display 206 of operation terminal 200A. As another example, ranking information 80 may be displayed on a display of management device 100. As yet another example, ranking information 80 may be displayed on a display of machine tool 400.

[0052] 3, the ranking information 80 shows information indicating the tool classification and the number of times that tool events have occurred, sorted by tool classification and in order of the number of times that tool events have occurred. By checking the tool classification with a high number of tool events, the worker can recognize the tools that should be prepared. On the other hand, by checking the tool classification with a low number of tool events, the worker can recognize the tools that do not need to be prepared.

[0053] Preferably, the control unit 50 monitors the number of occurrences of a plurality of types of tool events and outputs the number of occurrences of each type of tool event as the ranking information 80.

[0054] As an example, the control unit 50 monitors the number of occurrences of each of a first tool event and a second tool event. The second tool event is different from the first tool event. In this case, the ranking information 80 includes a counting result for each of the first tool event and the second tool event.

[0055] More specifically, the ranking information 80 shows information indicating the tool classification, the number of occurrences of the first tool event, and the number of occurrences of the second tool event, sorted by tool classification and in order of the number of occurrences of the first tool event. In this way, the number of occurrences of multiple types of tool events is displayed as the ranking information 80, so that the worker can more accurately determine whether or not a tool needs to be prepared.

[0056] Preferably, the control unit 50 accepts a selection operation of either the first tool event or the second tool event. The selection operation is accepted, for example, by a button displayed on the ranking information 80. The control unit 50 updates the ranking information 80 according to the order of occurrence counts of the tool events selected by the selection operation.

[0057] As an example, when the control unit 50 receives an operation from an operator to select the first tool event, it sorts the aggregation results in the order of the occurrence frequency of the first tool event. On the other hand, when the control unit 50 receives an operation from an operator to select the second tool event, it sorts the aggregation results in the order of the occurrence frequency of the second tool event. Thereby, the operator can analyze more detailedly whether it is necessary to prepare a spare tool.

[0058] <D. Functional Configuration of Production System 10> Next, with reference to FIGS. 4 to 10, the functional configuration of the production system 10 will be described. FIG. 4 is a diagram showing an example of the functional configuration of the production system 10.

[0059] As shown in FIG. 4, the production system 10 includes a control unit 50. The control unit 50 includes, as functional components, a schedule generation unit 52, a monitoring unit 54, and an output unit 62. These functional components will be described in order below.

[0060] Note that each functional component may be implemented in any device within the production system 10. Part or all of the functional configuration shown in FIG. 4 may be implemented in the above-described management device 100 (see FIG. 2), or may be implemented in the above-described PLC 150 (see FIG. 2), or may be implemented in the above-described operation terminal 200A (see FIG. 2), or may be implemented in the above-described CNC 401 (see FIG. 2).

[0061] (D1. Schedule Generation Unit 52) First, with reference to FIGS. 5 to 7, the function of the schedule generation unit 52 shown in FIG. 4 will be described.

[0062] The schedule generation unit 52 generates a transfer schedule 126 shown in FIG. 7 based on the machining setting 123 shown in FIG. 5 and the workpiece database 124 shown in FIG. 6.

[0063] 5 is a diagram showing an example of the processing setting 123. The worker registers the workpiece to be processed in advance by registering the processing setting 123. The processing setting 123 is registered by the worker, for example, in the above-mentioned management device 100 or the above-mentioned operation terminal 200A. The contents registered by the worker include, for example, identification information of the workpiece to be processed, the number of workpieces to be processed, and the processing order of the workpieces.

[0064] In the example of Figure 5, a processing task for 10 workpieces "A", a processing task for 8 workpieces "D", a processing task for 5 workpieces "C", and a processing task for 4 workpieces "B" are registered in processing order.

[0065] 6 is a diagram showing an example of the workpiece database 124. As an example, the workpiece database 124 associates, with the type of workpiece to be machined, a machining program for realizing the machining of the workpiece, a tool to be used when machining the workpiece, a machining time required for machining the workpiece, and other information related to the machining of the workpiece.

[0066] The machining program defined in the work database 124 is registered by an operator, for example, in the above-mentioned management device 100, the above-mentioned operation terminal 200A, or the above-mentioned machine tool 400. The machining program may be generated in any manner. As an example, some machine tools 400 have a function for automatically generating a machining program by having an operator answer questions in an interactive format. The machining program is generated, for example, by this function. Alternatively, the machining program may be designed by an operator writing program code.

[0067] The tools to be used, which are defined in the workpiece database 124, are set in advance by a user, for example. Alternatively, the tools to be used may be specified from a machining program. More specifically, a command code for calling the tools to be used is defined in the machining program. The command code is, for example, a T-code for specifying the tool to be attached to the spindle. The schedule generating unit 52 searches for the T-code from each machining program to specify the identification information of the tool to be used in machining each workpiece.

[0068] The machining time defined in the workpiece database 124 is, for example, input in advance by an operator. Alternatively, the machining time may be calculated from the past machining results of each workpiece.

[0069] The schedule generating unit 52 refers to the workpiece database 124 and specifies the machining time for each workpiece defined in the machining setting 123. Next, the schedule generating unit 52 generates a tool transport schedule 126 for each machining based on the specified machining time, the number of each workpiece defined in the machining setting 123, and the machining sequence of each workpiece defined in the machining setting 123.

[0070] Fig. 7 is a diagram showing an example of the transfer schedule 126. In the example of Fig. 7, the transfer schedule 126 specifies, for each tool to be transferred, the identification information of the tool, the scheduled transfer date and time of the tool, the transfer origin of the tool, and the transfer destination of the tool.

[0071] The identification information of the tool defined in the transfer schedule 126 is information for uniquely identifying the tool. The identification information is assigned in advance to each tool. As an example, the identification information may be indicated by a tool number such as ID (Identification) or may be indicated by a tool name.

[0072] The planned transfer date and time defined in the transfer schedule 126 represents the start timing of tool transfer. In the example of Fig. 7, the start timing is defined by a date and time, but the start timing may be defined by the remaining time from the present until the start of transfer, or may be defined by other information capable of representing the start timing.

[0073] The transfer origin defined in the transfer schedule 126 is information indicating the current storage location of the tool. The transfer origin is defined by information for uniquely identifying a location in the production system 10. As an example, the transfer origin indicates the storage position of the tool in the work station 200, the storage position of the tool in the tool storage unit 250, the storage position of the tool in the transfer device 300, or the storage position of the tool in the machine tool 400. These storage positions are indicated, for example, by coordinate values.

