Conveying device

Abstract

This product provides a conveying system that can flexibly accommodate increases or decreases in shipping lines due to changes in product specifications, even in environments where equipment space is limited. [Solution] This conveying device 10 comprises a manufacturing line 11 in which multiple types of products W (W1 to W6) are conveyed in a mixed state, multiple shipping lines 12a to 12d, an identification unit 13a that identifies the type of product W, and a control unit 14. The shipping lines 12a to 12d are free shipping lines that can accommodate all types of products W1 to W6 conveyed by the manufacturing line 11. The control unit 14 sets an empty free shipping line 12a, into which no type of product W has been brought, as a specific shipping line corresponding to the type of product W2 identified by the identification unit 13a, distributes the identified product W2 to the corresponding specific shipping line 12a, and, when a predetermined number of products W2 of the type corresponding to the specific shipping line 12a have been brought in, it is configured to ship a predetermined number of products W2 from the specific shipping line 12a.

Description

Technical Field

[0001] The present invention relates to a conveying device, and particularly to a technique for sorting products manufactured on a production line in a state where a plurality of types of products are mixed into corresponding shipping lines.

Background Art

[0002] In recent years, in manufacturing processes including those for automobiles, production lines in a state where a plurality of types of products corresponding to a plurality of specifications are mixed have become common. In such cases, in order to ship products in batches for each type, shipping lines corresponding to the types of products flowing on the production line are provided, and the products are automatically or manually sorted and conveyed to the corresponding shipping lines by reading product information attached to the products (for example, see Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] On the other hand, when the above-described configuration is adopted, every time the specification of a product is changed, it is necessary to newly add a line (shipping line) for shipping products of a type corresponding to the new specification. Usually, in this type of manufacturing equipment, the layout of the equipment is designed assuming an increase in the number of shipping lines accompanying an increase in the number of types to some extent. However, if the specification is changed more frequently than expected, it may become difficult to add shipping lines, and if a product of a type that has been manufactured so far is discontinued due to a specification change, the shipping line corresponding to that type may become useless.

[0005] In light of the above circumstances, this specification aims to provide a conveying device that can flexibly respond to increases or decreases in shipping lines due to changes in product specifications, even in environments where equipment space is limited. [Means for solving the problem]

[0006] The aforementioned problem is solved by the conveying device according to the present invention. Specifically, the conveying device comprises a manufacturing line in which multiple types of products are conveyed in a mixed state, multiple shipping lines into which products are brought from the manufacturing line, an identification unit that identifies the type of product at a predetermined position on the manufacturing line, and a control unit that controls the distribution of products from the manufacturing line to each shipping line based on information regarding the type of product identified by the identification unit, wherein the shipping lines are free shipping lines that can accommodate all types of products conveyed on the manufacturing line, and the control unit is configured such that, if no products of the type identified by the identification unit have been brought into any of the free shipping lines, it sets an empty free shipping line into a specific shipping line corresponding to the type of product identified by the identification unit, distributes the identified product to the corresponding specific shipping line, and, when a predetermined number of products of the type corresponding to the specific shipping line have been brought in, it discharges a predetermined number of products from the specific shipping line.

[0007] In this context, "product" refers to the articles manufactured on the production line in question, and includes not only the final product but also intermediate products supplied to production lines for the manufacture of the final product located elsewhere. In this case, it is not necessary to consider whether the intermediate product itself is transferable for business purposes.

[0008] In the conveying device according to the present invention, the shipping lines, which were previously fixed for each product type, are made into free shipping lines that can handle any type of product, and the free shipping line is set to a shipping line corresponding to a specific product (specific shipping line) according to the type of product manufactured. In this way, the shipping line can be changed according to the type of product that is sequentially manufactured and transported, so that a specific shipping line does not go unused and is not wasted, and all shipping lines can be used efficiently at all times. In addition, since all products are transported from the shipping line when a predetermined number of products have been delivered, the shipping line can be emptied at a certain frequency. Therefore, even if a new type of product is transported afterward, the empty shipping line can be reset to the shipping line corresponding to that product, making it possible to operate a mixed-flow manufacturing line smoothly. In summary, the conveying device according to the present invention can flexibly respond to an increase or discontinuation of product types due to frequent specification changes without increasing the equipment space.

