Control device and display device

Abstract

To facilitate the tracking of the causes of defects. [Solution] The management device 40 manages the production line 12 (casting apparatus 12) of product 20. The management device 40 includes a storage unit 28 that stores sensor information from sensors 16 placed on the production line 12, a storage unit 24 that stores control information on the production line 12, and a storage unit 32 that stores defect information, including image data of products determined to be defective, regarding defects in product 20. The management device 40 also includes a display unit 48 and a display control unit 46 that causes the display unit 48 to display a single screen G12 including defect information 52, sensor information 54 corresponding to the defect information 52, and control information 56 corresponding to the defect information 52.

Description

Technical Field

[0001] This disclosure relates to a management device and a display device.

Background Art

[0002] Patent Document 1 discloses a casting facility including a plurality of processes as a production line. In this casting facility, a ladle receives molten metal in a melting furnace and is conveyed to a pouring machine. Further, a plurality of molds are molded by a molding machine and are conveyed to the pouring machine one by one. In the pouring machine, the molten metal in the ladle is poured into the conveyed mold. The mold after pouring is cooled over time, and the molten metal solidifies into a casting before reaching the mold-breaking device. The mold-breaking device disassembles the mold and takes out the casting. The casting is shipped as a product through subsequent processes.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In inspections before shipment, castings may be produced that are determined to be defective. Therefore, it is required to easily identify the cause of the defect. An object of this disclosure is to provide a management device and a display device capable of easily identifying the cause of a defect.

Means for Solving the Problems

[0005] The management device of this disclosure is a management device for managing a target object in a manufacturing line, and includes: a first storage unit for storing sensor information from a plurality of sensors arranged in the manufacturing line; a second storage unit for storing control information in the manufacturing line; a third storage unit for storing defect information, including image data of the target object that has been determined to be defective; a display unit; and a display control unit for causing the display unit to display a single screen including the defect information, the sensor information corresponding to the defect information, and the control information corresponding to the defect information.

[0006] The display device of this disclosure is a display device that displays a single screen including defect information including image data of a managed object determined to be defective, sensor information from a plurality of sensors arranged on the manufacturing line, and control information in the manufacturing line. [Effects of the Invention]

[0007] The management device and display device disclosed herein make it possible to easily identify the cause of a defect. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a schematic diagram of the manufacturing system of the first embodiment. [Figure 2] Figure 2 is a block diagram showing an example of the configuration of the casting apparatus shown in Figure 1. [Figure 3] Figure 3 is an explanatory diagram showing an example of a screen displayed by the management device shown in Figure 1. [Figure 4] Figure 4 is an explanatory diagram showing an example of a screen displayed by the management device shown in Figure 1. [Figure 5] Figure 5 is an explanatory diagram showing an example of a screen displayed by the management device shown in Figure 1. [Figure 6] Figure 6 is an explanatory diagram showing an example of a screen displayed by the management device shown in Figure 1. [Figure 7] Figure 7 is an explanatory diagram showing an example of a screen displayed by the management device shown in Figure 1. [Figure 8]FIG. 8 is an explanatory diagram showing a modified example of the screen displayed by the management device of FIG. 1. [Figure 9] FIG. 9 is an explanatory diagram showing the factor table of the management device of FIG. 1. [Figure 10] FIG. 10 is an explanatory diagram showing a modified example of the screen displayed by the management device of FIG. 1. [Figure 11] FIG. 11 is an explanatory diagram showing a modified example of the screen displayed by the management device of FIG. 1. [Figure 12] FIG. 12 is a schematic configuration diagram of the manufacturing system of the second embodiment. [Figure 13] FIG. 13 is a block diagram showing an example of the configuration of the shot processing device of FIG. 12. [Figure 14] FIG. 14 is an explanatory diagram showing an example of the screen displayed by the management device of FIG. 12. [Figure 15] FIG. 15 is an explanatory diagram showing an example of the screen displayed by the management device of FIG. 12. [Figure 16] FIG. 16 is an explanatory diagram showing an example of the screen displayed by the management device of FIG. 12. [Figure 17] FIG. 17 is an explanatory diagram showing a modified example of the creation of the factor table of FIG. 9.

MODE FOR CARRYING OUT THE INVENTION

[0009] Hereinafter, embodiments and modified examples will be described with reference to the drawings. In the present disclosure, terms such as "first", "second", "third", etc. are used only for distinguishing objects and do not rank the objects.

[0010] (First Embodiment) Hereinafter, the manufacturing system 10 of the first embodiment will be described. (Schematic Configuration of Manufacturing System) As shown in FIG. 1, the manufacturing system 10 includes a casting device 12, a control device 14, and a sensor 16. The casting device 12 constitutes a production line 12 for manufacturing a product 20 from a material 18. The casting device 12 includes one or more facilities for manufacturing the product 20.

[0011] The control device 14 controls the facilities included in the casting device 12. The control device 14 controls the facilities of the casting device 12 based on control information stored in the storage unit 24 of the control system 22. The control results in the facilities of the casting device 12 controlled by the control device 14 are stored in the storage unit 24 of the control system 22 through the control device 14. The control information includes information on the facilities to be controlled, control parameters for the facilities, and control results in the facilities.

[0012] The control results include detection results obtained by sensors such as pressure sensors according to the control targets. The control results include the control results of the facilities by the control device 14 and the control time for the facilities. The control information may include other information. The control device 14 associates the control results and the control time with the control information and stores them in the storage unit 24. The storage unit 24 of the control system 22 is an example of the "second storage unit".

[0013] The sensor 16 acquires sensor information on various management items related to the manufacturing in the casting device 12. The sensor 16 is provided on various facilities included in the casting device 12 and acquires various information in the production line 12. For example, the sensor 16 may include a temperature sensor, a pressure sensor, an acceleration sensor, etc. The sensor information collection system 26 includes a storage unit 28. The sensor information collection system 26 stores the sensor information acquired by the sensor 16 in the storage unit 28.

[0014] The sensor information includes the measurement result of the management item measured by the sensor 16 and the measurement time measured by the sensor 16. The sensor information may also include other information. The sensor information collection system 26 stores the management item measured by the sensor 16 and the detection time in association with each other as sensor information in the storage unit 28. The storage unit 28 of the sensor information collection system 26 is an example of a "first storage unit".

[0015] The defective product registration system 30 is for registering information relating to products 20 that have been determined to be defective during shipment inspection as defective information. The defective product registration system 30 includes a storage unit 32. The storage unit 32 stores the defective information of the products 20 that have been determined to be defective. Products 20 are determined to be good or defective by, for example, an inspector. The defective information includes, as information relating to the product 20, image data of the product 20 that has been determined to be defective, location data indicating the defective part of the product 20, and the registration time when the image data and location data were registered. The defective information may also include other information. The defective product registration system 30 stores the image data, location data and registration time in association with each other in the storage unit 32. The storage unit 32 of the defective product registration system 30 is an example of a "third storage unit".

[0016] The manufacturing system 10 includes a control device 40. The control device 40 manages the manufacturing line 12 of product 20 in the manufacturing system 10. The control device 40 may be configured as a PLC (Programmable Logic Controller) or a computer system. The computer system includes a CPU (Central Processing Unit), main memory such as RAM (Random Access Memory) and ROM (Read Only Memory), input devices such as a touch panel and keyboard, output devices such as a display, and auxiliary storage devices such as a hard disk.

[0017] The management device 40 displays various screens based on the information stored in the memory units 24, 28, and 32 of each system 22, 26, and 30. The management device 40 can be said to operate based on the information of each system 22, 26, and 30. Furthermore, the management device 40 can function as including each system 22, 26, and 30. Therefore, the management device 40 can also be said to include the memory units 24, 28, and 32.