[0074] The transfer destination defined in the transfer schedule 126 is information indicating the destination of the tool transfer by the transfer device 300. The transfer destination is defined by information for uniquely identifying a location within the production system 10. As an example, the transfer destination indicates the storage position of the tool within the work station 200, the storage position of the tool within the tool storage unit 250, the storage position of the tool within the transfer device 300, or the storage position of the tool within the machine tool 400. These storage positions are indicated, for example, by coordinate values.

[0075] (D2. Monitoring Department 54) Next, the function of the monitoring unit 54 shown in FIG. 4 will be described.

[0076] The monitoring unit 54 monitors whether or not a tool event has occurred for each tool in the production system 10, and counts the number of times the tool event has occurred for each tool. The type of tool event monitored by the monitoring unit 54 may be one, or two or more types. Preferably, the monitoring unit 54 monitors a plurality of tool events of different types.

[0077] The monitoring unit 54 includes, as functional components for monitoring the occurrence of various tool events, a transported tool monitoring unit 56, a missing tool monitoring unit 58, and an unavailable tool monitoring unit 60. These functions will be described below in order.

[0078] (a) Transport tool monitoring unit 56 The function of the transport tool monitoring unit 56 shown in FIG. 4 will be described with reference to FIG.

[0079] The transported tool monitoring unit 56 monitors, as an example of a tool event, an event indicating that the transport device 300 has transported a tool to the machine tool 400. More specifically, the transport device 300 transports a tool at a designated transport source to a designated transport destination in accordance with the above-mentioned transport schedule 126 (see FIG. 7). At this time, the transported tool monitoring unit 56 counts up the number of transports of each tool every time the tool is carried into the machine tool 400.

[0080] The number of times the tool is transported is stored, for example, in the tool database 130 shown in Fig. 8. Fig. 8 is a diagram showing an example of the tool database 130.

[0081] The tool database 130 defines information on each tool managed by the production system 10. In the example of Fig. 8, the tool database 130 associates, as information on each tool, the identification information of the tool, the tool classification assigned to the tool, the number of times the tool has been transported, the number of times the tool is in short supply, the available amount of the tool, the current amount of use of the tool, the remaining life of the tool, and the state of the tool.

[0082] The tool identification information defined in the tool database 130 is information for uniquely identifying a tool. The identification information is assigned in advance to each tool. As an example, the identification information may be indicated by a tool number such as an ID or may be indicated by a tool name.

[0083] The tool classification defined in the tool database 130 is information indicating the type of tool, and is assigned in advance to each tool. The tool classification is set in advance by an operator. The setting of the tool classification may be accepted, for example, by the management device 100 or by the work station 200. The type may be indicated by a group number such as an ID, or may be indicated by a group name.

[0084] The number of transfers defined in the tool database 130 indicates the number of times a tool is transferred from a predetermined transfer source to a predetermined transfer destination. Examples of the transfer source of the tool include the work station 200, the tool storage unit 250, and the machine tool 400. Examples of the transfer destination of the tool include the work station 200, the tool storage unit 250, and the machine tool 400.

[0085] Preferably, the transported tool monitoring unit 56 monitors a transport event of a tool from the work station 200 or the tool storage unit 250 to the machine tool 400. The transported tool monitoring unit 56 counts up the number of transports of the target tool based on the occurrence of the transport event.

[0086] (b) Missing tool monitoring section 58 Next, with continuing reference to FIG. 8, the function of the tool shortage monitor unit 58 shown in FIG. 4 will be described with reference to FIG.

[0087] The shortage tool monitoring unit 58 monitors an event indicating a shortage of a tool as an example of a tool event. More specifically, the transport device 300 transports a designated tool to a designated destination according to the above-mentioned transport schedule 126 (see FIG. 7). At that time, the shortage tool monitoring unit 58 refers to the storage information 132 shown in FIG. 9 to determine whether the tool to be transported is not present in the production system 10.

[0088] 9 is a diagram showing an example of the storage information 132. The storage information 132 defines information on the tools stored in each of the tool storage locations in the production system 10.

[0089] The storage location defined in the storage information 132 is information for uniquely identifying the storage location of the tool. The storage information may be indicated by a number such as an ID, or may be indicated by the name of the storage location.

[0090] The storage location specified in the storage information 132 indicates, for example, the storage position of the tool within the work station 200, the storage position of the tool within the tool storage section 250, the storage position of the tool within the conveying device 300, or the storage position of the tool within the machine tool 400.

[0091] The coordinate values ​​defined in the storage information 132 are information for identifying the position of each storage location. The coordinate values ​​may be defined in two dimensions or in three dimensions. In the example of Fig. 9, the coordinate values ​​are indicated by a coordinate value "x" in a direction parallel to the rail 331 and a coordinate value "z" in a vertical direction.

[0092] The identification information of the tool defined in the storage information 132 is information for uniquely identifying the tool. The identification information may be indicated by a tool number such as an ID, or may be indicated by a tool name.

[0093] The shortage tool monitoring unit 58 determines that a tool to be transported, which is indicated in the transport schedule 126, is in short supply when the tool is not specified in the storage information 132. In this case, the shortage tool monitoring unit 58 counts up the number of times the target tool is in short supply in the above-mentioned tool database 130.

[0094] (c) Disabled tool monitoring section 60 Next, the function of the disabled tool monitor unit 60 shown in FIG. 4 will be described with reference to the above-mentioned FIG.

[0095] The disabled tool monitoring unit 60 monitors, as an example of a tool event, an event indicating that each tool in the production system 10 has become disabled. The state of a tool is identified based on, for example, information defined in the tool database 130 shown in FIG.

[0096] The usable amount specified in the tool database 130 indicates the maximum usable amount of a tool from when it is new until the end of its life. The usable amount of each tool is determined in advance by the tool manufacturer or the like, and is registered in advance in the tool database 130. The "amount" here is a concept that includes time, distance, and number of times.

[0097] The current usage amount defined in the tool database 130 indicates the amount of usage of the tool from when it was new to the present. The term "amount" here is a concept that includes time, distance, and number of times.

[0098] The remaining life defined in the tool database 130 indicates the remaining amount of tool usage from the present until the end of the tool's life. The term "amount" here is a concept that includes time, distance, and number of times. Typically, the remaining life corresponds to the result of subtracting the current amount of tool usage from the maximum usable amount of the tool.