[0009] Furthermore, the conveying device according to the present invention may further include a stockyard where multiple types of products are stored, and an input port into which a predetermined product from the multiple types of products can be loaded from the stockyard into the manufacturing line, and the control unit may be configured to distribute the products loaded from the stockyard into the manufacturing line through the input port to the predetermined specific shipping line if the number of products brought into the predetermined specific shipping line remains below a predetermined number for a predetermined period of time, or if it becomes necessary to unload all products that are in the loading state from the predetermined specific shipping line as quickly as possible.

[0010] The conveying device according to the present invention has the advantage of being able to reduce the number of shipping lines (free shipping lines) that need to be prepared to fewer than the number of types of products manufactured (transported) on the manufacturing line, due to the features described above. On the other hand, in this type of manufacturing line, if a product is determined to be defective during the manufacturing process (inspection, etc.) and a product that should be there is missing, the products may not be transported to the shipping line in the originally planned order, resulting in a shipping line where the predetermined number of products is never available, that is, the number of products remains below the minimum number required for shipping. Alternatively, a new type of product may be manufactured and transported while all shipping lines are in use. In this regard, the conveying device according to the present configuration allows products of the type corresponding to a specific shipping line that is short of a predetermined number to be brought into the manufacturing line from the stockyard and replenished. This makes it possible to immediately transport multiple products that have reached the predetermined number from that specific shipping line and make them ready for shipping. Therefore, even if, for example, an unforeseen event occurs and a new type of product is immediately transported to the shipping line, the empty shipping line can be designated as a specific shipping line corresponding to the new type of product, and the new type of product can be brought in, thereby enabling the smooth and continuous transport and shipment of products. [Effects of the Invention]

[0011] As described above, the conveying device according to the present invention makes it possible to flexibly respond to increases or decreases in the shipping line due to changes in product specifications, even in environments where equipment space is limited. [Brief explanation of the drawing]

[0012] [Figure 1] This is a plan view showing the main components of a conveying device according to one embodiment of the present invention. [Figure 2] This figure shows an example of the display mode of the display unit shown in Figure 1. [Figure 3] Figure 1 shows an example of how the conveying device is used, illustrating a state in which a predetermined number of products have been delivered to a predetermined specific shipping line. [Figure 4] This is a front view of a display unit that shows a predetermined shipping line filled with a predetermined number of products. [Figure 5] This is a front view of the display unit, showing the state from empty to a state where it has been set up on a specific shipping line corresponding to a new type of product. [Figure 6] This is a front view of the display unit showing that the number of products delivered to any specific shipping line is less than the predetermined number. [Figure 7] This is a plan view of the main components of a conveying device showing the state after the necessary products have been transferred from the stockyard to the production line. [Modes for carrying out the invention]

[0013] The contents of the transport device according to one embodiment of the present invention will be described below based on the drawings.

[0014] Figure 1 shows a plan view of a conveying device 10 according to one embodiment of the present invention. This conveying device 10 comprises a manufacturing line 11 in which multiple types of products W (W1, W2…) are conveyed in a mixed state, multiple shipping lines 12 connected to the manufacturing line 11 at its downstream end, identification units 13a to 13c for identifying the types of products W, a control unit 14 for driving and controlling the manufacturing line 11 and each shipping line 12, and a display unit 15 for visualizing the loading status of products W in each shipping line 12.

[0015] Furthermore, the conveying device 10 according to this embodiment further comprises a stockyard 16, an input port 17, and a discharge line 18.

[0016] The manufacturing line 11 is, for example, a line for manufacturing transmissions, and in this embodiment, it is configured so that multiple types (six types in this embodiment) of products W (W1, W2, W3, W4, W5, W6) of different types are transported in a mixed flow state toward the shipping line 12.

[0017] The shipping line 12 is a line for preparing the product W conveyed on the manufacturing line 11 for shipment. In this embodiment, four shipping lines 12a to 12d from the first shipping line 12a to the fourth shipping line 12d are provided in parallel. The upstream ends of each of the shipping lines 12a to 12d are continuous with the branched downstream ends of the manufacturing line 11. That is, the product W conveyed on the manufacturing line 11 can be carried in in a state of being distributed to a predetermined one of the plurality of shipping lines 12a to 12d by a control unit 14 described later.