[0018] The control device 40 includes a display device 42. The display device 42 displays information related to the manufacturing system 10. The display device 42 includes an input unit 44, a display control unit 46, and a display unit 48. The input unit 44 may be an input device of the computer system that constitutes the control device 40. The display unit 48 may be an output device of the computer system that constitutes the control device 40.

[0019] The display control unit 46 controls the collection of information in the display image of the display unit 48, the method of display, etc. The display control unit 46 causes the display unit 48 to display several screens. The screens displayed on the display unit 48 include those related to defective information.

[0020] The display control unit 46 displays a single screen on the display unit 48 that includes defect information, sensor information corresponding to the defect information, and control information corresponding to the defect information. By displaying the sensor information and control information together with the defect information on a single screen in this way, it becomes easy to identify the cause of the defect in the product 20.

[0021] (An example of a casting apparatus configuration) As shown in Figure 2, the casting apparatus 12 includes a sand treatment facility 61, a molding facility 62, a core installation facility 63, a pouring facility 64, a cooling and conveying facility 65, and a post-processing facility 66. These facilities 61-66 represent an example of the configuration of the casting apparatus 12, and the configuration of the casting apparatus 12 is not limited to this.

[0022] Each piece of equipment 61-66 in the casting apparatus 12 performs a process in the manufacturing line 12. The processes performed by the casting apparatus 12 include the molding process, core placement process, cooling and conveying process, pouring process, post-processing process, and sand processing process. The casting apparatus 12 is an example of a manufacturing line 12 that includes multiple processes.

[0023] The sand processing equipment 61 processes the mold sand used for forming molds. Specifically, the sand processing equipment 61 separates and removes impurities from the recovered sand. The sand processing equipment 61 measures the temperature and moisture content of the recovered sand and adds an amount of water proportional to the measured values ​​to the recovered sand. The sand processing equipment 61 further mixes the recovered sand with additives such as bentonite and water, and stirs it to produce mold sand (mixed sand). In the sand processing equipment 61, for example, the CB value (compactability value), moisture content, sand temperature, air permeability, and compressive strength are measured by the sensor 16 as parameters (sensor information) that define the status of the sand processing process. The sensor information may include measurement results from other sensors.

[0024] The molding equipment 62 puts the mold sand, which has been processed by the sand processing equipment 61, into the mold frame and compacts the mold sand to form the mold. The mold includes an upper mold and a lower mold. It is composed of upper and lower squeeze boards and match plates, and an upper or lower frame on the side. The molding equipment 62 forms the upper and lower molds by introducing the mold sand into the mold frame and squeezing it with the squeeze boards.

[0025] In the molding equipment 62, the aeration pressure, sand tank pressure, squeeze pressure (upper frame, lower frame), compressibility (mold compressibility), and release agent spray volume are managed as parameters (control information) that define the status of the molding process. Aeration is the process of introducing molding sand from the sand tank into the mold frame while blowing air from the side wall of the sand tank. In addition, the molding time when the mold is formed is managed as control information in the molding equipment 62. The control information may also include other information such as the molding cycle.

[0026] The core installation equipment 63 installs an auxiliary mold called a core inside the mold in order to manufacture a casting with a hollow portion. In the core installation equipment 63, the time of core installation and the setting load, which is the load at the time of installation, are managed as parameters (control information) that define the status of the core installation process.

[0027] The pouring equipment 64 melts material 18 such as iron to produce molten metal and pours the molten metal into the mold. In the pouring equipment 64, the pouring temperature, pouring time, pouring weight, and parameters (control information) that define the status of the pouring process are managed. The control information may include the pouring time, material number, ladle number of the ladle that transports the molten metal, etc.

[0028] The cooling and conveying equipment 65 conveys the molds formed in the molding equipment 62 to the pouring equipment 64. The cooling and conveying equipment 65 also conveys the molds into which molten metal has been poured in the pouring equipment 64 while cooling them, disassembles the molds to remove the castings, and further conveys the removed castings to the post-processing equipment 66 while cooling them. The disassembled molds are sent to the sand processing equipment 61 as recovered sand.

[0029] In the cooling and transporting equipment 65, the cooling time for the mold being transported and the mold dismantling time are managed as parameters (control information) that define the status of the cooling and transporting process. The post-processing equipment 66 performs post-processing such as marking the castings and folding the castings. In the post-processing process, the post-processed products 20 (castings) are inspected by workers. The inspection checks for any defects such as scratches on the products 20 (castings). If any defects such as scratches are found in the product 20 during the inspection, the workers determine that the product 20 is defective.

[0030] The worker registers the defect information for the product 20 that was determined to be defective in the defect registration system 30 shown in Figure 1. The information registered in the defective registration system 30 includes image data of the product 20 determined to be defective, information on the type of defect, information on the location of the defect, and the registration time. The information on the type of defect includes, for example, information on at least one of the following types of defects: sand inclusion, mold loss, misalignment, chipping, indentation, molten metal leakage, dents, cracks, shrinkage, blowing, molten metal boundary, slag, scooping, metal erosion, and seizure. The information on the location of the defect indicates the location of the defect in the product 20 (casting). For example, the location of the defect is the position (coordinate value) indicated by the worker on the image data of the product 20.

[0031] (Display of information by the management device) As shown in Figure 1, the display control unit 46 of the management device 40 causes the display unit 48 to display various screens based on the information stored in the memory units 24, 28, and 32 of each system 22, 26, and 30. One screen G12 to be displayed on the display unit 48 includes fault information 52, sensor information 54, and control information 56. The display control unit 46 of the management device 40 causes the display unit 48 to display one screen that includes fault information 52, sensor information 54 corresponding to the fault information 52, and control information 56 corresponding to the fault information 52.

[0032] The defect information 52, sensor information 54, and control information 56 include a management number set for each managed object, as information that identifies the managed object in the casting apparatus 12. The objects to be managed in the casting apparatus 12 refer to the materials processed or used in each of the equipment 61-66 (each process). In the sand processing process, the objects to be managed refer to the recovered sand and mold sand. In the core installation process, the objects to be managed refer to the mold in which the core is installed. In the pouring process, the objects to be managed refer to the molten metal and the mold. In the cooling and conveying process, the objects to be managed refer to the mold and the casting. In the post-processing process, the objects to be managed refer to the casting (product). The objects to be managed described above are just examples. Each process can be any of the multiple processes that make up the production line 12. The objects to be managed can be any materials processed or used in each process.

[0033] In the sand processing process, the control number used is the mold number of the mold into which the mold sand was placed. The mold number is an example of an identification number that identifies individual molds. In the core placement process, the control number used is, for example, the mold number of the mold into which the core was placed. The mold number is associated with information that identifies the placed core. In the pouring process, the control number used is, for example, the mold number of the mold. The mold number is associated with the ladle number corresponding to the ladle into which the molten metal was poured. In the cooling and transporting process, the control number used is, for example, the mold number of the mold being transported. In the post-processing process, the control number used is, for example, the product number (serial number) of the casting. The product number is an example of an identification number that identifies individual castings.

[0034] From the sand processing process to the cooling and transport process, the control device 14 controls the molds to be managed in equipment 61-66. Furthermore, the state of the mold sand and other materials being introduced into the molds to be managed is detected by sensor 16. Therefore, sensor information and control information include a management number for each managed item in the casting apparatus 12, which is the production line. For example, the management number is the mold number corresponding to the mold used to manufacture the casting. The sensor information includes the mold number, the detection time by the sensor when the mold sand was introduced into the mold with that mold number, and the detection result of sensor 16. In other words, the sensor information includes the mold number, which is the management number for each managed item, and the detection time and detection result associated with that mold number. Similarly, the control information includes the mold number, the control time and control result of the control performed on the mold with that mold number. The control results include, for example, the pressure inside the sand tank and the pouring temperature during sand filling into the mold, which can be detected by sensors, and the pouring time, which can be measured. In other words, the control information includes the mold number, which is a management number for each managed item, the control time associated with the mold number, and the control result.