[0099] The current usage and remaining life defined in the tool database 130 are updated successively. The current usage and remaining life are monitored by various methods. As an example, the machining program of the machine tool 400 is defined in G-code, and includes a tool exchange command for specifying a tool to be attached to the spindle, and a drive command for rotating / feeding the spindle and the tool. The production system 10 specifies the type of tool to be used for machining the workpiece based on the tool exchange command defined in the machining program. Next, the production system 10 starts counting down the remaining life of the tool based on the execution of the drive command defined in the machining program. Next, the production system 10 stops counting down the remaining life of the tool based on the execution of a stop command or a command in the final line defined in the machining program.

[0100] The tool states defined in the tool database 130 include, for example, an available state indicating that the tool is available for use in machining, and an unavailable state indicating that the tool is unavailable for use in machining.

[0101] In the example of Fig. 8, a usable tool is shown as either "normal" or "life warning". "Life warning" indicates that the tool is nearing the end of its life. As an example, the disabled tool monitor 60 changes the status of a tool in the tool database 130 from "normal" to "life warning" when the remaining life of the tool falls below a predetermined threshold.

[0102] In the example of Fig. 8, the unusable tool is indicated as "out of service life" or "damaged". An "unusable tool" means a tool that is not recommended for use in machining a workpiece. Typically, an "unusable tool" refers to a tool other than a "usable tool".

[0103] As an example, a tool in an unusable state includes a tool whose life has expired due to wear, etc. For example, when the life of a tool has reached zero, the disabled tool monitoring unit 60 changes the state of the tool in the tool database 130 from “life warning” to “life expired.”

[0104] As another example, a tool in an unusable state includes a damaged tool. Types of damage to a tool include, for example, deformation of the tool due to application of excessive force, chipping of the tool blade, and breakage of the tool. Whether or not a tool is in a "damaged state" is detected, for example, by a damage sensor provided in machine tool 400.

[0105] In one aspect, the damage sensor includes a pressure sensor provided on a spindle in machine tool 400. The pressure sensor detects a force applied to the spindle during machining of a workpiece. The dead tool monitoring unit 60 monitors an output value of the pressure sensor, and determines that an excessive force has been applied to the tool when the output value exceeds a predetermined value. When the dead tool monitoring unit 60 determines that an excessive force has been applied to the tool, it determines that the tool may have been bent, and changes the state of the tool to "damaged state."

[0106] In another aspect, the damage sensor includes a measurement sensor for measuring the outer shape of a tool. The measurement sensor is, for example, a distance sensor, a touch sensor, or other sensor capable of detecting the outer shape of a tool. As an example, an example of detecting damage to a tool using a distance sensor will be described. The machine tool 400 rotates a tool attached to a spindle in front of the distance sensor to obtain time series data representing the outer shape of the tool from the distance sensor. The dead tool monitoring unit 60 calculates the difference between the time series data and a predetermined normal value, and determines that the tool is chipped when the absolute value of the difference result exceeds a predetermined value. When the dead tool monitoring unit 60 determines that the tool is chipped, it changes the state of the tool to "damaged state."

[0107] In still another aspect, the damage sensor includes a camera for photographing a tool in machine tool 400. The dead tool monitoring unit 60 determines whether or not the tool is damaged by performing predetermined image processing on the image obtained from the camera. When the dead tool monitoring unit 60 determines that the tool is damaged, it changes the state of the tool to "damaged state."

[0108] (D3. Output section 62) Next, with reference to Fig. 8 described above and Fig. 10, the function of the output unit 62 shown in Fig. 4 will be described. Fig. 10 is a diagram showing ranking information 80, which is an example of the output result of the output unit 62.

[0109] 10 with reference to the tool database 130. The ranking information 80 is displayed, for example, on the display 206 of the operation terminal 200A. Alternatively, the ranking information 80 may be displayed on the display of the management device 100. Alternatively, the ranking information 80 may be displayed on the display of the machine tool 400.

[0110] The ranking information 80 refers to the above-mentioned tool database 130 and tally up the occurrence counts of various tool events by tool classification. Next, the output unit 62 displays the tally up results in order of the occurrence count of a predetermined tool event. The tally up results may be displayed in descending order or ascending order.

[0111] In the example of Figure 10, the ranking information 80 includes information 85A indicating the ranking of the number of times a tool event occurred, information 85B indicating the tool classification, information 85C indicating the number of times a tool transport occurred, information 85D indicating the number of times a tool shortage occurred, and information 85E indicating the number of times a tool was unavailable.

[0112] The tool events that are the basis for sorting can be arbitrarily selected by the user. The basis can be switched, for example, by pressing one of the sort buttons B1 to B3.

[0113] The sort button B1 is a button for using the number of times tool transports have occurred as the sorting criterion. The sort button B1 includes an ascending order button and a descending order button. As an example, the ascending order button is represented by an up arrow, and the descending order button is represented by a down arrow. When the ascending order button is pressed, the output unit 62 sorts the various tally results in descending order of the number of times tool transports have occurred. On the other hand, when the descending order button is pressed, the output unit 62 sorts the various tally results in descending order of the number of times tool transports have occurred.

[0114] The sort button B2 is a button for using the number of times tool shortages have occurred as a sorting criterion. The sort button B2 includes an ascending order button and a descending order button. As an example, the ascending order button is represented by an up arrow, and the descending order button is represented by a down arrow. When the ascending order button is pressed, the output unit 62 sorts the various tally results in descending order of the number of times tool shortages have occurred. On the other hand, when the descending order button is pressed, the output unit 62 sorts the various tally results in descending order of the number of times tool shortages have occurred.

[0115] The sorting button B3 is a button for using the number of occurrences of tool unavailability as a sorting criterion. The sorting button B3 includes an ascending order button and a descending order button. As an example, the ascending order button is represented by an upward arrow, and the descending order button is represented by a downward arrow. When the ascending order button is pressed, the output unit 62 sorts various aggregation results in descending order of the number of occurrences of tool unavailability. On the other hand, when the descending order button is pressed, the output unit 62 sorts various aggregation results in ascending order of the number of occurrences of tool unavailability.

[0116] <E. Modification Example of Ranking Information 80> Next, with reference to FIG. 11, a modification example of the above-described ranking information 80 will be described. FIG. 11 is a diagram showing ranking information 80A according to the modification example.

[0117] In this modification example, the production system 10 stores the date and time when various tool events occurred in the tool database 130. Then, the output unit 62 extracts data belonging to the specified period from the data included in the tool database 130, and aggregates the number of occurrences of various tool events separately for each tool classification using the extracted data.

[0118] The specified period is received, for example, in the input field 82. The input field 82 receives, for example, the input of a start date and an end date. The period from the start date to the end date is regarded as the specified period.