[0018] Here, each of the shipping lines 12a to 12d is a free shipping line capable of corresponding to all types of products W (here, six types from the first product W1 to the sixth product W6) conveyed on the manufacturing line 11, and can be set to a specific shipping line (specific shipping line) corresponding to a predetermined type of product W by a control unit 14 described later. Also, even after each of the shipping lines 12a to 12d is once set to a specific shipping line corresponding to a predetermined type of product W, it is configured to be able to be changed to a specific shipping line corresponding to another type of product W. In this embodiment, the number of shipping lines 12 is set to be less than the number of types of products W conveyed on the manufacturing line 11. Details will be described later.

[0019] The identification units 13a to 13c are for making it possible to identify the type of the product W. In this embodiment, a first identification unit 13a configured to be able to identify the type of the product W at a first position on the manufacturing line 11, a second identification unit 13b configured to be able to identify the type of the product W at a second position downstream of the first position on the manufacturing line 11, and a third identification unit 13c configured to be able to identify the type of the product W at a third position at or near the downstream end on the payout line 18. Information regarding the type of the product W obtained by each of the identification units 13a to 13c can be transmitted to the control unit 14.

[0020] Note that the identification units 13a to 13c can have any configuration as long as they can identify the type of the product W. For example, each of the identification units 13a to 13c may be constituted by an IC tag reader capable of reading an IC tag incorporating information regarding the type of the product W arranged on the side of the product W.

[0021] The control unit 14 is for controlling the production line 11 and the plurality of shipping lines 12a to 12d. Specifically, based on the information regarding the type of the product W obtained by the first identification unit 13a or the second identification unit 13b, the control unit 14 controls the production line 11 and each of the shipping lines 12 so that the product W is sorted and carried into the plurality of shipping lines 12a to 12d.

[0022] Also, prior to the above-mentioned sorting, the control unit 14 appropriately sets the type of the product W corresponding to each of the shipping lines 12a to 12d, which are free shipping lines, based on the information regarding the type of the product W obtained by the first identification unit 13a and the carrying state of the product W in each of the shipping lines 12a to 12d. In other words, the control unit 14 sets the empty free shipping line 12 as a specific shipping line 12 corresponding to the type of the product W to be carried in immediately thereafter. Therefore, after the setting, the control unit 14 controls the production line 11 and the corresponding shipping line 12 so as to sort and convey the identified product W to the corresponding specific shipping line 12.

[0023] The display unit 15 is for visualizing the carrying state of the product W in the plurality of shipping lines 12, and is disposed, for example, at a position and in a posture visible to an operator performing the shipping operation within the working range.

[0024] As shown in Figure 2, the display unit 15 includes a delivery status display unit 15a that displays the delivery status of products W in each shipping line 12, and a type display unit 15b that displays the types of products W that can be delivered to each shipping line 12. In this embodiment, there are as many delivery status display units 15a as there are shipping lines 12, and a type display unit 15b is provided adjacent to each delivery status display unit 15a. In the delivery status display unit 15a shown in Figure 2, a circle with a crosshatch pattern represents a product W that is in the delivery state, and a blank circle represents a product W that is scheduled to be delivered.

[0025] The display unit 15 in the above configuration is electrically connected to each shipping line 12 and the control unit 14, and can update information on the delivery status and delivery schedule of products W in each shipping line 12 (status of delivery status display unit 15a) and information on the types of products W that can be delivered (type display unit 15b) at any time.

[0026] The stockyard 16 is capable of stocking all types of products W to be shipped, and in this embodiment, it is capable of stocking a predetermined number of each of the six types of products W1 to W6 that can be transported on the production line 11. In this embodiment, a person picks up the desired type of product W from the stockyard 16 and puts it onto the production line 11 through the input port 17, so each of the products W1 to W6 in the stockyard 16 can be flexibly arranged as long as a person can pick them up as they see fit.

[0027] Furthermore, while each type of product W may be arranged in a way that allows for visual confirmation by a person, for example, sensors may be installed at the location of each product W within the stockyard 16, allowing the control unit 14 to be informed of which type of product W is located where at any given time.

[0028] Hereinafter, an example of the use of the conveying device 10 according to this embodiment will be described in order with reference to the drawings.