[0035] An example of registering defect information in the defect registration system 30 will be explained. The worker registers defect information for castings that have been determined to be defective in the defect registration system 30. For example, the worker displays an input screen on the display unit of the defect registration system 30 by operating the input unit of the defect registration system 30. The worker then uses the camera of the defect registration system 30 to photograph the casting that has been determined to be defective. The worker also operates the input unit to input product-related data such as the casting model number, casting product number, type of defect, and location of the defect. Based on the worker's confirmation of the input, the defect registration system 30 stores the defect information, including the various data entered, in the storage unit 32. The stored defect information includes the registration time of various data, including image data.

[0036] The display control unit 46 of the management device 40 causes the display unit 48 to display a single screen that includes the defect information from the defect registration system 30, as well as sensor information and control information corresponding to the defect information. The defect information includes the registration time when image data of the product determined to be defective was registered. The sensor information includes the management number of the managed item and the detection time for each managed item. The control information includes the control time for the control applied to the managed item. Based on the registration time, the display control unit 46 displays the sensor information and control information, which include the management number corresponding to the product determined to be defective, on the display unit 48.

[0037] For products determined to be defective, the management number used may, for example, be the sensor information management number, which is the detection time within a predetermined period based on the registration time of the defect information. Alternatively, for products determined to be defective, the management number used may be the control information management number, which is the control time within a predetermined period based on the registration time of the defect information. This is because the sensor information or control information management numbers may not directly correspond to products determined to be defective.

[0038] As described above, the molds created by the molding equipment 62 are sequentially transported to each of the equipment 61-66 from the molding equipment 62 to the cooling and transport equipment. Therefore, sensor information and control information can be referenced by the mold number of the mold. However, castings removed from the mold by disassembly do not have a mold number attached to them, and the order of the disassembled castings may differ from the order in which the molds were transported. In addition, castings formed by pouring cannot be inspected by workers until they have cooled sufficiently after being disassembled from the mold, so the timing of the inspection of the castings may be significantly different from the timing of the castings' manufacture.

[0039] Therefore, the display control unit 46 of the management device 40 sets a predetermined period for the time frame in which the mold in which the registered product (casting) was made was made, relative to the registration time of the product (casting) determined to be defective. The management number of the mold under management within that predetermined period is then set to the management number corresponding to the product determined to be defective. This makes it possible to estimate the management number of the mold in which the product was made from the product after dismantling. For this reason, the display control unit 46 displays the sensor information and management information containing the management number together with the defect information of the product on a single screen. This makes it possible to easily trace the cause of the defect.

[0040] Depending on the manufactured product (casting), detection may be performed on multiple molds within a predetermined period, resulting in multiple detection times and thus multiple control numbers within that period. In such cases, the display control unit 46 of the management device 40 sets the control number corresponding to the product determined to be defective based on the detection results of multiple sensor information containing multiple control numbers. The sensor information includes the detection results from sensor 16. In molds where the detection results have fluctuated, defects may occur in the products made using those molds. Also, in molds with detection results exceeding a threshold, defects may occur in the products made using those molds.

[0041] Therefore, if the detection times for multiple management numbers fall within a predetermined period, the display control unit 46 identifies the detection results from the sensor 16 within the predetermined period that show fluctuations or exceed a threshold as the specific detection result. The display control unit 46 identifies the management number of the specific detection result as the management number corresponding to the product determined to be defective. The sensor information and control information containing this management number are then displayed on a single screen along with the product defect information. The information displayed on this screen makes it easy to trace the cause of the defect.

[0042] Note that the detection results may vary from the desired result for each individual mold. The range of variation in the detection results is set for each detection target, such as the moisture content of the mold sand. A detection result with variation refers to a detection result that exceeds the set range of variation. In addition, an acceptable range is set for the detection results. The acceptable range includes at least one of the upper and lower limits for each detection target, such as the moisture content of the mold sand. If the detection result is within the acceptable range, the status of the control item for that detection result is determined to be "normal," and if the detection result is outside the acceptable range, the status of the control item for that detection result is determined to be "abnormal." Note that even if the detection result is within the acceptable range, the status of the control item may be set to "caution" if the difference between the detection result and the upper or lower limit is smaller than a predetermined value. The threshold for the above detection results may be the upper or lower limit of the acceptable range, or it may be a different value from the upper or lower limit.

[0043] The display control unit 46 may, if the detection result is "abnormal", designate the detection result as a specific detection result, and may set the management number of the sensor information including that specific detection result as a management number corresponding to the product determined to be defective. Alternatively, the display control unit 46 may, if the detection result is "abnormal" or "caution", designate the detection result as a specific detection result, and may set the management number of the sensor information including that specific detection result as a management number corresponding to the product determined to be defective.

[0044] The above describes sensor information, but the same applies to control information. In other words, control information includes the control results of the control applied to the mold. For molds with fluctuating control results, or molds with control results exceeding a threshold, defects may occur in products manufactured using those molds. Therefore, if the control times for multiple management numbers fall within a predetermined period, the display control unit 46 designates the control results that fluctuated or exceeded a threshold as specific control results. The display control unit 46 then designates the management number of the specific control result as the management number corresponding to the product determined to be defective. The sensor information and control information containing this management number are then displayed on a single screen along with the product defect information. The information displayed on this screen makes it easy to trace the cause of the defect.

[0045] Furthermore, the control results may vary from the desired result for each individual mold. The range of variation in the control results is set for each detection target, such as pouring temperature. A control result with variation refers to a control result that exceeds the set range of variation. In addition, an acceptable range is set for the control results. The acceptable range includes at least one of an upper limit and a lower limit for each detection target, such as pouring temperature. If the control result is within the acceptable range, the state of the control item for that control result is determined to be normal; if the control result is outside the acceptable range, the state of the control item for that control result is determined to be abnormal. The threshold for the control result described above may be the upper or lower limit of the acceptable range, or it may be a value different from the upper or lower limit.

[0046] The display control unit 46 may, with respect to the control result, designate a control result as a specific control result if the state is "abnormal," and may set the management number of the sensor information including that specific control result as a management number corresponding to the product determined to be defective. Alternatively, the display control unit 46 may, with respect to the control result, designate a control result as a specific control result if the state is "abnormal" or "caution," and may set the management number of the sensor information including that specific control result as a management number corresponding to the product determined to be defective.

[0047] (Example of a display screen) Next, an example of the display screen by the display control unit 46 of the management device 40 will be described with reference to Figures 3 to 7. Note that Figures 3 to 7 show the case where English is used as the display language, but the display language may be changed to any language. Furthermore, the display language may be configured to be changeable as a setting.

[0048] As shown in Figure 3, the display control unit 46 of the management device 40 causes the startup screen G11 to be displayed on the display unit 48. The startup screen G11 includes the operation display area A111, the actual count display area A112, the trend display area A113, the difference display area A114, and the failure display area A115.

[0049] The operation display area A111 shows the Operation Start Time and Operating Time. The actual quantity display area A112 shows the Plan Production, Actual Production, and Difference. The trend display area A113 shows the temporal trend (cumulative) of production quantity, and displays the graph L11 of the Plan Production and the graph L12 of the Actual Production against time. The difference display area A114 shows the Short-time Breakdown and Process Cycle Time. In addition, detail buttons 1141 and 1142 for the Short-time Breakdown and Cycle Time are displayed in the difference display area A114, respectively. The detail buttons 1141 and 1142 function as GUI elements that are operated to transition from the startup screen G11 to the screen that displays the details. The defective product display area A115 shows the number of defective products and the product numbers 1151, 1152, and 1153 of the castings that were determined to be defective. Product numbers 1151-1153 function as GUI elements that are manipulated to transition to a screen displaying information about the corresponding defective castings.

