Manufacturing support system

Abstract

This invention provides a means to suppress deformation in manufactured products that undergo numerous sequential processes, each time which deformation accumulates. [Solution] A manufacturing support system comprising a 3D measuring device, a display device, and an analysis device, which is applied sequentially to a number of processes, wherein the analysis device comprises a calculation device and a memory device, and the system includes a first step of measuring the deformation of the workpiece in the previous process, a second step of modifying the working conditions based on the deformation, a third step of displaying work instructions based on the modified working conditions from the display device, and after the completion of work based on the modified work instructions, determining whether there is a next process, and if there is a next process, repeating from the first step.

Description

Technical Field

[0001] The present invention relates to a manufacturing support system.

Background Art

[0002] In recent years, systems for supporting manufacturing work and construction work have been proposed.

[0003] Patent Document 1 discloses a construction drawing projection system that projects data after correction at a construction site. Patent Document 2 discloses a change prediction system for spot welding.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] The construction drawing projection system of Patent Document 1 discloses that when the projection surface is not smooth, the construction drawing information is corrected and projected. However, there is no disclosure regarding instructing the construction work in consideration of changes caused by the construction work itself.

[0006] The change prediction system of Patent Document 2 discloses a change prediction system for spot welding. However, there is not enough disclosure regarding reflecting the predicted results in the manufacturing work.

[0007] Also, for products that are sequentially subjected to a large number of processes and whose deformation accumulates each time, a method for suppressing deformation has not been known.

[0008] Therefore, the present invention aims to provide a manufacturing support system that can predict deformation caused by the manufacturing process itself and suppress such deformation. In particular, it aims to provide a means for suppressing deformation in manufactured products in which deformation accumulates as a result of numerous sequential processes. [Means for solving the problem]

[0009] A manufacturing support system comprising a 3D measuring device, a display device, and an analysis device, which is applied sequentially to a number of processes, wherein the analysis device comprises a calculation device and a memory device, and the system includes a first step of measuring the deformation of the workpiece in the previous process, a second step of modifying the working conditions based on the deformation, a third step of displaying work instructions based on the modified working conditions from the display device, and after the completion of work based on the modified work instructions, determining whether there is a next process, and if there is a next process, repeating from the first step. [Effects of the Invention]

[0010] According to the above method, it is possible to provide a manufacturing support system that can predict deformation caused by the manufacturing process itself and suppress that deformation. In particular, it can suppress deformation in manufactured products where deformation accumulates as numerous processes are carried out sequentially.

[0011] Further means and effects of the present invention will become apparent throughout the entire specification below. [Brief explanation of the drawing]

[0012] [Figure 1A] This is a schematic diagram illustrating the components and projections. [Figure 1B] This is a schematic diagram illustrating the components and projections. [Figure 2A] This is an example of a system configuration diagram. [Figure 2B] This is an example of a system configuration diagram. [Figure 2C] This is an example of a system configuration diagram. [Figure 3] This is a flowchart illustrating one embodiment of a manufacturing support system. [Figure 4] This is an example of a manufacturing support system. [Figure 5] This is an example of a manufacturing support system. [Figure 6] This is a flowchart diagram in one embodiment. [Figure 7] This is a flowchart diagram in one embodiment.

Embodiments for Carrying Out the Invention

[0013] Hereinafter, embodiments of the present invention will be described with reference to the drawings as necessary.

Embodiment

[0014] FIGS. 1A and 1B are schematic explanatory diagrams of components and projections. They are schematic explanatory diagrams for understanding the necessity of the invention. In the following description, welding work will be described as an example. Of course, it also includes the case of applying to other manufacturing operations. [[ID=********]]

[0015] 1A and 1B are members. 3 is a display device, which shows the projection by a projector in the figure. 5 is the member loading position in the next process.