[0119] In addition, the production system 10 stores the cause information of various tool events in the tool database 130. The cause information is stored in association with the occurrence date and time and the identification information of the tool.

[0120] As an example of the above cause information, the identification information of the processing program that is the source of the tool event can be mentioned. The identification information is information for uniquely identifying the processing program. Examples of the identification information include, for example, the processing program name, the processing program ID, and the like.

[0121] Another example of the cause information is identification information of the machine tool that is the source of the tool event. The identification information is information for uniquely identifying the machine tool. Examples of the identification information include the machine tool name and the machine tool ID.

[0122] The ranking information 80A includes information 90A indicating the ranking of the number of times a tool event has occurred, information 90B indicating the tool classification, information 90C indicating the number of times a tool shortage has occurred, information 90D indicating an event type related to a tool unusable state, and information 91A to 91C for identifying the cause of the tool event.

[0123] In the example of FIG. 11, each of the information 91A to 91C indicates the number of times a tool event has occurred for each combination of the machine tool that is the source of the tool event and the machining program that is the source of the tool event.

[0124] More specifically, the disabled tool monitoring unit 60, based on the detection of the damaged state of the tool, identifies the machine tool that caused the damage and the machining program that caused the damage. After that, the disabled tool monitoring unit 60 stores the identification information of the identified machine tool and the identification information of the identified machining program in the tool database 130 in association with the identification information of the damaged tool.

[0125] When the output unit 62 receives a counting instruction, the output unit 62 counts the number of occurrences of tool damage events separately for at least one of the machine tool and the machining program, and separately for the tool classification. Preferably, the number of occurrences of tool damage events is counted separately for the tool classification, the machine tool, and the machining program.

[0126] In the example of Figure 11, for tools belonging to tool classification "720156," preparation was not completed in time 15 times, seven breakages occurred when machine tool "MC_01" was executing machining program "7203," three breakages occurred when machine tool "MC_01" was executing machining program "7702," and one breakage occurred when machine tool "MC_03" was executing machining program "7777."

[0127] Similarly, for tools belonging to tool classification "154687", eight breaks were not prepared in time, four breaks occurred when machine tool "MC_04" was executing machining program "6125", and four breaks occurred when machine tool "MC_01" was executing machining program "7203".

[0128] Similarly, for a tool belonging to tool classification "541468", it shows that preparation was not completed in time once, and that a breakage occurred once when machine tool "MC_04" was executing machining program "5822".

[0129] The display mode of the ranking information 80A is not limited to the example shown in Fig. 11. As an example, assume that a user performs an operation to search for tools that frequently break. The ranking information 80A displayed thereby includes information indicating the tool classification, the number of breakage occurrences, and information on the cause of breakage, sorted by tool classification and in order of the number of breakage occurrences. The cause information may include, for example, at least one of information indicating the number of breakages by machine tool that caused the tool breakage, information indicating the number of breakages by machining program that caused the tool breakage, and the total number of tools belonging to the tool classification.

[0130] As another example, assume that an operation of searching for frequently lacking tools is performed by a user. The ranking information 80A displayed thereby includes, for each tool classification and in the order of the number of occurrences of the lack, information indicating the tool classification, the number of occurrences of the tool lack, and information on the cause of the tool lack. Examples of the cause information include at least one of information indicating the number of occurrences of the tool lack for each machine tool that is the source of the tool lack, information indicating the number of occurrences of the tool lack for each processing program that is the source of the tool lack, and the total number of tools belonging to the above tool classification.

[0131] As yet another example, assume that an operation of searching for frequently lacking tools is performed by a user. The ranking information 80A displayed thereby includes, for each tool classification and in the order of the length of time during which the tool lack has occurred, information indicating the tool classification, the length of time of the occurrence of the tool lack, and information on the cause of the tool lack. The length of the occurrence time is, for example, the time from when the tool lack is detected until the tool lack is resolved. This time may be indicated by an average value or a median value. Examples of the cause information include at least one of information indicating the number of occurrences of the tool lack for each machine tool that is the source of the tool lack, information indicating the number of occurrences of the tool lack for each processing program that is the source of the tool lack, and the total number of tools belonging to the above tool classification.

[0132] <F. Process of Loading Tools into Tool Storage Unit 250> Next, with reference to FIG. 12, the process of loading tools from the work station 200 into the tool storage unit 250 will be described. FIG. 12 is a diagram schematically showing the flow of the process of loading tools from the work station 200 into the tool storage unit 250.

[0133] In step S1, the operator sets the tool holder H1 to be loaded into the magazine M1 within the work station 200. The tool to be loaded is attached to the tool holder H1. The number of tool holders that can be stored in the work station 200 is less than the number of tool holders that can be stored in the tool storage unit 250.

[0134] A barcode or QR code (registered trademark) reader (not shown) is provided near the position where the worker sets the tool holder H1 in the magazine M1. The reader reads the barcode or QR code attached to the tool holder H1. This allows the identifier of the tool holder H1 to be loaded to be read. When the worker has completed setting the tool holder H1, he or she performs a completion operation on the operation terminal 200A.

[0135] Next, in step S2, the control unit 50 controls the motor 235A (see FIG. 2) to drive the magazine M1 in the work station 200. As a result, the control unit 50 moves the tool holder H1 to be carried in to a predetermined tool exchange position. The ATC 238 is provided near the tool exchange position. The ATC 238 removes the tool holder H1 at the tool exchange position from the magazine M1 and rotates it half a turn.

[0136] Next, in step S3, the arm robot 330 removes the tool holder H1 from the ATC 238, and places the tool holder H1 in the temporary storage area 336 on the cart 332. If there are other tool holders to be carried in, the processes of steps S1 to S3 are repeated within the range not exceeding the maximum number of tool holders that can be stored in the temporary storage area 336.

[0137] Next, in step S4, the control unit 50 controls the motor 335A to drive the cart 332. As a result, the control unit 50 moves the cart 332 to the instructed tool loading position. The tool loading position is determined, for example, based on the above-mentioned storage information 132 (see FIG. 9).

[0138] The control unit 50 determines the storage destination of the tool holder H1 by referring to the empty storage locations defined in the storage information 132. When there are multiple empty storage locations, the control unit 50 may determine one storage location randomly selected from the multiple empty storage locations as the storage destination, or may determine one of the multiple empty storage locations that is closer to the transport device 300 as the storage destination.

[0139] Next, in step S5, the arm robot 330 removes the tool holder H1 to be carried in from the temporary storage location 336, and stores the tool holder H1 in the determined storage destination. After that, the control unit 50 updates the storage information 132 by associating the identifier of the tool holder H1 with the corresponding storage location.