[0050] The startup screen G11 allows you to check the planned production quantity and the actual production quantity. Additionally, the startup screen G11 allows you to check for any products deemed defective during inspection, along with their product numbers (1151-1153).

[0051] Figure 4 shows the defect information display screen G12, which displays defect information for product number "ABC1A". The display control unit 46 in Figure 1 displays the defect information display screen G12 in Figure 4 on the display unit 48 when product number 1151 in Figure 3 is selected. In addition, a back button 1200 is displayed in the upper left corner of the defect information display screen G12 shown in Figure 4. This back button 1200 functions as a GUI element for transitioning from the defect information display screen G12 to the startup screen G11 shown in Figure 3. The display position of the back button 1200 may be changed to any position.

[0052] The malfunction information display screen G12 includes a first display area A121 for malfunction information 52, a second display area A122 for sensor information 54, and a third display area A123 for control information 56. The first display area A121 displays image data 1211 and 1212 of the product included in the defect information 52, and a location indicator mark 1213 indicating the location of the defect. At least one location indicator mark 1213 may be displayed. In addition, the display form of the location indicator mark 1213 may be changed for each type of defect. The display form may be color, shape, etc.

[0053] The second display area A122 displays sensor information 54 corresponding to the product displayed in the first display area A121. The second display area A122 includes multiple display rows 1221 to 1225. Sensor information is displayed in each of the display rows 1221 to 1225. In one example, each display row 1221 to 1225 displays the process, control point, and state in which the sensor information 54 is acquired as items of the sensor information 54. The number of display rows in the second display area A122 may be changed as desired. The items displayed in each display row 1221 to 1225 may be changed as desired.

[0054] The third display area A123 displays control information 56 corresponding to the product displayed in the first display area A121. The third display area A123 contains multiple display rows 1231 to 1237. Each of the display rows 1231 to 1237 displays control information. In one example, each of the display rows 1231 to 1237 displays the process, control point, and state from which the control information 56 is acquired, as items of the control information 56. The number of display rows in the third display area A123 may be changed arbitrarily. The items displayed in each of the display rows 1231 to 1237 may be changed arbitrarily.

[0055] In Figure 4, among the sensor information 54 displayed in the second display area A122, display row 1221 displays the sensor information (display item) "CB (Compactability)" and the status "Error". In this way, the display control unit 46 first displays the information of sensors that have been determined to be abnormal for multiple display rows 1221 to 1225. The sensor information includes detection results from multiple sensors corresponding to the product number, which is the management number. Therefore, by first displaying the information of sensors that have been determined to be abnormal, it is easy to check the information of the abnormal sensor for products that have been determined to be defective. Note that in Figure 4, the control information displayed in the third display area A123 does not include any that have been determined to be "abnormal". If the control information also includes control information that has been determined to be "abnormal", the display control unit 46 first displays that control information. This makes it easy to check the information of the abnormal control for products that have been determined to be defective.

[0056] The display control unit 46 changes the display format of the sensor information displayed in each display row 1221 of the second display area A122 according to the status. For example, in display row 1222, the sensor information (display item) "Moisture Content" is "Normal". The display control unit 46 displays this "Moisture Content" display row 1222 in a first display format. Then, the display control unit 46 displays the "CB" display row 1221 in a second display format that is different from the first display format. The display format is changed by one or a combination of the following: character color, background color, blinking of characters or background, character thickness, character shape, etc. In one example, display row 1221 is shown with a red background color, and display row 1222 is shown with a normal color (system background color). In Figure 4, the difference in background color between display lines 1222-1225 is indicated by dot hatching, and the dots around the characters displayed in display line 1221 are omitted to improve readability. Note that when the status is "Caution," the display format may be the same as for "Normal" or "Abnormal," or it may be a different display format from both "Normal" and "Abnormal." The same applies to the display format in the third display area A123, which displays control information.

[0057] In Figure 4, a details button 1201 is displayed below the second display area A122. The details button 1201 functions as a GUI element that is operated to transition to a display screen that shows detailed sensor information.

[0058] Furthermore, the defect information display screen G12 includes a fourth display area A124 that displays alarm information. Each display row 1241 to 1243 of the fourth display area A124 displays information about alarms that occurred in the casting apparatus 12 shown in Figure 1. The alarm information includes the time of occurrence, installation, level, and alarm. The alarm level may be expressed by differences in display format (e.g., color). By displaying alarm information together with sensor information and control information related to product defects in this way, it becomes possible to easily trace the cause of the defect.

[0059] Figure 5 shows the detailed display screen G13, which displays detailed sensor information. This detailed display screen G13 is accessed from the defect information display screen G12 by selecting the details button 1201 shown in Figure 4. Also, a back button 1300 is displayed in the upper left corner of the detailed display screen G13, as shown in Figure 5. This back button 1300 functions as a GUI element for transitioning from the detailed display screen G13 to the defect information display screen G12 shown in Figure 4. The display position of the back button 1300 can be changed to any position.

[0060] The detailed display screen G13 in Figure 5 displays more types of sensor information than the second display area A122 in Figure 4. The detailed display screen G13 includes a parameter display area A131 and a management item display area A132. The management item display area A132 displays a list of management items. This management item display area A132 displays detailed sensor information. The sensor information includes management items, units, maximum and minimum values ​​of the detection result, upper and lower limits of the tolerance range, and judgment results. In this management item display area A132, the display format may be changed for detection results that exceed the tolerance range. The sensor information displayed in this management item display area A132 allows for a more detailed examination of sensor information that may be a cause of failure.

[0061] The parameter display area A131 displays the detection results for each control item in the control item display area A132 as bar graphs. The parameter display area A131 also shows a dashed line L131 indicating the upper limit of the acceptable range and a dashed line L132 indicating the lower limit of the acceptable range. The bar graph length for each control item's detection result is adjusted relative to these dashed lines L131 and L132, making it easy to determine whether each control item is within or outside the acceptable range.

[0062] Figure 6 shows the short-stop analysis screen G14. This short-stop analysis screen G14 is accessed by selecting the details button 1141 on the startup screen G11 shown in Figure 3. A back button 1400 is displayed in the upper left corner of this short-stop analysis screen G14. This back button 1400 functions as a GUI element for transitioning from the short-stop analysis screen G14 to the startup screen G11 shown in Figure 3. The display position of the back button 1400 may be changed to any position.

[0063] The short-stop analysis screen G14 includes a first display area A141 showing the operating rate, a second display area A142 showing the downtime in each process, and a third display area A143 showing a warning list.

[0064] The utilization rate displayed in the first display area A141 is the ratio of actual working time to the specified production time, and is shown as a pie chart. The second display area A142 shows the process names 1421 in the casting apparatus 12 shown in Figure 1, the stop times 1422 for each process name 1421, and the total stop time 1423 for the casting apparatus 12. If the total stop time 1423 exceeds a set value (threshold), the display format of the total stop time 1423 is changed to match the format when it does not exceed the set value. The display format of the stop times 1422 and 1423 may be one or a combination of the following: text color, background color, text or background blinking, text thickness, text shape, etc. In one example, if the set value is exceeded, the stop times 1422 and 1423 are displayed in red text.

[0065] Furthermore, the display format of process name 1421 may be changed according to the warning list displayed in the third display area A143. The third display area A143 displays the warning list, including the time of occurrence of the warning, the time of registration, and the type of warning. The display format of process name 1421 may be one or a combination of the following: text color, background color, flashing of text or background, text thickness, text shape, etc. In one example, the background color of process name 1421 is changed to "green," "yellow," and "red" according to the warning list. This makes it easy to grasp the alarm status in each process and the short stop time in each process. Therefore, it is possible to obtain the information necessary for the operation of the equipment included in the casting apparatus 12 shown in Figure 1.