[0016] FIG. 1A shows an ideal case. When members 1A and 1B are welded, no deformation occurs between them. Therefore, it has no effect on the position 5 where the members are loaded in the next process. Therefore, when the position 5 where the members are to be loaded is projected and displayed by the display device 3 and instructions are given to the operator, the operator can perform accurate work by following the instructions.

[0017] FIG. 1B shows the case where deformation occurs. When members 1A and 1B are welded, inclination deformation occurs between them. Therefore, in the position 5 where the members are loaded in the next process, the designed position is shifted by the amount of inclination. Therefore, when the designed position 5 where the members are to be loaded is projected and displayed by the display device 3 and instructions are given to the operator, the operator will load and weld the parts at the shifted position even if following the instructions.

[0018] Therefore, in this invention, the deformation caused by the previous process is measured, the impact on the next process is determined, and the position 5 for loading the new component is indicated with the aim of reducing or eliminating that impact.

[0019] In particular, for manufactured products in which numerous processes are carried out sequentially and deformation accumulates each time, by measuring the deformation caused by the previous process at each process, or at multiple processes, determining the impact on the next process, and indicating the position 5 where new components are loaded with the aim of reducing or eliminating that impact, it is possible to provide a means of suppressing deformation for manufactured products in which numerous processes are carried out sequentially and deformation accumulates each time.

[0020] Figure 2A is an example of a system configuration diagram. 1 is the object to be constructed, 2 is a 3D measuring instrument, and 3 is a display device. In Figure 2A, the 3D measuring instrument 2 is illustrated as a stereo camera. However, it is not limited to any means capable of 3D measurement, and as shown in Figure 2B, it could also be a laser rangefinder. In Figure 2A, the display device 3 is illustrated as a projector that directly projects construction information, working conditions, dimensions, position, etc., onto the object to be constructed. However, it is not limited to any means that allows the worker to recognize the construction information, working conditions, dimensions, position, etc. Figure 2C is an image diagram where the display device 3 is a monitor or tablet, and the worker performs work on the object to be constructed 1 according to the information displayed on the display device 3.

[0021] In Figures 2A to 2C, 10 is the analysis device. The analysis device 10 has an input device 11, a calculation device 12, a storage device 13, and an image output device 14. Information from the 3D measuring instrument 2 is input to the input device 11. Information such as construction information, working conditions, dimensions, and position for the next process for the construction target object 1 is output from the image output device 14 to the display device 3.

[0022] Information such as construction information, working conditions, dimensions, and location for the next process, as well as information on welding locations and positions, displayed by the display device 3, is processed by the calculation device 12. It is generated from the three-dimensional shape or 3D shape of the object to be constructed input from the input device 11, past construction information or construction results stored in the storage device 13, and information on newly welded members, specifications, required welding strength, and allowable deformation input from the specification input device 15. If deformation occurs, or if deformation has occurred, or if there is a possibility of changes exceeding a threshold in some areas, or if deformation has occurred, the calculation of welding conditions and welding positions to suppress deformation is performed by referring to past construction information or construction results stored in the storage device 13. Based on the calculated information, the display device 3 displays the corrected construction information, working conditions, dimensions, location, etc. The specification input device 15 can also be omitted by inputting CAD data or using CAD data registered on the storage device 13.

[0023] Figure 3 is a flowchart of one embodiment. It shows a simplified example of the manufacturing support system of the present invention.

[0024] At S, the manufacturing process begins. This signifies the start of application of the manufacturing support system of the present invention. At 90, information about the part to be processed is acquired. At 91, deformation during processing is measured or predicted. 3D measurement is used for the measurement.

[0025] When measuring, if the manufactured object is large, for example, a bus or vehicle exceeding several meters in size, performing 3D measurement on its entire surface would result in an enormous number of measurement points and would be time-consuming. Furthermore, if a part is welded, for example, the degree of deformation caused by welding will differ between the immediate vicinity and a location 10 meters away. Therefore, by limiting the area of ​​3D measurement to the area where the deformation effect is expected to be significant, it is possible to achieve both high accuracy in 3D measurement and reduced manufacturing time.