[0140] If there are other tool holders to be carried in remaining in the temporary storage location 336, the control unit 50 repeats the steps S4 and S5 until there are no more tool holders on the temporary storage location 336.

[0141] <G. Tool Loading Process into the Machine Tool 400> Next, with reference to FIG. 13, the tool loading process following FIG. 12 will be described. FIG. 13 is a diagram schematically showing the flow of the tool loading process from the tool storage unit 250 to the machine tool 400.

[0142] The control unit 50 identifies the tool to be carried in and the destination machine tool 400 according to the above-described transfer schedule 126. Suppose the tool holder H2 is identified as the tool to be carried in in this case. In this situation, the control unit 50 identifies the storage location of the tool holder H2 from the above-described storage information 132 (see FIG. 9). After that, the control unit 50 drives the carriage 332 by controlling the motor 335A (see FIG. 2), and moves the carriage 332 in front of the storage location of the tool holder H2.

[0143] Next, in step S11, the arm robot 330 takes out the tool holder H2 to be transferred from the tool storage unit 250, and places the tool holder H2 on the temporary storage location 336 on the carriage 332.

[0144] Next, in step S12, the control unit 50 drives the carriage 332 to the position of the destination machine tool 400 by controlling the motor 335A.

[0145] Next, in step S13, the arm robot 330 delivers the tool holder H2 to the ATC 438 provided in the machine tool 400 at the destination. Thereafter, the ATC 438 sets the tool holder H2 in the magazine within the machine tool 400.

[0146] <H. Process of Removing Tools to the Working Station 200> Next, referring to FIG. 14, the process of removing tools will be described. FIG. 14 is a diagram schematically showing the flow of the process of removing tools from the machine tool 400 to the working station 200.

[0147] Assume that at a certain timing, the control unit 50 receives an instruction to retrieve a tool holder. Based on this, the control unit 50 identifies the tool holder to be retrieved from among the tool holders stored in the machine tool 400. As a result, assume that the tool holder H3 is identified as the one to be retrieved. The control unit 50 refers to the above-described storage information 132 (see FIG. 9) to identify the storage location of the tool holder H3. Thereafter, the control unit 50 drives the carriage 332 by controlling the above-described motor 335A (see FIG. 2) and moves the carriage 332 in front of the machine tool 400 that stores the tool holder H3. Next, the arm robot 330 takes out the tool holder H3 from the machine tool 400 and places the tool holder H3 in the temporary placement area 336 on the carriage 332. Also, the control unit 50 deletes the identifier of the tool holder H3 from the storage information 132 and rewrites the storage source of the tool holder H3 to an empty state.

[0148] Next, in step S21, the control unit 50 drives the carriage 332 by controlling the above-described motor 335A and moves the carriage 332 from in front of the machine tool 400 to in front of the working station 200.

[0149] Next, in step S22, the arm robot 330 removes the tool holder H3 to be removed from the temporary placement area 336 and attaches the tool holder H3 to the above-described ATC 238 (see FIG. 12) provided in the working station 200. Thereafter, the ATC 238 attaches the tool holder H3 to the magazine M1 of the working station 200.

[0150] Next, in step S23, the control unit 50 drives the magazine M1 by controlling the above-described motor 235A to move the tool holder H3 to be carried out in front of the outlet. Thereafter, the operator takes out the tool holder H3 to be carried out from the outlet.

[0151] <I. Hardware Configuration of Management Device 100> Next, with reference to FIG. 15, the hardware configuration of the management device 100 shown in FIG. 2 above will be described. FIG. 15 is a diagram showing an example of the hardware configuration of the management device 100.

[0152] The management device 100 includes a control circuit 101, a ROM (Read Only Memory) 102, a RAM (Random Access Memory) 103, a communication interface 104, a display interface 105, an input interface 107, and an auxiliary storage device 120. These components are connected to a bus 110.

[0153] The control circuit 101 is composed of at least one integrated circuit. The integrated circuit can be composed of, for example, at least one CPU (Central Processing Unit), at least one GPU (Graphics Processing Unit), at least one ASIC (Application Specific Integrated Circuit), at least one FPGA (Field Programmable Gate Array), or a combination thereof.

[0154] The control circuit 101 controls the operation of the management device 100 by executing various programs such as a control program 122 and an operating system. Based on receiving an execution command for the control program 122, the control circuit 101 reads the control program 122 from the auxiliary storage device 120 or the ROM 102 to the RAM 103. The RAM 103 functions as a working memory and temporarily stores various data required for the execution of the control program 122.

[0155] A LAN (Local Area Network), an antenna, and the like are connected to the communication interface 104. The management device 100 is connected to a network NW1 via the communication interface 104. As a result, the management device 100 exchanges data with external devices connected to the network NW1. The external devices include, for example, a PLC 150 and a server (not shown).

[0156] A display 106 is connected to the display interface 105. The display interface 105 sends an image signal for displaying an image to the display 106 according to a command from the control circuit 101 or the like. The display 106 displays, for example, an operation screen for receiving an interrupt instruction for processing. The display 106 is, for example, a liquid crystal display, an organic EL (Electro Luminescence) display, or other display device. The display 106 may be configured integrally with the management device 100, or may be configured separately from the management device 100.

[0157] An input device 108 is connected to the input interface 107. The input device 108 is, for example, a mouse, a keyboard, a touch panel, or other device capable of accepting user operations. The input device 108 may be configured integrally with the management device 100, or may be configured separately from the management device 100.

[0158] The auxiliary storage device 120 is a storage medium such as a hard disk or a flash memory, for example. The auxiliary storage device 120 stores a control program 122, the above-described work database 124, the above-described transport schedule 126, the above-described tool database 130, and the above-described storage information 132, etc. These storage locations are not limited to the auxiliary storage device 120 and may be stored in the storage area of the control circuit 101 (for example, cache memory, etc.), ROM 102, RAM 103, other devices (for example, a server, PLC 150, or operation terminal 200A), etc.

[0159] The control program 122 is a program for realizing part or all of the functional configuration shown in FIG. 4 above. The control program 122 may be provided not as a single program but incorporated into a part of any program. Even a program that does not include such a part of the module does not deviate from the gist of the control program 122 according to the present embodiment. Further, part or all of the functions provided by the control program 122 may be realized by dedicated hardware. Further, the management device 100 may be configured in a form such as a so-called cloud service in which at least one server executes part of the processing of the control program 122.

[0160] <Hardware Configuration of J.PLC150> Next, with reference to FIG. 16, an example of the hardware configuration of the PLC 150 shown in FIG. 2 above will be described. FIG. 16 is a diagram showing an example of the hardware configuration of the PLC 150.