[0029] First, as shown in Figure 1, when products W of the same type corresponding to all four shipping lines 12 are delivered, the type of product W is identified by the first identification unit 13a at the first position on the manufacturing line 11. If the product W identified here is product W1 of the first model (hereinafter simply referred to as the first product W1; the same applies to products W2 to W6 of other models), the control unit 14 controls the manufacturing line 11 and the first shipping line 12a to distribute the first product W1 to the shipping line 12 (in this case, the first shipping line 12a) if a specific shipping line 12 corresponding to the first product W1 has already been set. In this case, as soon as the first identification unit 13a identifies that it is the first product W1, a mark (a blank circle) is newly displayed on the display unit 15, indicating that the next product W (W1) will be delivered to the corresponding first shipping line 12a (see Figure 2). Subsequently, after the second identification unit 13b identifies the product W1 again, the control unit 14 drives and controls the manufacturing line 11 and the first shipping line 12a to distribute the first product W1 to the first shipping line 12a. As a result, the first product W1 is delivered to the first shipping line 12a (see Figure 3). This is also displayed on the display unit 15 (see Figure 4).

[0030] Furthermore, the control unit 14 sorts products of a specific type (in this case, the first product W1) corresponding to a predetermined specific shipping line (in this case, the first shipping line 12a). As shown in Figure 3, when a predetermined number (in this case, four) of products W1 are brought into the first shipping line 12a, the control unit 14 controls the first shipping line 12a to discharge them all at once. The predetermined number of products W1 discharged from the first shipping line 12a are sequentially transported by the dispensing line 18 to the downstream end of the dispensing line 18, which is the shipping work area. Meanwhile, since the operator has confirmed that a predetermined number of first products W1 have been brought in using the display unit 15 (see Figure 4), after confirming that they are the first products W1 using the third identification unit 13c at the downstream end of the dispensing line 18, the operator can smoothly carry out the preparation for shipping the first products W1 (for example, transferring them to the corresponding shipping pallet).

[0031] In this way, after product W1 is unloaded from the first shipping line 12a and prepared for shipment, the control unit 14 sets the now-empty first shipping line 12a to a specific shipping line corresponding to the type of product W to be transported next. For example, as shown in Figure 3, if the second product W2 is to be transported next, and none of the second to fourth shipping lines 12b to 12d are set to a specific shipping line corresponding to the second product W2, the control unit 14 resets the first shipping line 12a to a specific shipping line corresponding to the second product W2 (see Figure 5). In this way, each shipping line 12a to 12d is used efficiently, and the shipment of product W is carried out smoothly.

[0032] Furthermore, if the number of products W brought into a predetermined specific shipping line remains below a predetermined number for a predetermined period of time, or if it becomes necessary to remove all products W currently in the delivery state from a predetermined specific shipping line as quickly as possible, the control unit 14 controls the manufacturing line 11 and shipping line 12 to distribute the products W that have been brought into the manufacturing line 11 from the stockyard 16 through the input port 17 to the predetermined specific shipping line. For example, as shown in Figure 6, if the fourth shipping line 12d has received the largest number of corresponding products W (in this case, the fifth product W5), and as shown in Figure 7, the next product W to be brought into the manufacturing line 11 is a type of product W that does not correspond to any of the shipping lines 12a to 12d (in this case, the sixth product W6), the control unit 14 confirms that the fifth product W5 is stocked in the stockyard 16 and issues a command to the worker to pick up the fifth product W5 and put it into the manufacturing line 11 through the input port 17. This command may be displayed on the display unit 15 or output by voice.

[0033] Then, when the control unit 14 detects that the fifth product W5 has been manually fed from the stockyard 16 to the production line 11 through the input port 17, it distributes the fed-in fifth product W5 to the corresponding fourth shipping line 12d. As a result, the fifth product W5 is delivered to the fourth shipping line 12d, and a predetermined number of products W5 are delivered. Therefore, the control unit 14 then removes all the delivered products W5 from the fourth shipping line 12d, leaving it empty, and then reconfigures the fourth shipping line 12d to a specific shipping line according to the type of product W that will be transported from the production line 11 next. As shown in Figure 7, when the sixth product W6 is to be transported next, the control unit 14 configures the empty fourth shipping line 12d to a specific shipping line corresponding to the sixth product W6. As a result, the sixth product W6 is distributed to and delivered to the fourth shipping line 12d. In this manner, the distribution of more types of products W1 to W6 from shipping lines 12a to 12d is carried out smoothly.