[0066] Figure 7 shows the cycle time display screen G15. This cycle time display screen G15 is accessed by selecting the details button 1142 on the startup screen G11 shown in Figure 3. A back button 1500 is displayed in the upper left corner of this cycle time display screen G15. This back button 1500 functions as a GUI element for transitioning from the cycle time display screen G15 to the startup screen G11 shown in Figure 3. The display position of the back button 1500 may be changed to any position.

[0067] The cycle time display screen G15 shows the cycle time with the horizontal axis representing time and the vertical axis representing duration. The cycle time display screen G15 displays the cycle time transitions in chronological order. The time on the horizontal axis can be viewed in relation to the control time in the control information. Therefore, the cycle time display screen G15 allows us to obtain the information necessary for the operation of the equipment included in the casting apparatus 12 shown in Figure 1.

[0068] (Effects of the first embodiment) The effects and advantages of the first embodiment will be described below. (1-1) The control device 40 manages the production line 12 (casting apparatus 12) of product 20. The control device 40 includes a storage unit 28 that stores sensor information from sensors 16 located on the production line 12, a storage unit 24 that stores control information on the production line 12, and a storage unit 32 that stores defect information, including image data of products determined to be defective, regarding defects in product 20. The control device 40 also includes a display unit 48 and a display control unit 46 that causes the display unit 48 to display a single screen G12 including defect information 52, sensor information 54 corresponding to the defect information 52, and control information 56 corresponding to the defect information 52.

[0069] In this way, by displaying sensor information and control information along with defect information on a single screen, it becomes easy to identify the cause of the defect in product 20 that has been determined to be defective.

[0070] (1-2) Sensor information includes a management number for each managed object in the manufacturing line, the detection time for each managed object for multiple sensors, and the detection result from the sensor, all associated with each object. Control information includes the control time in the manufacturing line and the control status associated with each management number. Defect information includes the registration time of the image data. The display control unit 46 causes the display unit to display sensor information and control information that include at least one of the management numbers of the sensor information including the detection time corresponding to the registration time and the control information including the control time corresponding to the registration time, corresponding to the product that has been determined to be defective.

[0071] As a result, in cases where the management number for defect information does not directly correspond to the management number for sensor information or control information, the sensor information for a management number that includes a detection time corresponding to the registration time may represent the detection result of the sensor 16 for the product 20 that was determined to be defective. Similarly, the control information for a management number that includes a control time corresponding to the registration time may represent the result of the control applied to the product 20 that was determined to be defective. Therefore, by displaying the sensor information and control information for the product 20 that was determined to be defective on the defect information display screen G12, it becomes easy to confirm the cause of the defect in the product 20 that was determined to be defective.

[0072] (1-3) The display control unit 46 assigns a management number corresponding to the product determined to be defective to the management number for which the detection time of the sensor information falls within a predetermined period relative to the registration time. Sensor information including the detection time within a predetermined period relative to the registration time includes the detection result of the sensor 16 for the product 20 determined to be defective. Therefore, by displaying sensor information that is more likely to be a cause of defect for the product 20 determined to be defective, it becomes easier to confirm the cause of defect for the product 20 determined to be defective.

[0073] (1-4) The display control unit 46 assigns a management number corresponding to the product determined to be defective to the control time of the control information within a predetermined period relative to the registration time. The control information including the control time within a predetermined period relative to the registration time includes the results of the control applied to the product 20 determined to be defective. Therefore, by displaying control information that may be a contributing factor to the defect of the product 20 determined to be defective, it becomes easier to confirm the defect factors of the product 20 determined to be defective.

[0074] (1-5) If the detection times for multiple management numbers fall within a predetermined period, the display control unit 46 selects a specific detection result from among the sensor detection results within the predetermined period that has fluctuated or exceeded a threshold, and selects the management number of the specific detection result from among the multiple management numbers to be the management number corresponding to the product that was determined to be defective.

[0075] Products 20 manufactured using molds that yielded fluctuating detection results or detection results exceeding a threshold may be defective. Therefore, when there are multiple control numbers for detection times within a predetermined period, displaying sensor information that is more likely to result in a defective product 20 makes it easier to identify the cause of the defect in products 20 that have been determined to be defective.

[0076] (1-6) If the detection times for multiple management numbers fall within a predetermined period, the display control unit 46 selects a control result that has changed or exceeded a threshold from among the control results from the sensor within the predetermined period as a specific control result, and selects the management number of the specific control result from among the multiple management numbers as the management number corresponding to the product that was determined to be defective.

[0077] Products 20 manufactured using a mold that yielded fluctuating control results or control results exceeding a threshold may be defective. Therefore, when there are multiple control numbers for detection times within a predetermined period, displaying control information that is more likely to result in a defective product 20 makes it easier to identify the cause of the defect in a product 20 that has been determined to be defective.

[0078] (1-7) The display control unit 46 displays the detection results of multiple sensors in a first display mode, and displays specific detection results in a second display mode that is different from the first display mode. This type of display makes specific control results easier to see, thus making it easier to track down the causes of defects.

[0079] (1-8) The display control unit 46 displays multiple control results in a first display mode and displays a specific control result in a second display mode different from the first display mode. This type of display makes specific detection results easier to see, thus facilitating the tracking of the cause of defects.

[0080] (1-9) The manufacturing line involves forming a mold and pouring molten metal into the mold to obtain a casting as a product. A product judged to be defective is a casting that has been removed from the mold. The detection results of the sensor 16 and the control results for the mold during the manufacturing process are managed by the mold number of the mold, but the mold number may not correspond to a casting that has been removed from the mold. In this regard, by using the detection time and control time in relation to the registration time of the defect information for a casting judged to be defective by inspection, it becomes easier to associate the mold with the casting judged to be defective. Therefore, by displaying the defect information of a casting judged to be defective, along with the sensor information and control information corresponding to that defect information, on a single screen G12, it becomes easier to trace the cause of the defect.

[0081] (Example of modification of the first embodiment) The first embodiment can be implemented with the following modifications. The first embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically. In the following modifications, parts common to the first embodiment are denoted by the same reference numerals as in the first embodiment, and their descriptions are omitted.

[0082] The display control unit 46 may display the sensor information detection results in the second display area A122 in order from the detection results with the largest variation. The larger the variation in the detection results, the greater the impact on the occurrence of defects in product 20. By displaying the sensor information in this way, it becomes easier to trace the factors that led to product 20 being determined to be defective. Similarly, the display control unit 46 may display the control information detection results in the third display area A123 in order from the largest variation. By displaying the control information in this way, it becomes easier to trace the factors that led to product 20 being determined to be defective.

[0083] Figure 8 shows an example of the malfunction information display screen G12A displayed on the management device 40. This defect information display screen G12A is displayed by selecting product number 1151, as shown in Figure 3, similar to the defect information display screen G12 shown in Figure 4. Furthermore, selecting the return button 1200 transitions to the startup screen G11 shown in Figure 3.

[0084] In this fault information display screen G12A, the display format of the second display area A122 differs from that of the fault information display screen G12 shown in Figure 4. In the modified example of fault information display screen G12A, among the sensor information displayed in the second display area A122, sensor information with a status of "normal" is displayed entirely in gray, for example, in rows 1222 to 1225, making the text difficult to read. This display format makes it easier to recognize sensor information with a status of "abnormal". Therefore, it becomes easier to trace the cause of a failure using the sensor information displayed in this fault information display screen G12A.