[0161] The PLC 150 includes a control circuit 151, a ROM (Read Only Memory) 152, a RAM (Random Access Memory) 153, communication interfaces 154, 155, and an auxiliary storage device 170. These components are connected to a bus 160.

[0162] The control circuit 151 is configured by at least one integrated circuit. The integrated circuit is configured by, for example, at least one CPU, at least one MPU (Micro Processing Unit), at least one ASIC, at least one FPGA, or a combination thereof.

[0163] The control circuit 151 controls the operations of the conveying device 300, the machine tool 400, etc., by executing various programs such as a control program 172. Based on receiving an execution command for the control program 172, the control circuit 151 reads the control program 172 from the auxiliary storage device 170 to the ROM 152. The RAM 153 functions as a working memory, and temporarily stores various data required for the execution of the control program 172.

[0164] A LAN, an antenna, and the like are connected to the communication interface 154. The PLC 150 is connected to the network NW1 via the communication interface 154. As a result, the PLC 150 exchanges data with external devices connected to the network NW1. The external devices include, for example, the management device 100 and a server (not shown).

[0165] The communication interface 155 is an interface for connecting to the network NW2, which is a field network. The PLC 150 exchanges data with external devices connected to the network NW2 via the communication interface 155. The external devices include, for example, the above-mentioned remote I / O units 71 to 73.

[0166] The auxiliary storage device 170 is, for example, a storage medium such as a hard disk or a flash memory. The auxiliary storage device 170 stores a control program 172 and the like. The storage location of the control program 172 is not limited to the auxiliary storage device 170, and may be stored in a storage area (for example, a cache area) of the control circuit 151, the ROM 152, the RAM 153, an external device (for example, a server), or the like.

[0167] The control program 172 is a program for realizing part or all of the functional configuration shown in FIG. 4 described above. The control program 172 may be provided not as a single program but incorporated into a part of any program. In this case, the control processing according to the present embodiment is realized in cooperation with any program. Even a program that does not include such a part of the module does not deviate from the gist of the control program 172 according to the present embodiment. Furthermore, part or all of the functions provided by the control program 172 may be realized by dedicated hardware. Furthermore, the PLC 150 may be configured in a form such as a so-called cloud service in which at least one server executes part of the processing of the control program 172.

[0168] <Hardware Configuration of the Operation Terminal 200A> Next, with reference to FIG. 17, the hardware configuration of the operation terminal 200A shown in FIG. 2 described above will be described. FIG. 17 is a diagram showing an example of the hardware configuration of the operation terminal 200A.

[0169] The operation terminal 200A includes a control circuit 201, a ROM 202, a RAM 203, a communication interface 204, a display interface 205, an input interface 207, and an auxiliary storage device 220. These components are connected to a bus 210.

[0170] The control circuit 201 is constituted by, for example, at least one integrated circuit. The integrated circuit can be constituted by, for example, at least one CPU, at least one GPU, at least one ASIC, at least one FPGA, or a combination thereof.

[0171] The control circuit 201 controls the operation of the operation terminal 200A by executing various programs such as a control program 222 and an operating system. Based on receiving an execution command for the control program 222, the control circuit 201 reads the control program 222 from the auxiliary storage device 220 or the ROM 202 to the RAM 203. The RAM 203 functions as a working memory and temporarily stores various data required for the execution of the control program 222.

[0172] A LAN, an antenna, and the like are connected to the communication interface 204. The operation terminal 200A is connected to the network NW1 via the communication interface 204. As a result, the operation terminal 200A exchanges data with external devices connected to the network NW1. The external devices include, for example, the PLC 150 and a server (not shown).

[0173] A display 206 is connected to the display interface 205. The display interface 205 sends an image signal for displaying an image to the display 206 in accordance with an instruction from the control circuit 201 or the like. The display 206 displays, for example, an operation screen for receiving an instruction to carry in a tool, a tool selection screen for specifying a tool to be transported, or a machine tool selection screen for specifying a machine tool 400 to be transported. The display 206 is, for example, a liquid crystal display, an organic EL display, or other display device. The display 206 may be configured integrally with the operation terminal 200A, or may be configured separately from the operation terminal 200A.

[0174] An input device 208 is connected to the input interface 207. The input device 208 is, for example, a mouse, a keyboard, a touch panel, or other device capable of receiving a user's operation. The input device 208 may be configured integrally with the operation terminal 200A, or may be configured separately from the operation terminal 200A.

[0175] The auxiliary storage device 220 is a storage medium such as a hard disk or a flash memory, for example. The auxiliary storage device 220 stores the control program 222 of the operation terminal 200A and the like. The storage location of the control program 222 is not limited to the auxiliary storage device 220 and may be stored in the storage area of the control circuit 201 (for example, cache memory), ROM 202, RAM 203, an external device (for example, a server), or the like.

[0176] The control program 222 is a program for realizing part or all of the functional configuration shown in FIG. 4 described above. The control program 222 may be provided not as a single program but incorporated into a part of any program. Even a program that does not include such a part of the module does not deviate from the gist of the control program 222 according to the present embodiment. Further, part or all of the functions provided by the control program 222 may be realized by dedicated hardware. Further, the management device 100 may be configured in a form such as a so-called cloud service in which at least one server executes part of the processing of the control program 222.

[0177] Note that the above-described conveyance schedule 126, the above-described tool database 130, and the above-described storage information 132 may be stored in the auxiliary storage device 220 of the operation terminal 200A instead of the management device 100.

[0178] <Hardware Configuration of Machine Tool 400> Next, with reference to FIG. 18, an example of the hardware configuration of the machine tool 400 shown in FIG. 2 described above will be described. FIG. 18 is a diagram showing an example of the hardware configuration of the machine tool 400.

[0179] The machine tool 400 includes a CNC 401, a ROM 402, a RAM 403, a communication interface 404, motor drivers 411A-411D, motors 412A-412D, encoders 413A-413D, ball screws 414A and 414B, and a spindle 415 for mounting a tool. These devices are connected via a bus (not shown).

[0180] The CNC 401 is configured by at least one integrated circuit. The integrated circuit is configured by, for example, at least one CPU, at least one MPU, at least one ASIC, at least one FPGA, or a combination thereof.

[0181] The CNC 401 controls the operation of the machine tool 400 by executing various programs such as a machining program 422. Upon receiving an execution command for the machining program 422, the CNC 401 reads the machining program 422 from the auxiliary storage device 420 to the ROM 402. The RAM 403 functions as a working memory and temporarily stores various data required for the execution of the machining program 422.