[0026] For example, by limiting the measurement to the vicinity of the area where work was performed in the previous process, or to the vicinity of the area where component mounting or work is planned to be performed in the next process, it becomes possible to achieve both high accuracy in deformation measurement and reduced measurement time.

[0027] In step 92, the working conditions are modified. The working conditions include any of the following information: position, dimensions, welding locations, welding positions, and parts loading positions. When modifying the working conditions, a threshold may be set, and step 92 may be omitted if the conditions are below that threshold. This is because performing calculations for deformations below the allowable dimensional range when performing many processes will lead to an unnecessary increase in the required work time. In step 93, the work instructions based on the modified working conditions are displayed. The work instructions include any of the following information: modified position, dimensions, welding locations, welding positions, and parts loading positions.

[0028] The worker performs the work at position 94. Following the work instructions displayed on the display device 3, such as the corrected position, dimensions, welding location, welding position, and parts loading position, the worker performs the work for the next process.

[0029] At step 95, determine if the entire process is complete. If NO, meaning there are subsequent work steps, return to the point between steps 90 and 91, and proceed with measuring the deformation again and adjusting the work conditions. If YES, the work is complete.

[0030] In a manufacturing support system that is applied sequentially to multiple processes, by performing the above steps sequentially to multiple processes, a manufacturing support system can be realized that suppresses the accumulation of deformation due to the cumulative work of multiple processes.

[0031] Figure 4 shows an example of a manufacturing support system.

[0032] 110 is the construction instruction condition for the area to be constructed. 111 is the shape of the area to be constructed.

[0033] 110 and 111 are input to the analysis unit 120.

[0034] The analysis unit 120 derives the deformation of the area to be constructed, based on the information in the database 101, as a local deformation prediction value 130.

[0035] Database 101 should ideally contain various types of information. An example is described below.

[0036] Database 101 contains a deformation database 121. The deformation database 121 contains, as an example, information on welding angle deformation, welding lateral shrinkage, welding longitudinal shrinkage, and construction method 122.

[0037] Construction method 122 is further detailed in the construction database 123. The construction database 123 includes, as an example, information on the welded joint structure 124, welding method, welding current, welding voltage, tack welding, welding speed, and wire feeding speed.

[0038] The welded joint structure 124 also has detailed information in the structural database 125.

[0039] The structural database 125 includes, as an example, plate thickness, groove depth, groove width, groove gap, groove shape, restraint line length, shape of non-welded material, and restraint pattern.

[0040] 100 is a work support system.

[0041] The local deformation prediction value 130 is input into the structural deformation prediction program 132 along with the CAD data 131 of the entire structure. The structural deformation prediction program 132 derives the deformation amount 133 of the entire structure. Then, using the deformation data 134 of the actual structure, the dimension values ​​and display positions are updated 137. In the display unit 138, the updated dimensions are displayed, for example, by the display device 3 in Figure 1 or Figure 2. This includes dimensions and information to suppress deformation at the area to be constructed. One example is the display of welding positions, as shown in Figure 2B.

[0042] Furthermore, the deformation data 134 of the actual structure is subjected to difference extraction using 3D measurement and point cloud matching in 135. The results are then added to the database 101 as measured deformation values ​​in 136.

[0043] Figure 5 illustrates how the manufacturing support system described in Figure 4 can be applied to welding operations.

[0044] 210 is the construction instruction condition for the weld to be welded. 211 is the shape of the weld to be welded.

[0045] 210 and 211 are input to the analysis unit 120.

[0046] The analysis unit 120 uses the information from the database 101 to derive the deformation of the area to be constructed as a predicted local welding deformation value 230.

[0047] Database 101 should ideally contain various types of information. An example is described below.

[0048] Database 101 contains a welding deformation database 221.

[0049] The welding deformation database 221 includes, as an example, information on welding angle deformation, welding lateral shrinkage, welding longitudinal shrinkage, and construction method 222.