[0085] The control device 40 may also display the defect information display screen G12A using a factor table T11 (see Figure 9) in which defect information and its causes are stored in association. The factor table T11 stores the type of defect and the cause of the defect associated with that type of defect. The cause of a defect includes at least one item from the detection items related to the sensor 16 and the control items related to the control information for each type of defect. The cause of a defect is set based on the types of defects that have occurred in the past and the causes of those defects. In the example shown in Figure 9, for the defect information "Square", the substantive "Moisture content" is associated as factor 1, the "Sand temperature" of the sensor 16 is associated as factor 2, and the "Pouring temperature" in the control is associated as factor 3. For the defect information "Sand jamming", the "CB value" of the sensor 16 is associated as factor 1, and the "Sand tank internal pressure" in the control is associated as factor 2. For the defect information "dent defect," the "compression strength" of sensor 16 is associated as factor 1, and the "casting time" in the control is associated as factor 2.

[0086] The display control unit 46 of the management device 40 reads the factors associated with the defect information registered in the defect registration system 30 shown in Figure 1, based on the factor table T11. It displays only the "CB value," which is the sensor information for that factor, as shown in display row 1221 in Figure 8, while display rows 1222 to 1225 are grayed out, for example, so that the text is difficult to read. As a result, it becomes possible to easily check the status of the sensor information associated with the factors of the defect information, making it easier to track the causes of defects.

[0087] Furthermore, in the defect information display screen G12A shown in Figure 8, in the third display area A123, display rows 1231, 1233-1237 may be grayed out based on the factor table T11 in Figure 9, and the display format of display row 1232 may not be changed. By doing so, the visibility of display row 1232 can be made easier. As a result, it becomes possible to easily check the status of the control information associated with the factors of the defect information, and it becomes easier to trace the cause of the defect.

[0088] As shown in Figure 10, the management device 40 may display a defect information display screen G12B that includes only sensor information and control information related to the defect information of the product. In one example, the management device 40 displays only the sensor information and control information that have been determined to be abnormal for the defect information of product 20 that has been determined to be defective. For example, in the defect information display screen G12B, sensor information is displayed only for display row 1221 of the second display area A122, and sensor information for display rows 1222 to 1225 is not displayed. In the modified example shown in Figure 10, since the control information has not been determined to be abnormal, control information is not displayed for display rows 1231 to 1237. Sensor information or control information that has been determined to be abnormal is often a cause of defect in product 20. This makes it possible to easily trace the cause of defect for product 20 that has been determined to be defective.

[0089] As shown in Figure 11, the control device 40 may display only the information stored as a factor in the factor table T11 shown in Figure 9 on the defect information display screen G12C for the defect information of the product 20 that has been determined to be defective. In the example shown in Figure 9, the defect information is "sand jamming", the "CB value" of the sensor 16 is associated as factor 1, and the "sand tank pressure" in the control is associated as factor 2. The control device 40 displays only "CB" and "Error" as sensor information in display row 1221 of the second display area A1222 of the defect information display screen G12C. In addition, the control device 40 displays only "Sand Tank Pressure" and "Normal" as control information in display row 1231 of the third display area A123 of the defect information display screen G12C. Therefore, the sensor information and control information displayed on this defect information display screen G12C makes it easier to trace the cause of the defect for the product 20 that has been determined to be defective.

[0090] The items to be registered in the defect registration system 30 are not limited to the product 20, but can be any item to be managed in the casting apparatus 12. For example, defect information on the mold may be registered as an item to be managed. In the case of a mold, a defect may be judged by an operator during the process of setting the core. In this case, the operator setting the core, or someone who has been contacted by that operator, registers the defect information in the defect registration system 30. In this way, by registering defect information on items to be managed other than the product 20, it becomes possible to track the causes of defects in the manufacturing system 10.

[0091] (Second Embodiment) The manufacturing system 210 of the second embodiment will be described below. In addition, for the manufacturing system 210 of the second embodiment, the same reference numerals are used for components similar to those in the manufacturing system 10 of the first embodiment, and some of the descriptions may be omitted.

[0092] (Outline configuration of the manufacturing system) As shown in Figure 12, the manufacturing system 210 includes a shot processing device 212, a control device 214, and a sensor 216. The shot processing device 212 constitutes a manufacturing line 212 for producing product 220 from material 218. The shot processing device 212 includes one or more pieces of equipment for producing product 220.

[0093] The shot blasting apparatus 212 performs surface processing on the workpiece, which is the object to be processed. The material 218 supplied to the shot blasting apparatus 212 is the workpiece before surface processing, and is the object to be processed by the shot blasting apparatus. The control number for this material 218 is, for example, the product number stamped on the material 218. The product 220 manufactured by the shot blasting apparatus 212 is the workpiece after surface processing. The control number for this product 220 is the product number stamped on the product 220. In other words, the object to be processed in the manufacturing system 210 of the second embodiment includes the workpiece before surface processing and the workpiece after surface processing. Examples of surface processing include shot blasting, which removes scale, deburrs, and roughens the surface of workpieces such as steel, and shot peening, which improves fatigue strength, etc. The shot blasting apparatus 212 processes the surface of the workpiece by projecting or spraying shot material onto the surface of the workpiece.

[0094] The control device 214 controls the equipment included in the shot processing device 212. The control device 214 controls the equipment of the shot processing device 212 based on control information stored in the storage unit 24 of the control system 22. The control results in the equipment of the shot processing device 212 controlled by the control device 214 are stored in the storage unit 24 of the control system 22 through the control device 214. The control information includes information about the equipment to be controlled, control parameters for the equipment, and control results in the equipment.

[0095] The control result includes detection results obtained by sensors such as current sensors corresponding to the controlled object. The control result includes the control result of the equipment by the control device 214 and the control time for the equipment. The control result may include other information. The control device 214 stores the control information in the storage unit 24, associating the control result and the control time. The storage unit 24 of the control system 22 is an example of a "second storage unit".

[0096] Sensor 216 acquires sensor information of various control items related to manufacturing in the shot processing apparatus 212. Sensor 216 is installed in various pieces of equipment included in the shot processing apparatus 212 and acquires various information in the manufacturing line. For example, sensor 216 may include a temperature sensor, etc. Sensor information acquisition system 26 includes a storage unit 28. Sensor information acquisition system 26 stores the sensor information acquired by sensor 216 in the storage unit 28. Sensor information includes the measurement result of the control item by sensor 216 and the measurement time measured by sensor 216. Sensor information may include other information. Sensor information acquisition system 26 stores the control item by sensor 216 and the detection time in association with each other as sensor information in the storage unit 28. The storage unit 28 of sensor information acquisition system 26 is an example of a "first storage unit".

[0097] The defective product registration system 30 is for registering information relating to products 220 that have been determined to be defective during shipment inspection as defective information. The defective product registration system 30 includes a storage unit 32. The storage unit 32 stores the defective information of the products 220 that have been determined to be defective. Products 220 are determined to be good or defective by, for example, an inspector. The defective information includes, as information relating to product 220, image data of the product 220 that has been determined to be defective, location data indicating the defective part of the product 220, and the registration time when the image data and location data were registered. The defective information may also include other information. The defective product registration system 30 stores the image data, location data and registration time in association with each other in the storage unit 32. The storage unit 32 of the defective product registration system 30 is an example of a "third storage unit".

[0098] The manufacturing system 210 includes a control device 40. The control device 40 manages the manufacturing line for product 220 in the manufacturing system 210. The management device 40 displays various screens based on the information stored in the memory units 24, 28, and 32 of each system 22, 26, and 30. The management device 40 includes a display device 42. The display device 42 displays information related to the manufacturing system 210. The display control unit 46 controls the collection of information in the display image of the display unit 48, the display method, etc. The display control unit 46 causes the display unit 48 to display several screens. The screens displayed on the display unit 48 include those related to defect information.

