Production support system

Abstract

To provide a production support system capable of increasing the number of instruments whose use can be controlled while suppressing an increase in manufacturing cost.SOLUTION: In this production support system 100 provided with a host device 1 for managing the transition of a plurality of processes and a control panel 2 connected to the host device 1 by a cable 6, the host device 1 can output an instruction signal composed of a 1-bit digital signal, and the control panel 2 is connected to a plurality of instruments 3 used in the processes. The host device 1 outputs an instruction signal determined for each process to the control panel 2, and the control panel 2 outputs a permission signal for permitting the use of the instrument 3 to the instrument 3 corresponding to the combination of the input instruction signals. By determining the equipment 3 that can be used by the combination of the instruction signals, even if there is an upper limit in the number of the equipment 3 that can be directly connected to the host device 1, the number of the equipment 3 whose use can be controlled by the instruction from the host device 1 can be increased without adding the host device 1.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a production support system that supports workers in correctly selecting and using tools that are specified for each production process. [Background technology]

[0002] Various tools are used in production sites, and the order in which processes proceed and the tools to be used in each process are predetermined. For this reason, production support systems are used to assist workers in selecting and using tools so that they can carry out their work in the predetermined order without making any mistakes.

[0003] For example, in Patent Document 1, the control unit of the work support device is connected to a manual work state detection means that is connected to an implement (manual implement), and the control unit transitions the process when a signal indicating the completion of work using the implement is input from the manual work state detection means. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2006-126931 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the above-mentioned work support device has a limit to the number of tools that can be connected, so in order to control the use of more tools than that limit, it is necessary to increase the number of work support devices, which increases manufacturing costs.

[0006] The present invention has been made to solve the above-mentioned problems, and has an object to provide a production support system that can increase the number of appliances whose use can be controlled while suppressing increases in manufacturing costs. [Means for solving the problem]

[0007] The present invention provides A host device that manages the transition of multiple processes; a control panel connected to the host device by a cable, the host device includes a plurality of host input / output units to which one end of the cable is connected and which are capable of outputting an instruction signal formed of a 1-bit digital signal; The control panel includes: a first input / output unit to which the other end of the cable is connected and to which the instruction signal is input; a second input / output unit connected to a plurality of tools used in the process and performing input and output of signals between the tools, The host device outputs the instruction signal determined for each process from each of the host input / output units, The control panel is a production support system that outputs a permission signal from the second input / output unit to the appliance according to the combination of the input instruction signals, thereby permitting the use of the appliance. [Effects of the Invention]

[0008] By configuring as described above, it is possible to increase the number of appliances whose use can be controlled by the production support system while suppressing increases in manufacturing costs. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is an example of a production facility using the production support system of this embodiment. [Figure 2] FIG. 1 is a block diagram of a production support system according to an embodiment of the present invention. [Figure 3] 10 is a table showing the relationship between combinations of instruction signals and second input / output units that output permission signals. DETAILED DESCRIPTION OF THE INVENTION

[0010] A preferred embodiment of the present invention will be briefly described below, showing the operation of the present invention.

[0011] The present invention provides a production support system including a host device that manages the transitions of multiple processes and a control panel connected to the host device by cables, wherein the host device includes multiple host input / output units to which one end of the cable is connected and which are capable of outputting instruction signals consisting of 1-bit digital signals, and the control panel includes a first input / output unit to which the other end of the cable is connected and which inputs the instruction signals, and a second input / output unit connected to multiple appliances used in the processes and which inputs and outputs signals to and from the appliances, wherein the host device outputs instruction signals determined for each process from each host input / output unit, and the control panel outputs an authorization signal from the second input / output unit to an appliance corresponding to a combination of the input instruction signals, permitting the use of the appliance. Because there are more combinations of instruction signals than the number of outputs from the host device, by matching the combinations of instruction signals with the appliances, the number of appliances whose use can be controlled by instructions from the host device can be increased without incurring additional costs.

[0012] The control panel also includes a first connection section to which a first connector different from the appliance is connected, and the control panel outputs a transition signal to the host device to transition the process when a first condition or a second condition is met, the first condition being that a completion signal indicating that the appliance has been used is input from the appliance to the second input / output section, and the second condition being that a signal is input from the first connector to the first connection section. In this way, by connecting the first connector to the control panel and setting the first condition based on the use of the appliance and the second condition based on the signal from the first connector, the control panel can appropriately determine the completion of the process and output a transition signal regardless of whether the appliance is being used in the process, and therefore the host device can accurately manage the process transition.

[0013] The control panel also has a second connection section to which a second connector different from the appliance is connected, and when a signal is input from the second connector to the second connection section, the control panel outputs an enable signal from the second input / output section to all appliances, and does not output a transition signal even if a completion signal is input from the appliance. This allows the appliances to be used separately from processes managed by the higher-level device, making it possible to flexibly respond to unplanned appliance use, such as for correcting a work error. [Example]

[0014] An embodiment of the present invention will now be described with reference to the drawings.