[0050] Construction method 222 is further detailed in the construction database 223.

[0051] The construction database 223 includes, as an example, information on the weld structure 224, welding method, welding current, welding voltage, tack welding, welding speed, and wire feeding speed.

[0052] The welded structure 224 has further detailed information available in the welded structure database 225.

[0053] The weld structure database 225 includes, as an example, plate thickness, groove depth, groove width, groove gap, groove shape, restraint line length, shape of non-welded material, and restraint pattern.

[0054] The local welding deformation prediction value 230 is input into the welding structure deformation prediction program 232 along with the CAD data 231 of the entire welding structure. The welding structure deformation prediction program 232 derives the deformation amount 133 of the entire structure. Then, using the deformation data 134 of the actual structure, the dimension values ​​and display positions are updated 137. In the display unit 138, the updated dimensions are displayed, for example, by the display device 3 in Figure 1 or Figure 2. This includes dimensions and information to suppress deformation at the area to be constructed. One example is the display of the welding position, as shown in Figure 2B.

[0055] Furthermore, the deformation data 134 of the actual structure is subjected to difference extraction using 3D measurement and point cloud matching in 135. The results are then added to the database 101 as measured deformation values ​​in 136.

[0056] As described in detail above, this embodiment provides a manufacturing support system that can predict deformation caused by the manufacturing process itself and suppress that deformation. [Examples]

[0057] Figure 6 shows an example of a flowchart in a manufacturing support system. This may be applied to Example 1.

[0058] This is an example of the details of the work support device 100, mainly as shown in Figure 4 or Figure 5, excluding parts 135 and 136.

[0059] S marks the start.

[0060] In step 301, the target of the construction is identified. In step 302, a database search of the construction section structure is performed. In step 303, it is determined whether a matching construction section exists. If YES, proceed to step 304. If NO, return to step 302.

[0061] 304 is for obtaining and displaying the construction section structure. 305 is for searching the construction record database. 306 determines if there is a construction record corresponding to the construction section. If YES, proceed to 307. If NO, return to 305.

[0062] 307 is for acquiring and displaying construction data. 308 is for comparing with the construction performance database. 308 is for acquiring deformation data around the construction area. Using the data from 309 along with the actual construction machine from 310, 311 is used in the analysis unit to perform deformation analysis of the structure based on the deformation around the construction area. 312 is used to acquire deformation prediction data for the entire structure. 313 is used to check whether changes to the dimension support lines are necessary based on thresholds. Note that 313 is performed to reduce calculation processing and can be omitted.

[0063] In step 314, determine if there is a deformation exceeding the threshold. If YES, proceed to step 315. If NO, proceed to step 316.

[0064] Function 315 updates the values ​​and display positions of dimension indicator lines. In the case of welding, updating the values ​​and display positions of the welding positions may also be used.

[0065] In step 316, the dimension indication is projected onto the calculated position on the display unit. In the case of welding, the welding position or welding area may be projected instead.

[0066] At step 317, determine if there is another construction section. If YES, return to step 301. If NO, proceed to E, which means the process is complete. [Examples]

[0067] Figure 7 shows an example of a flowchart in a manufacturing support system. It may be applied to Example 1 or Example 2. Of course, it can also be used independently.

[0068] Figure 4 or 5 shows a detailed example of parts 137 and 138, mainly relating to the work support device 100.

[0069] Furthermore, this flowchart alone can also be referred to as a manufacturing support system that accumulates deformation data, a deformation data accumulation system, or a deformation prediction system. This is because it embodies the technological philosophy of the learning process itself.

[0070] S marks the start.

[0071] In step 330, deformation prediction data for the entire welded structure is obtained. In step 331, point cloud data of the CAD data after deformation is obtained.

[0072] In step 332, welding performance data is obtained. In step 333, 3D measurement is performed. In step 334, point cloud data of the measurement area is acquired.