[0099] The display control unit 46 displays a single screen on the display unit 48 that includes defect information, sensor information corresponding to the defect information, and control information corresponding to the defect information. By displaying the defect information, sensor information, and control information together on a single screen in this way, it becomes easy to identify the cause of the defect in the product 220.

[0100] (An example of a shot processing device configuration) As shown in Figure 13, the shot processing device 212 includes a cabinet 261, a projection device 262, a conveying device 263, and a dust collector 264 as equipment. Figure 13 shows an example of the configuration of the shot processing device 212, and the configuration of the shot processing device 212 may be changed as desired.

[0101] The cabinet 261 is a housing configured to accommodate the material 218 to be processed. Inside the cabinet 261 is a processing chamber for applying shot blasting to the material to be processed.

[0102] The projection device 262 performs shot blasting by projecting a blasting material onto the target object. One example of the projection method used by the projection device 262 is an impeller type (centrifugal type). An air-powered projection method may also be used. Examples of blasting materials include steel shot and steel grid. The type of blasting material can be selected according to the shot blasting process.

[0103] The projection device 262 includes a projection material tank, a control cage, and an impeller. The projection material tank stores the projection material. The control cage is a component for adjusting the area of ​​the opening in the path from the projection material tank to the impeller. The control cage supplies a predetermined amount of projection material to the impeller. The impeller is rotated at high speed, for example, by a motor. The centrifugal force generated by this rotation projects the projection material supplied onto the impeller blades. The projection device 262 may include multiple impellers. In one example, the projection device 262 includes five impellers.

[0104] The conveying device 263 transports the material 218, which is to be processed, into the processing chamber of the cabinet 261. The conveying device 263 also transports the processed product 220 out of the processing chamber of the cabinet 261.

[0105] The dust collector 264 collects the dust generated by the shot blasting process. In the projection device 262, ambient temperature is detected by sensor 216 as sensor information. In the projection device 262, the energy from the impact of the abrasive material used in shot processing is converted into heat. The heat generated by the projection device 262 can affect the durability of the motor that drives the impeller and the conveying equipment within the projection device 262. In addition, the projection device 262 manages control information such as the current value of the motor that drives the impeller (impeller current value), the particle size of the abrasive material, and the conveying speed.

[0106] As shown in Figure 12, the display control unit 46 of the management device 40 displays various screens on the display unit 48 based on various information stored in the memory units 24, 28, and 32 of each system 22, 26, and 30. One screen to be displayed on the display unit 48 includes fault information 252, sensor information 254, and control information 256. The display control unit 46 of the management device 40 displays one screen on the display unit 48 that includes fault information 252, sensor information 254 corresponding to fault information 252, and control information 256 corresponding to fault information 252.

[0107] (Example of a display screen) Next, an example of the display screen by the display control unit 46 of the management device 40 will be described with reference to Figures 14 to 16. Note that Figures 14 to 16 show the case where English is used as the display language, but the display language may be changed to any language. Furthermore, the display language may be configured to be changeable as a setting.

[0108] As shown in Figure 14, the display control unit 46 of the management device 40 causes the startup screen G21 to be displayed on the display unit 48. The startup screen G21 includes the operation display area A211, the actual count display area A212, the trend display area A213, the difference display area A214, and the defect display area A215.

[0109] The operation display area A211 shows the operating status of the shot processing device 212, operating time, cumulative projection time, pre-operation inspection results, and shot replenishment amount. The actual figures display area A212 shows the planned figures, actual figures, and the difference.

[0110] The trend display area A213 shows the temporal (cumulative) trend of production volume, displaying graphs of planned volume and actual volume against time. The difference display area A214 displays the current operating status, the number of abnormalities, and the replacement forecast. Here, the replacement forecast is a warning issued when the replacement time for consumable parts in the shot processing device 212 is approaching, for example, when the impeller is nearing replacement time. These function as GUI elements that are operated to transition to the operating status display screen G23 in Figure 16.

[0111] The defective display area A215 displays the product numbers 2151-2154 of the products 220 that have been determined to be defective, along with the defect rate. Product numbers 2151-2154 function as GUI elements that are manipulated to transition to a screen displaying the defective product information for the corresponding product 220.

[0112] The startup screen G21 allows you to check the planned production quantity and the actual production quantity. Additionally, the startup screen G21 allows you to check for any products deemed defective during inspection, along with their product numbers 2151-2154.

[0113] Figure 15 shows the defect information display screen G22, which displays defective product information for product number "AA01". The display control unit 46 in Figure 12 displays the defect information display screen G22 in Figure 15 on the display unit 48 when product number 2151 in Figure 14 is selected. In addition, a back button 2200 is displayed in the upper left corner of the defect information display screen G22 in Figure 15. This back button 2200 functions as a GUI element for transitioning from the defect information display screen G22 to the startup screen G21 shown in Figure 14. The display position of the back button 2200 may be changed to any position.

[0114] The malfunction information display screen G22 includes a first display area A221 for malfunction information 252, a second display area A222 for sensor information 254, and a third display area A223 for control information 256. The first display area A221 displays product image data 2211 and 2212 included in the defect information 252, and a location indicator mark 2213 indicating the location of the defect. At least one location indicator mark 2213 may be displayed. The display form of the location indicator mark 2213 may be changed for each type of defect. The display form may be color, shape, etc.

[0115] The second display area A222 displays sensor information 254 corresponding to the product displayed in the first display area A221. The sensor information includes the status of detection results from multiple sensors, corresponding to the product number, which is the management number. Therefore, by first displaying the information of the sensor that was determined to be abnormal, it is easy to check the information of the abnormal sensor for a product that has been determined to be defective.

[0116] The third display area A223 displays control information 256 corresponding to the product displayed in the first display area A221. If the control information also includes control information that has been determined to be "abnormal," the display control unit 46 will first display that control information. This makes it easy to check the abnormal control information for products that have been determined to be defective.

[0117] In the second display area A222, the display format is changed according to the status, similar to the second display area A122 in the first embodiment shown in Figure 4. Note that in the second display area A222, sensor information indicating a "normal" status may be displayed in a way that makes it difficult to see, for example, by using gray text. Alternatively, only sensor information indicating an "abnormal" status may be displayed in the second display area A222.

[0118] In the third display area A223, the display format is changed according to the status, similar to the second display area A122 in the first embodiment shown in Figure 4. Note that in the third display area A223, sensor information indicating a "normal" status may be displayed in a way that makes it difficult to see, for example, by using gray text. Alternatively, only sensor information indicating an "abnormal" status may be displayed in the third display area A223.

[0119] Furthermore, the defect information display screen G22 includes a fourth display area A224 that displays alarm information. Each display row 2241 to 2243 of the fourth display area A224 displays information about alarms that occurred in the shot processing device 212 shown in Figure 12. The alarm information includes the time of occurrence, level, and alarm. The alarm level may be represented by differences in display format (e.g., color). By displaying alarm information together with sensor information and control information related to product defects in this way, it becomes possible to easily trace the cause of the defect.

[0120] Figure 16 shows the operating status display screen G23. This operating status display screen G23 is accessed by selecting the difference display area A214 shown in Figure 14. A return button 2300 is displayed in the upper left corner of this operating status display screen G23. This return button 2300 functions as a GUI element for transitioning from the operating status display screen G23 to the startup screen G21 shown in Figure 14. The display position of the return button 2300 may be changed to any position.

[0121] The operating status display screen G23 includes a first display area A231 that displays the operating status, etc. The first display area A231 displays the operating status of the shot processing device 212, operating time, cumulative projection time, number of shots processed, and shot replenishment amount.

[0122] The operating status display screen G23 includes a second display area A232 that displays sensor information and control information, and a third display area A233 that displays a graph showing the time-series transition of the sensor information and control information. The sensor information and control information displayed in the second display area A232 show the values ​​obtained at the present time. The operating status display screen G23 allows users to check the current and past operating status.