[0182] The communication interface 404 is an interface for realizing communication with the PLC 151 via the remote I / O unit 73. The CNC 401 exchanges data with the PLC 151 via the communication interface 404.

[0183] The CNC 401 controls the motor drivers 411A to 411D in accordance with the machining program 422. Each of the motor drivers 411A to 411D may be, for example, a driver for a servo motor or a driver for a stepping motor.

[0184] More specifically, the CNC 401 sequentially outputs a control signal including a target rotation speed (or a target position) to the motor driver 411A. The motor driver 411A calculates the actual rotation speed (or actual position) of the motor 412A from the feedback signal of the encoder 413A, and outputs a current to the motor 412A so that the difference between the actual rotation speed and the target rotation speed becomes small. In this way, the motor driver 411A brings the rotation speed of the motor 412A closer to the target rotation speed while sequentially receiving feedback of the rotation speed of the motor 412A. In this way, the motor driver 411A moves the workpiece placement table connected to the ball screw 414A to an arbitrary position in the X-axis direction.

[0185] Similarly, the CNC 401 sequentially outputs a control signal including a target rotation speed (or target position) to the motor driver 411B. The motor driver 411B calculates the actual rotation speed (or actual position) of the motor 412B from the feedback signal of the encoder 413B, and outputs a current to the motor 412B so that the difference between the actual rotation speed and the target rotation speed becomes small. In this way, the motor driver 411B brings the rotation speed of the motor 412B closer to the target rotation speed while sequentially receiving feedback of the rotation speed of the motor 412B. In this way, the motor driver 411B moves the workpiece placement table connected to the ball screw 414B to an arbitrary position in the Y-axis direction.

[0186] Similarly, the CNC 401 sequentially outputs a control signal including a target rotation speed (or target position) to the motor driver 411C. The motor driver 411C calculates the actual rotation speed (or actual position) of the motor 412C from the feedback signal of the encoder 413C, and outputs a current to the motor 412C so that the difference between the actual rotation speed and the target rotation speed becomes small. In this way, the motor driver 411C brings the rotation speed of the motor 412C closer to the target rotation speed while sequentially receiving feedback of the rotation speed of the motor 412C. In this way, the motor driver 411C moves the spindle 415 to an arbitrary position in the Z-axis direction.

[0187] Similarly, the CNC 401 sequentially outputs a control signal including a target rotational speed (or a target position) to the motor driver 411D. The motor driver 411D calculates the actual rotational speed (or the actual position) of the motor 412D from the feedback signal of the encoder 413D, and outputs a current to the motor 412D so that the difference between the actual rotational speed and the target rotational speed becomes small. In this way, the motor driver 411D approaches the rotational speed of the motor 412D to the target rotational speed while sequentially receiving the feedback of the rotational speed of the motor 412D. Thereby, the motor driver 411D controls the rotational speed of the main shaft 415.

[0188] The auxiliary storage device 420 is a storage medium such as a hard disk or a flash memory, for example. The auxiliary storage device 420 stores a machining program 422 and the like. The storage location of the machining program 422 is not limited to the auxiliary storage device 420, and may be stored in a storage area of the CNC 401 (for example, a cache area), the ROM 402, the RAM 403, an external device (for example, a server), or the like.

[0189] <M. Flowchart related to the update process of the tool database 130> Next, with reference to FIG. 19, the control flow related to the update process of the above-described tool database 130 will be described. FIG. 19 is a diagram showing a flowchart related to the update process of the tool database 130.

[0190] The process shown in FIG. 19 is realized by the control unit 50 of the production system 10 executing a control program. In other aspects, part or all of the process may be executed by circuit elements or other hardware.

[0191] In step S110, the control unit 50 functions as the above-described conveyance tool monitoring unit 56 (see FIG. 4), and determines whether or not a tool event indicating that a tool has been conveyed from the work station 200 or the tool storage unit 250 to the machine tool 400 has occurred. The tool event occurs, for example, based on the arrival of the conveyance timing of the tool defined in the above-described conveyance schedule 126.

[0192] When the control unit 50 determines that a tool event has occurred indicating that a tool has been transported from the work station 200 or the tool storage unit 250 to the machine tool 400 (YES in step S110), the control unit 50 switches control to step S112. Otherwise (NO in step S110), the control unit 50 switches control to step S120.

[0193] In step S112, the control unit 50 functions as the above-mentioned transported tool monitoring unit 56, and counts up the number of tool transports associated with the tool to be transported with reference to the tool database 130 (see FIG. 8). At this time, the control unit 50 also stores in the tool database 130 the date and time when the tool event occurred.

[0194] In step S120, the control unit 50 functions as the above-mentioned tool shortage monitoring unit 58 (see FIG. 4) and determines whether or not a tool event indicating a tool shortage has occurred. The tool event occurs, for example, when a tool to be transported cannot be transported to the machine tool 400.

[0195] If the control unit 50 determines that a tool event has occurred indicating that a tool is insufficient (YES in step S120), the control unit 50 switches control to step S122. Otherwise (NO in step S120), the control unit 50 switches control to step S130.

[0196] In step S122, the control unit 50 functions as the above-mentioned tool shortage monitoring unit 58, and counts up the number of times the tool is in short supply, which is associated with the tool to be transported, by referring to the tool database 130 (see FIG. 8). At this time, the control unit 50 also stores in the tool database 130 the date and time when the tool event occurred.

[0197] In step S130, the control unit 50 functions as the above-described unusable tool monitoring unit 60 (see FIG. 4), and determines whether a tool event indicating that the tool has become unusable has occurred. The tool event occurs, for example, when tool damage is detected.

[0198] When the control unit 50 determines that a tool event indicating that the tool has become unusable has occurred (YES in step S130), the control is switched to step S132. Otherwise (NO in step S130), the control unit 50 returns the control to step S110.

[0199] In step S132, the control unit 50 functions as the above-described unusable tool monitoring unit 60, refers to the tool database 130 (see FIG. 8), and changes the tool state associated with the tool to be transported to the "damaged state". At this time, the control unit 50 also stores the date and time when the tool event occurred in the tool database 130. Preferably, the control unit 50 further stores in the tool database 130 the identification information indicating the machine tool when the tool becomes unusable. Preferably, the control unit 50 further stores in the tool database 130 the identification information indicating the machining program used at that time.

[0200] <Flowchart of the display process of the O. ranking information 80> Next, with reference to FIG. 20, the control flow related to the above-described display process of the ranking information 80 will be described. FIG. 20 is a diagram showing a flowchart of the display process of the ranking information 80.