[0073] In step 335, the measured point cloud and the CAD point cloud are aligned using the information from steps 334 and 331. In step 336, the measured point cloud and the CAD point cloud are compared. In step 337, the difference with the deformation prediction data is obtained. In step 338, it is determined whether there is a difference. If YES, proceed to step 339. If NO, return to step 337.

[0074] In step 339, add the change data to the welding deformation performance database.

[0075] In step 340, the parameters of the welding deformation model, which is based on machine learning, are reset.

[0076] In step 341, update the welding deformation model. The welding deformation model includes the deformation data resulting from the calculations, as well as the CAD data reflecting this deformation. In this case, you may also modify the CAD data for the entire welded structure in step 231.

[0077] At point E, the process ends.

[0078] Machine learning in 340 may be performed using the analysis device 10 shown in Figures 2A to 2C. This also includes cases where the machine learning process is handled by an external system in cooperation with an external server or AI engine, either partially or entirely.

[0079] As described above, the accumulation and learning of deformation data will enable the provision of means to suppress deformation in manufactured products where deformation accumulates as numerous processes are carried out sequentially. Furthermore, as the existing database is progressively expanded, the number of processed objects and shapes that do not require new calculations based on past cases will increase. As a result, calculation time and manufacturing time will be further reduced. [Examples]

[0080] This embodiment is suitable for use in combination with any of Examples 1 to 3, but it can also be used on its own.

[0081] A feature of this embodiment is that, based on the local deformation prediction value 130 or the structural deformation prediction program 132, measurements are limited to areas where deformation is large or is predicted to be large, and measurements are performed using the 3D measuring instrument 2.

[0082] When the manufactured object is large, for example, a bus or vehicle exceeding several meters in length, performing 3D measurements on its entire surface would result in an enormous number of measurement points and would be time-consuming. Furthermore, if a certain part is welded, the degree of deformation caused by the welding will differ between the immediate vicinity of the weld and a location 10 meters away.

[0083] This embodiment achieves both high accuracy in 3D measurement and reduced manufacturing time by limiting the area where 3D measurement is performed to the area where deformation is expected to have a significant impact.

[0084] As long as the ideas and concepts disclosed above are used, any modifications or similar examples thereof are also included within the scope of the present invention.

[0085] Furthermore, an example of the present invention described using the above embodiments can also be expressed as follows.

[0086] <Part 1> In a manufacturing support system that includes a 3D measuring device, a display device, and an analysis device, and is applied sequentially to numerous processes, The analysis device comprises a computing device and a storage device. The first step is to measure the deformation of the workpiece in the preceding process, A second step involves modifying the working conditions based on the deformation, A third step involves displaying work instructions based on the modified working conditions on a display device, A manufacturing support system that, after completing a task based on revised work instructions, determines whether there is a next step, and if there is, restarts from step 1. <Part 2> The manufacturing support system described in <Part 1> suppresses the accumulation of deformation due to the cumulative work of multiple processes by sequentially performing the first, second, and third steps described above for multiple processes. <Part 3> The manufacturing support system described in <Part 1>, wherein the first step described above is performed only in the vicinity of the work area in the previous process. <Part 4> The manufacturing support system described in <Part 1>, wherein the first step described above is performed only on regions where a large amount of deformation is expected. <Part 5> The aforementioned work instructions are part of the manufacturing support system described in <Part 1>, which includes information on dimensions and location. <Part 6> The second step is the manufacturing support system described in <Part 5>, wherein the computing device calculates the amount of deformation using the deformation database and 3D shape data on the storage device. <Part 7> A manufacturing support system as described in <Part 6>, which uses the 3D measurement results from the first step and the 3D shape data to derive actual deformation values ​​and add them to the deformation database. <Part 8> A manufacturing support system as described in <Part 7>, which has a welding model and updates the welding deformation model by machine learning. <Part 9> A manufacturing support system as described in <Part 6>, in which the value and position of the dimension indication are updated in multiple processes based on the calculation result of the amount of deformation, and the updated dimension is displayed by the display device. <Part 10> The deformation database comprises a welding deformation database, calculates the amount of deformation of the target weld between welding passes, and displays the updated dimensional value and dimensional indication position of the next welded part by the display device based on the amount of deformation of the welded structure. (Part 9) <Part 11> A manufacturing support system as described in <Part 6>, which performs 3D measurement in the first step, compares the results of the 3D measurement with the point cloud data of the 3D shape data, and stores the amount of deformation in the deformation database if there is a difference. <Part 12> The manufacturing support system described in <Part 11> has a function to update the deformation model using machine learning based on the aforementioned deformation amount and to improve the accuracy of predicting deformation in the process. <Part 13> A manufacturing support system as described in <7>, which has a function to perform 3D measurement in the first step, compare the results of the 3D measurement with the calculated deformation amount, and expand the deformation database. <Part 14> The manufacturing support system described in <Part 13> has a function to update the deformation model using machine learning based on the aforementioned deformation amount and to improve the accuracy of predicting deformation in the process. [Explanation of Symbols]