[0015] Fig. 1 shows an example of a production facility using the production support system of this embodiment. The production support system 100 is a system that supports workers in correctly selecting and using tools 3 to be used in each production process, and is composed of a host device 1, a control panel 2, and a cable 6 that connects the host device 1 and the control panel 2. In the figure, three cables 6 are provided, but the number of cables is not limited to this.

[0016] The upper device 1 that constitutes the production support system 100 is a device that manages the transition of multiple processes based on a stored program, and is capable of outputting a 1-bit digital signal to a control panel 2 via a cable 6. In this embodiment, the control panel 2 is a PLC, and is connected to multiple devices 3 used in the processes as well as a first connector 4 and a second connector 5, which are push-button switches.

[0017] The tools 3 are, for example, torque drivers or picking sensors, and in this embodiment, seven tools 3A to 3G are connected to the control panel 2. Power is supplied to the tools 3, and the production support system 100 manages whether the tools are usable or not.

[0018] The first connector 4 is also a switch that inputs to the control panel 2 that a task that cannot be controlled by connecting to the production support system 100 has been completed. The target process is a process that does not use tools 3, such as visual inspection or turning over pages of a work procedure manual. When a worker performs the target process and presses the first connector 4, a signal is input from the first connector 4 to the control panel 2.

[0019] The second connector 5 is a switch that allows the use of all of the multiple tools 3. When the worker presses the second connector 5, all of the tools 3 become usable, and when the worker presses the second connector 5 again, the state in which all of the tools 3 can be used is canceled. Note that the type of switch is not limited to a push-button type, and may be, for example, a selector switch.

[0020] Fig. 2 is a block diagram of the production support system of this embodiment, and Fig. 3 is a table showing the relationship between combinations of instruction signals and second input / output units that output permission signals. The upper device 1 includes an upper control unit 10 and three upper input / output units 11A-11C, and the control panel 2 includes a control unit 20, three first input / output units 21A-21C, seven second input / output units 23A-23G, a first connection unit 24, and a second connection unit 25. Note that the arrows in the figure indicate the direction in which signals are transmitted, with a single-headed arrow indicating that the signal is transmitted in only one direction and a double-headed arrow indicating that the signal is transmitted in both directions.

[0021] The host control unit 10 manages the transitions of a plurality of processes in accordance with a stored program, and instructs each of the host input / output units 11A to 11C to output an instruction signal consisting of a 1-bit digital signal according to the process currently being executed. Furthermore, when a transition signal is input from the first input / output unit 21A to the host input / output unit 11A, the transition signal is transmitted from the host input / output unit 11A to the host control unit 10, and the host control unit 10 transitions the currently being executed process to the next process. Note that the number of host input / output units 11 to which the transition signal is input is not limited to that in this embodiment, and the transition signal may be input to a plurality of host input / output units 11.

[0022] The first input / output units 21A to 21C receive instruction signals from the upper input / output units 11A to 11C and transmit the received instruction signals to the control unit 20. The control unit 20 determines the combination of instruction signals and instructs the second input / output unit 23 corresponding to the combination to output an authorization signal that authorizes use of the appliance 3.

[0023] The relationship between the combinations of instruction signals and the second input / output units 23 corresponding to the combinations is predetermined as shown in the table in Fig. 3. Three instruction signals input to the first input / output units 21A to 21C form one combination, and the instruction signals input to the first input / output units 21A to 21C can be either 0 or 1, so there are eight combinations of instruction signals in this embodiment. When all instruction signals are 0, the control unit 20 does not instruct any of the second input / output units 23 to output an enabling signal, but when any of the other seven combinations are input, the control unit 20 instructs the second input / output unit 23 corresponding to that combination to output an enabling signal. Appliances 3A to 3G are connected to the second input / output units 23A to 23G, respectively, and only the appliance 3 that receives the enabling signal can be used.

[0024] If the number of host input / output units 11 is n (n≧2), there are 2n combinations of instruction signals, which is more than the number of outputs from the host device 1. Therefore, by associating these combinations with the second input / output unit 23 that outputs the permission signal, it is possible to increase the number of appliances 3 whose use can be controlled without incurring manufacturing costs such as adding more host devices 1. In this embodiment, the number of appliances 3 is seven, but any number of appliances 3 can be connected to the control panel 2 depending on the number of combinations of instruction signals.

[0025] When use of the tool 3 is completed, the tool 3 outputs a completion signal to the second input / output unit 23. For example, if the tool 3 is a torque driver, the completion signal is output when a specified torque is reached, or if the tool 3 is a picking sensor, the completion signal is output when light is blocked. The completion signal input to the second input / output unit 23 is transmitted to the control unit 20, and upon receiving the completion signal, the control unit 20 instructs the first input / output unit 21A to output a transition signal.