[0201] The process shown in FIG. 20 is realized by the control unit 50 of the production system 10 executing a control program. In other aspects, part or all of the process may be executed by circuit elements or other hardware.

[0202] In step S150, the control unit 50 determines whether it has received a display operation of ranking information. As an example, the display operation is received by the input device 108 of the management device 100. As another example, the display operation is received by the input device 208 of the operation terminal 200A. At that time, the control unit 50 also receives an input for the target period from the operator.

[0203] When the control unit 50 determines that it has received a display operation of ranking information (YES in step S150), the control is switched to step S152. Otherwise (NO in step S150), the control unit 50 ends the process shown in FIG. 20.

[0204] In step S152, the control unit 50 functions as the above-described output unit 62 (see FIG. 4), refers to the above-described tool database 130, and totals the occurrence times of various tool events by tool classification. Then, the control unit 50 displays the aggregation result. Since the function of the output unit 62 is as described above, the description thereof will not be repeated.

[0205] <P. Modification Example> Note that in the above description, the production system 10 as a tool transfer system has been described, but the production system 10 may not have a tool transfer function. Further, in the above description, the target for generating ranking information based on the occurrence times of tool events that have occurred regarding the generation of tools is not limited to tools, and may be other targets related to processing. The target includes at least one of an event and an object. Examples of the event include setup and processing by an operator. Examples of the object include, in addition to tools, workpieces or pallets.

[0206] The disclosed embodiments should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is shown not by the above description but by the claims, and it is intended that all modifications within the meaning and scope equivalent to the claims are included.

Description of Reference Numerals

[0207] 10 Production system, 50 Control unit, 52 Schedule generation unit, 54 Monitoring unit, 56 Transport tool monitoring unit, 58 Missing tool monitoring unit, 60 Unavailable tool monitoring unit, 62 Output unit, 71 Remote I / O unit, 72 Remote I / O unit, 73 Remote I / O unit, 80 Ranking information, 80A Ranking information, 82 Input field, 85A Information, 85B Information, 85C Information, 85D Information, 85E Information, 90A Information, 90B Information, 90C Information, 90D Information, 91A Information, 91B Information, 91C Information, 100 Management device, 101 Control circuit, 102 ROM, 103 RAM, 104 Communication interface, 105 Display interface, 106 Display, 107 Input interface, 108 Input device, 110 Bus, 120 Auxiliary storage device, 122 Control program, 123 Machining setting, 124 Work database, 126 Transport schedule, 130 Tool database, 132 Storage information, 151 Control circuit, 152 ROM, 153 RAM, 154 Communication interface, 155 Communication interface, 160 Bus, 170 Auxiliary storage device, 172 Control program, 200 Work station, 200A Operation terminal, 201 Control circuit, 202 ROM, 203 RAM, 204 Communication interface, 205 Display interface, 206 Display, 207 Input interface, 208 Input device, 210 Bus, 220 Auxiliary storage device, 222 Control program, 234 Motor driver, 234A Motor driver, 234B Motor driver, 235 Motor, 235A Motor, 235B Motor, 250 Tool storage unit, 300 Transport device, 330 Arm robot, 331 Rail, 332, cart, 334, motor driver, 334A motor driver, 334B motor driver, 335, motor, 335A motor, 335B motor, 336 temporary storage area, 400, machine tool, 400A machine tool, 400B machine tool, 400C machine tool, 400D machine tool, 400E machine tool, 400F machine tool, 402, ROM, 403, RAM, 404, communication interface, 411A motor driver, 411B motor driver, 411C motor driver, 411D motor driver, 412AMotor, 412B motor, 412C motor, 412D motor, 413A encoder, 413B encoder, 413C encoder, 413D encoder, 414A ball screw, 414B ball screw, 415 spindle, 420 auxiliary storage device, 422 machining program, B1 change button, B2 change button, B3 change button, H1 tool holder, H2 tool holder, H3 tool holder, M1 magazine, NW1 network, NW2 network.

Claims

1. Display and Machine tools and A control unit. The control unit is obtaining a database defining a classification of each of a plurality of objects related to machining by the machine tool; A process of counting the occurrence amount of a first event that occurred for each of the plurality of objects by the classification; and displaying ranking information according to the occurrence amount of the first event on the display unit. The ranking information represents, by classification and in order of the occurrence rate of the first event, information indicating the classification, the occurrence rate of the first event, and information for identifying a cause of the occurrence of the first event.

2. the plurality of objects includes a plurality of tools; the production system further includes a transport device for transporting a designated tool among the plurality of tools to the machine tool; the database defines a classification for each of the plurality of tools; The production system according to claim 1 , wherein in the counting process, an occurrence amount of the first event occurring for each of the plurality of tools is counted for each of the classifications.

3. The control unit further executes a process of counting an occurrence amount of a second event that has occurred for each of the plurality of tools by the classification, the second event is different from the first event; 3. The production system according to claim 2, wherein the ranking information further indicates an occurrence amount of the second event for each of the categories.

4. The control unit further executes a process of receiving a selection operation of either the first event or the second event; The production system according to claim 3 , wherein the display process includes updating the ranking information in accordance with an order of occurrence of the events selected by the selection operation.

5. 5. The production system according to claim 2, wherein the first event is an event indicating that the transport device has transported a tool to the machine tool.

6. 5. The production system according to claim 2, wherein the first event is an event indicating that a tool is in short supply on the machine tool.

7. The production system according to any one of claims 2 to 4, wherein the first event is an event indicating that a tool has become unusable.

8. A method for controlling a production system, comprising: The production system includes: Display and A machine tool; The control method includes: obtaining a database defining a classification of each of a plurality of objects associated with machining on the machine tool; counting the occurrence amount of a first event occurring for each of the plurality of subjects by the classification; displaying, on the display unit, ranking information according to an occurrence amount of the first event; A control method, wherein the ranking information represents, by classification and in order of the occurrence rate of the first event, information indicating the classification, the occurrence rate of the first event, and information for identifying the cause of the occurrence of the first event.

9. A control program for a production system, comprising: The production system includes: Display and A machine tool; The control program is for the production system, obtaining a database defining a classification of each of a plurality of objects associated with machining on the machine tool; counting the occurrence amount of a first event occurring for each of the plurality of subjects by the classification; and displaying ranking information according to the occurrence amount of the first event on the display unit. A control program, wherein the ranking information represents, by classification and in order of the occurrence rate of the first event, information indicating the classification, the occurrence rate of the first event, and information for identifying the cause of the occurrence of the first event.

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