[0123] Furthermore, the operating status display screen G23 includes a fourth display area A234 that displays alarm information. Each display row 2341 to 2343 of the fourth display area A234 displays information about alarms that occurred in the shot processing device 212 shown in Figure 12. The alarm information includes the time of occurrence, the time of recovery, the level, and the alarm level. The alarm level may be represented by differences in display format (e.g., color). By displaying alarm information together with sensor information and control information related to product defects in this way, it becomes possible to easily trace the cause of the defect.

[0124] (Effects of the second embodiment) The effects and advantages of the second embodiment will be described below. (2-1) With respect to the product 220 processed by the shot processing device 212 that constitutes the manufacturing line of the manufacturing system 210 of the second embodiment, it is possible to easily trace the cause of defects, similar to the manufacturing system 10 of the first embodiment.

[0125] (Example of change) The above embodiment can be implemented with the following modifications. The above embodiment and the following modifications can be combined with each other to the extent that they do not contradict each other technically. In the following modifications, parts common to the above embodiment are denoted by the same reference numerals as in the above embodiment, and their descriptions are omitted.

[0126] The factors contributing to defects in the factor table T11 shown in Figure 9 may be stored, for example, by the worker. Furthermore, the factor table T11 may be generated by machine learning.

[0127] As shown in Figure 17, the processor P11 uses the defect information 52, sensor information 54, and control information 56 to create a factor table T11 using a trained model built by machine learning. There may be one or more processors P11. In this way, the factor table T11 is created by machine learning using one or more processors P11. This makes it easy to create the factor table T11. Furthermore, because it is done by machine learning, it becomes easy to modify the contents of the factor table T11, add factors, etc.

[0128] In the defective registration system 30, the determination of products 20 and 220 may be performed, for example, by a computer that performs image processing. The computer inspects the manufactured products 20 and 220 using a trained model constructed by machine learning using image data of good products and image data of defective products from the past. The computer then stores the inspection results as defective information in the storage unit 32.

[0129] The embodiments disclosed herein are illustrative in all respects, and the present invention is not limited to these examples. That is, the scope of the present invention is indicated by the claims, and all modifications within the meaning and scope equivalent to the claims are intended to be included. [Explanation of Symbols]

[0130] 10...Manufacturing system, 12...Casting equipment (production line), 14...Control device, 16...Sensor, 18...Material, 20...Product, 22...Control system, 24...Storage unit, 26...Sensor information collection system, 28...Storage unit, 30...Defect registration system, 32...Storage unit, 40...Management device, 42...Display device, 44...Input unit, 46...Display control unit, 48...Display unit, 52...Defect information, 54...Sensor information, 56...Control information, 61...Sand processing equipment, 62...Molding equipment, 63...Core installation equipment, 64...Pouring equipment, 65...Cooling and conveying equipment, 66...Post-processing equipment, 210...Manufacturing system, 212...Sho 214…Control device, 216…Sensor, 218…Material, 220…Product, 252…Defect information, 254…Sensor information, 256…Control information, 261…Cabinet, 262…Projection device, 263…Conveyor device, 264…Dust collector, 1141,1142…Details button, 1151~1153…Product number, 1200…Return button, 1201…Details button, 1211,1212…Image data, 1213…Position indicator mark, 1221~1225…Display row, 1231~1237…Display row, 1241~1243…Display row, 1300,1400…Return A111... Operation display area, A112... Actual count display area, A113... Transition display area, A114... Difference display area, A115... Defect display area, A121... 1st to 4th display area, A131... Parameter display area, A132... Management item display area, A1 41~A143…1st~3rd display area, A211…Operation display area, A212…Actual count display area, A213…Trend display area, A214…Difference display area, A215…Defect display area, A221~A224…1st~4th display area, A231~A234…1st~4th display area, G11…Startup screen, G12,G12A~G12C…Defect information display screen (screen), G13…Detailed display screen, G14…Short stop analysis screen, G15…Cycle time display screen, G21…Startup screen, G22…Defect information display screen, G23…Operation status display screen, L11,L12…Graph, L131,L132…Dashed line, P11…Processor, T11…Factor table.

Claims

1. A control device for managing objects in a manufacturing line, A first storage unit that stores sensor information from multiple sensors arranged on the aforementioned manufacturing line, A second storage unit that stores control information for the aforementioned manufacturing line, Regarding defects in the managed object, a third storage unit stores defect information including image data of the managed object that has been determined to be defective, Display unit and A display control unit that causes the display unit to display a single screen including the fault information, the sensor information corresponding to the fault information, and the control information corresponding to the fault information, A control device that includes this.

2. The sensor information includes, in association with, a management number for each managed object in the manufacturing line, the detection time for each managed object for the multiple sensors, and the detection result from the sensor. The control information includes the control time and control state in the manufacturing line associated with the management number. The aforementioned defect information includes the registration time of the image data, The display control unit causes the display unit to display at least one of the management numbers of the sensor information including the detection time corresponding to the registration time, and the control information including the control time corresponding to the registration time, the management number of the sensor information and the control information that includes the management number corresponding to the managed object that was determined to be defective. The control device according to claim 1.

3. The display control unit sets the management number for which the detection time of the sensor information falls within a predetermined period relative to the registration time to the management number corresponding to the management item determined to be defective. The control device according to claim 2.

4. The display control unit, when the detection time for a plurality of management numbers falls within the predetermined period, selects a detection result that has changed or a detection result that exceeds a threshold from among the detection results from the sensor within the predetermined period as a specific detection result, and selects the management number of the specific detection result from among the plurality of management numbers as the management number corresponding to the management unit that was determined to be defective. The control device according to claim 3.

5. The display control unit displays the detection results of the multiple sensors in a first display mode, and displays the specific detection result in a second display mode different from the first display mode. The control device according to claim 4.

6. The display control unit displays the sensor information from among the detection results of the multiple sensors, starting with the detection results with the largest variation in the detection result. The control device according to claim 3 or claim 4.

7. The display control unit displays only the sensor information for which the detection result is abnormal from among the detection results of the multiple sensors on the display unit. The control device according to claim 3 or claim 4.

8. The display control unit sets the management number for which the control time of the control information is within a predetermined period with respect to the registration time to the management number corresponding to the management item determined to be defective. The control device according to claim 2.

9. The display control unit, when the control time for a plurality of management numbers falls within the predetermined period, selects the management number from among the plurality of management numbers for which the control result in the control of the manufacturing line is determined to be abnormal, and sets that management number to the management number corresponding to the management unit that was determined to be defective. The control device according to claim 8.

10. The display control unit displays only the control items for which the control result is abnormal from among the plurality of control results on the display unit. The control device according to claim 9.

11. The display control unit, The table includes the type of defect and a factor table in which at least one of the detection items related to the sensor and the control items related to the control are associated with the type of defect. Based on the factor table, for the factors of the defect associated with the type of defect in the defect information, the management number of the item in which the defect factor changed or exceeded the threshold within the predetermined period shall be the management number corresponding to the managed item that was determined to be defective. The control device according to claim 3 or claim 8.

12. Includes one or more processors that generate the aforementioned factor table by machine learning, The control device according to claim 11.

13. The aforementioned manufacturing line involves forming a mold, pouring molten metal into the mold, and obtaining a casting as the subject of the management control. The object to be managed that was determined to be defective is the casting removed from the mold. The aforementioned management number includes the identification number of the mold, The control device according to claim 2.

14. The aforementioned manufacturing line obtains the control target by shot-processing the workpiece, The aforementioned management number includes the identification number of the object to be processed. The control device according to claim 2.

15. A display device, A single screen is displayed that includes defect information, including image data of the managed object determined to be defective, sensor information from multiple sensors placed on the manufacturing line, and control information for the manufacturing line. Display device.

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