[0087] 1: Object to be constructed 1A, 1B: Components 2: 3D measuring instruments 3:Display device 10: Analysis device 11: Image input device 12: Arithmetic device 13:Storage device 14: Image output device 100: Work support device 101: Database

Claims

1. In a manufacturing support system that includes a 3D measuring device, a display device, and an analysis device, and is applied sequentially to numerous processes, The analysis device comprises a computing device and a storage device. The first step is to measure the deformation of the workpiece in the preceding process, A second step involves modifying the working conditions based on the deformation, A third step involves displaying work instructions based on the modified working conditions from a display device, A manufacturing support system that, after completing a task based on revised work instructions, determines whether there is a next step, and if there is, restarts from the first step.

2. The manufacturing support system according to claim 1, wherein the first step, the second step, and the third step are performed sequentially for multiple processes, thereby suppressing the accumulation of deformation due to the cumulative work in multiple processes.

3. The manufacturing support system according to claim 1, wherein the first step is performed only in the vicinity of the work area in the previous step.

4. The manufacturing support system according to claim 1, wherein the first step is performed only on regions where a large amount of deformation is predicted.

5. The manufacturing support system according to claim 1, wherein the work instructions include information on dimensions and location.

6. The manufacturing support system according to claim 5, wherein the second step is that the calculation device calculates the amount of deformation using the deformation database and 3D shape data on the storage device.

7. A manufacturing support system according to claim 6, which uses the 3D measurement results from the first step and the 3D shape data to derive actual deformation values ​​and add them to the deformation database as examples.

8. A manufacturing support system according to claim 7, which has a welding model and updates the welding deformation model by machine learning.

9. A manufacturing support system according to claim 6, wherein, based on the calculation result of the amount of deformation, the value and position of the dimension indication are updated in multiple processes, and the updated dimension is displayed by the display device.

10. The manufacturing support system according to claim 9, wherein the deformation database comprises a welding deformation database, calculates the amount of deformation of the target weld between welding passes, and displays the updated dimensional value and dimensional indication position of the next welding site by the display device based on the amount of deformation of the welded structure.

11. The manufacturing support system according to claim 6, wherein 3D measurement is performed in the first step, the result of the 3D measurement is compared with the point cloud data of the 3D shape data, and if there is a difference, the amount of deformation is stored in the deformation database.

12. The manufacturing support system according to claim 11, which has a function to update the deformation model by machine learning using the amount of deformation and to improve the accuracy of predicting deformation in the process.

13. The manufacturing support system according to claim 7, which has a function to perform 3D measurement in the first step, compare the results of the 3D measurement with the calculated deformation amount, and expand the deformation database.

14. The manufacturing support system according to claim 13, which has a function to update the deformation model by machine learning using the aforementioned deformation amount and to improve the accuracy of predicting deformation in the process.

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