[0034] As described above, in the conveying device 10 according to this embodiment, all of the multiple shipping lines 12 (12a to 12d) are set as free shipping lines that can handle any type of product, and the free shipping lines are set to shipping lines (specific shipping lines) corresponding to specific products W1 to W6 according to the type of product W that has been manufactured. In this way, the shipping lines 12 can be changed according to the type of product W that is being transported after being manufactured in sequence, so that the situation in which a specific shipping line 12 is not used and is wasted can be avoided, and all shipping lines 12a to 12d can always be used efficiently without any waste. In addition, since all products W are transported from the shipping line 12 on the condition that a predetermined number of products W have been brought in, the shipping line 12 can be emptied at a certain frequency. Therefore, even if a new type of product W is transported thereafter, the empty shipping line 12 can be reset to the shipping line corresponding to that product W, making it possible to operate the mixed-flow manufacturing line 11 smoothly. Based on the above, the conveying device 10 according to this embodiment makes it possible to flexibly respond to an increase or discontinuation of product W models (types) due to frequent specification changes without increasing the equipment space.

[0035] Furthermore, in this embodiment, a stockyard 16 is provided where all types of products W1 to W6 transported on the manufacturing line 11 are stocked, and an input port 17 is provided through which a predetermined product W from these multiple types of products W1 to W6 can be loaded from the stockyard 16 into the manufacturing line 11. The control unit 14 is configured to, when it becomes necessary to load all products W5 that are in a loading state from a predetermined specific shipping line 12d as quickly as possible, to distribute the products W5 loaded into the manufacturing line 11 from the stockyard 16 through the input port 17 to the predetermined specific shipping line 12d. With this configuration, the products W5 can be loaded into the predetermined specific shipping line 12d and replenished. This makes it possible to immediately load a predetermined number of products W5 from the specific shipping line 12d and make them ready for shipment. For example, even if an unforeseen event occurs and a new type of product W6 is transported to the shipping line 12 immediately afterward, the empty shipping line 12d can be set as the specific shipping line corresponding to the new type of product W6, and the new type of product W6 can be loaded. Therefore, it becomes possible to continuously carry out the smooth transportation and shipment of products W1 to W6.

[0036] Although one embodiment of the present invention has been described above, the conveying device according to the present invention may also have configurations other than those described above, without departing from the spirit of the invention.

[0037] For example, in the above embodiment, a first identification unit 13a is provided at a first position on the manufacturing line 11, and a second identification unit 13b is provided at a second position downstream of the first position on the manufacturing line 11. However, it is also possible to have only one of the identification units 13a (13b).

[0038] Furthermore, in the above embodiment, an example was given in which the process of picking up a predetermined product W from the stockyard 16 and feeding the product W into the production line 11 from the input port 17 is performed manually. However, for example, some or all of the above-described series of operations may be automated. [Explanation of Symbols]

[0039] 10 Conveying device 11 Production Line 12 (12a~12d) Shipping Line 13a~13c Identification part 14 Control Unit 15 Display section 15a Delivery Status Display Unit 15b Type display section 16 Stockyards 17 Inlet 18 Payout Lines W(W1~W6) products

Claims

1. A manufacturing line in which multiple types of products are transported in a mixed state, Multiple shipping lines into which goods are delivered from the aforementioned manufacturing line, An identification unit for identifying the type of product at a predetermined position on the manufacturing line, A conveying device comprising a control unit that controls the distribution of the products from the manufacturing line to each of the shipping lines based on information regarding the type of product identified by the identification unit, The aforementioned shipping line is a free shipping line capable of handling all types of products transported by the manufacturing line, If the type of product identified by the identification unit is not delivered to any of the free shipping lines, the control unit sets the empty free shipping line, which does not contain any type of product, as a specific shipping line corresponding to the type of product identified by the identification unit, and distributes the identified product to the corresponding specific shipping line, and A conveying device configured to unload a predetermined number of products of the corresponding type from a specific shipping line when that predetermined number of products are brought into the specific shipping line.

2. The system further comprises a stockyard where the aforementioned multiple types of products are stored, and an input port into which a predetermined product from the aforementioned multiple types of products can be fed from the stockyard to the manufacturing line. The conveying device according to claim 1, wherein the control unit is configured to distribute the products that have been brought into the manufacturing line from the stockyard through the input port to the predetermined specific shipping line if the number of products brought into the predetermined specific shipping line remains below the predetermined number for a predetermined period of time, or if it becomes necessary to remove all of the products that have been brought into the predetermined specific shipping line.

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