[0026] The first connection unit 24 is connected to the first connector 4, and when the first connector 4 is pressed, a signal is input to the first connection unit 24. The input signal is transmitted from the first connection unit 24 to the control unit 20, and the control unit 20 receives the input of this signal and instructs the first input / output unit 21A to output a transition signal.

[0027] Furthermore, the second connection unit 25 is connected to the second connector 5, and when the second connector 5 is pressed, a signal is input to the second connection unit 25. The input signal is transmitted from the second connection unit 25 to the control unit 20, and the control unit 20 receives this signal and instructs the second input / output units 23A to 23G to output a permission signal. Note that if the appliance 3 is used after the signal is input to the second connection unit 25, the control unit 20 does not instruct the first input / output unit 21A to output a transition signal even if a completion signal is input from the appliance 3 via the second input / output unit 23.

[0028] Next, the control of the process managed by the above-described production support system 100 will be described.

[0029] The processes managed by the host device 1 include processes that use tools and processes that do not use tools. In this embodiment, the former will be called the first process and the latter the second process. When the control panel 2 determines that each process is complete, a transition signal is input to the host device 1, and the process transition occurs. The control panel 2 determines the completion of the first process based on a first condition, and the completion of the second process based on a second condition. Each process will be explained below.

[0030] The first process is a process in which work is performed, such as tightening screws with a torque driver or picking up necessary parts (a picking sensor detects the worker's hands). The host device 1 outputs instruction signals corresponding to the second input / output units 23 to which the tools 3 used in the process are connected, from the host input / output units 11A to 11C. Then, when the tools 3 corresponding to the combination of the input instruction signals are used and a completion signal is input from the tools 3 to the second input / output unit 23, the control panel 2 determines that the first condition is satisfied and outputs a transition signal to the host device 1.

[0031] The second step is a step in which work such as visual inspection or turning over pages of a work procedure manual is performed, for example. While the second step is being performed, the upper device 1 outputs 0 from the upper input / output units 11A to 11C, making it impossible to use any of the appliances 3. When the worker finishes the work and presses the first connector 4, and a signal is input from the first connector 4 to the first connection unit 24, the control panel 2 determines that the second condition is satisfied and outputs a transition signal to the upper device 1.

[0032] Even if the second condition is satisfied in the first step, the control panel 2 does not output a transition signal to the higher-level device 1. Furthermore, since none of the appliances 3 can be used in the second step, the first condition is never satisfied.

[0033] In this way, by connecting the first connector 4 to the control panel 2 and determining the output of a transition signal from the control panel 2 based on a first condition based on the use of the appliance 3 and a second condition based on the signal input from the first connector 4, the completion of the process can be appropriately determined regardless of whether the appliance 3 is being used or not, and the process transition can be accurately managed in the higher-level device 1.

[0034] Furthermore, the control panel 2 can execute forced ON control to enable the use of the tools 3 separately from the process managed by the higher-level device 1, and the forced ON control is initiated when a signal is input from the second connector 5 to the second connection section 25. When a signal is input to the second connection section 25, the control panel 2 outputs an enable signal to all tools 3, enabling the worker to use any tool 3. This makes it possible to flexibly respond to the use of tools 3 that are not part of the process, such as to correct a work error. [Explanation of symbols]

[0035] 1. Upper device 11 Upper input / output section 2 Control panel 21 1st input / output section 23 2nd input / output section 24 First connection part 25 Second connection part 3. Equipment 4 First connector 5 Second connector 6 Cables 100 Production Support System

Claims

1. A host device that manages the transition of multiple processes; a control panel connected to the host device by a cable, the host device includes a plurality of host input / output units to which one end of the cable is connected and which are capable of outputting an instruction signal formed of a 1-bit digital signal; The control panel includes: a first input / output unit to which the other end of the cable is connected and to which the instruction signal is input; a second input / output unit connected to a plurality of tools used in the process and performing input and output of signals between the tools, The host device outputs the instruction signal determined for each process from each of the host input / output units, The control panel outputs a permission signal from the second input / output unit to the appliance according to the combination of the input instruction signals, thereby permitting the use of the appliance.

2. The control panel includes a first connection portion to which a first connector different from the appliance is connected, the control panel outputs a transition signal to the host device to cause the process to transition when the first condition or the second condition is satisfied; the first condition is that a completion signal indicating that use of the appliance has been completed is input from the appliance to the second input / output unit; 2. The production support system according to claim 1, wherein the second condition is that a signal is input to the first connection unit from the first connector.

3. The control panel includes a second connection portion to which a second connector different from the appliance is connected, The control panel includes: When a signal is input from the second connector to the second connection unit, the permission signal is output from the second input / output unit to all of the appliances, 3. The production support system according to claim 2, wherein the transition signal is not output even when the completion signal is input from the tool.

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