Debugging the operation of mass production equipment

Abstract

To provide a method which more facilitates operation debugging of a facility including altered devices when a plurality of devices are partially altered.SOLUTION: In an operation debugging method for facility, a control unit has activation procedure information about a sequence and time series in accordance with which a plurality of devices are to be activated, with respect to a mass production facility including the plurality devices and performs sequence control of successively transmitting an OUT signal for starting a prescribed operation to the plurality of devices and successively receiving an IN signal showing the completion of the operation after the completion of the operation in the devices. The control unit is configured to actually transmit the OUT signal to altered devices out of the plurality of devices and receive the IN signal after actual activation but transmit a virtual OUT signal not prompting actual activation to unaltered devices in accordance with the comprehended sequence and time series and receive a virtual IN signal from these devices, thus activating only the altered devices.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a method for debugging the operation of equipment, and more particularly to a method for debugging the operation of equipment in which a plurality of devices are sequence-controlled by a control unit when some of the devices are modified. [Background technology]

[0002] In a mass production facility for automobiles and the like, for example, one section or one group of work (one cycle of work) is performed by a control unit that sequentially controls multiple devices, such as jigs, robots, and equipment (Non-Patent Document 1). Typically, this control unit is called a PLC (Programmable Logic Controller: Non-Patent Document 2), and the software that operates this PLC is called a ladder diagram (ladder).

[0003] In this sequence control, during one cycle of work, the control unit (PLC) sends a signal (OUT signal) to each of multiple devices, and when the device completes a specified operation, the control unit receives a signal (IN signal). The control unit uses this OUT signal to make each device perform its specified operation. The control unit keeps track of the devices that are to be operated during one cycle in chronological order, and is characterized by the fact that it cannot proceed to the next operation unless it receives an IN signal from the device that sent the OUT signal.

[0004] When a device is modified, the person who performed the modification usually inputs the modified software (i.e., the modified ladder diagram) into the control unit and performs operation debugging of the equipment, that is, work to resolve problems such as interference between the modified device and other devices and the stoppage of sequence control. In this case, the modified device and all devices related to one cycle of work are operated. [Prior art documents] [Non-patent literature]

[0005] [Non-Patent Document 1] "Sequence control" http: / / wikipedia.org /

[0006] [Non-patent document 2] "Programmable logic controller" http: / / wikipedia.org / Summary of the Invention [Problem to be solved by the invention]

[0007] Equipment operation debugging is performed while all devices controlled by the control unit (hereinafter sometimes referred to as PLC) are running. In other words, if a device is not running, even if the control unit sends a signal to that device, the signal cannot be received from the device, and the control unit will stop. Therefore, when there are multiple devices, the equipment operation debugging work cannot be performed unless all the people in charge of operating each of those devices are present. For example, even if the modified device is a single device, there are multiple people in charge of operating each device in the entire facility, which makes scheduling extremely complicated and prevents rapid operation debugging work.

[0008] The present invention has been made in view of the above-mentioned problems, and its object is to provide an operation debugging method for equipment that, when some of a plurality of devices have been modified, can more easily perform operation debugging of equipment including the modified devices. [Means for solving the problem]

[0009] In order to achieve the above object, the following is claimed in claim 1: mass production The method for debugging the operation of the equipment is as follows: Multiple devices death, Control unit but the plurality of devices A mass production facility for automobiles that performs a set of operations by performing sequence control of the above, and when some of the multiple devices are modified, In the method for debugging the operation of equipment, The control unit the plurality of devices The order in which the devices are operated and the operating procedure information for operating each device are included. Sequentially transmitting an OUT signal to the plurality of devices to start a predetermined operation, each The device has completed the predetermined operation. later emitted from the device When an IN signal is received indicating that the operation has finished, In addition, information on the OUT signal and the IN signal during mass production operation, which is the collective operation of all of the plurality of devices, is stored in advance, and the sequence control is performed by storing the information on the improvement to be the target of operation debugging. Other than the equipment that was designed The information on the OUT signal and the IN signal stored during mass production operation of the device is used to improve the target of the operational debugging. The device is constructed to In contrast, in reality Put it into operation Send the OUT signal and emitted from the device Receive the IN signal The time interval between the transmission of the OUT signal and the reception of the IN signal is used to verify the operation of the modified device. It is characterized by:

[0010] This method allows for debugging of equipment when modified equipment is present, with only the person in charge of operating the modified equipment present. Specifically, the control unit sends an OUT signal to the modified equipment to actually operate it, and receives an IN signal from the modified equipment once the specified operation of the modified equipment is complete. Meanwhile, for unmodified equipment, the control unit receives OUT and IN signals as virtual operation data based on the operation data from mass production stored in the control unit, i.e., the OUT and IN signals arranged in chronological order. Therefore, in a procedure where modified and unmodified equipment coexist, debugging of equipment operation is possible without operating the unmodified equipment. This allows debugging of equipment operation with only the presence of the person in charge of operating the modified equipment.

[0011] The method according to claim 2 mass production The method for debugging the operation of the equipment is as set forth in claim 1. mass production In the method for debugging the operation of equipment, the control unit teeth , the modified device is emitted If the IN signal cannot be received properly, the operating procedure information is corrected.

[0012] With this method, the operating procedure information for the modified device is corrected by the operator of the modified device to match the modification and input into the control unit. However, if there is an error in the operating procedure information, the IN signal from the modified device cannot be received properly, so the operator must immediately correct the operating procedure information at this stage. This allows for quick checking and adjustment of only the modified device in question. Therefore, not only can the operator perform operational debugging alone, but debugging is also achieved with smooth operation.

[0013] The method according to claim 3 mass production The method for debugging the operation of equipment is as set forth in claim 1 or 2. mass production In the method for debugging the operation of equipment, The control unit The modified device The aforementioned OUT signal and The aforementioned a time interval determination unit that determines the time interval between the IN signal and the The operation of the modified device is judged based on whether the time interval between the OUT signal and the IN signal stored before the modification has become longer or not; If the time becomes too long, a warning is issued.

[0014] According to this method, if the time interval between the OUT signal and the IN signal becomes longer after the modification, it basically means that the modification has not been performed properly. In that case, a warning is issued and the person in charge of operating the modified equipment is prompted to make the necessary adjustments. Therefore, not only can operation debugging be performed by the person in charge of operation alone, but the modification also effectively prevents the operating time of the entire equipment from being extended. [Effects of the Invention]

[0015] According to the equipment operation debugging method of the present invention, if there is a modified device in the equipment, the modified device is actually operated, and a virtual OUT signal that does not prompt actual operation and a virtual IN signal based on the OUT signal are sent and received to the unmodified devices. This allows the operation debugging work to be quickly performed by only the person in charge of operating the modified device that is actually operating. Therefore, it is possible to promote the operation debugging of equipment including modified devices. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a schematic diagram showing the relationship between a control unit (PLC) and each device in accordance with the method for debugging equipment operation of the present invention; [Figure 2] 1 shows a flow chart of the operation of the equipment operation debugging method of the present invention. [Figure 3] 1 shows an example of virtual operation data of an unmodified device according to the method for debugging equipment operation of the present invention. [Figure 4] 1 is a conceptual diagram showing an operation program for debugging an equipment operation according to the present invention. [Figure 5] 10 shows an example of the time interval between an OUT signal from the control unit (PLC) to each device and an IN signal from each device, in accordance with the equipment operation debugging method of the present invention. [Figure 6] 10 shows an example of a warning when the time interval between an OUT signal to a device and an IN signal from the device becomes long, in accordance with the method for debugging the operation of equipment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0017] The method for debugging the operation of equipment according to the present invention will be described in detail below with reference to the drawings.

[0018] 1 is a schematic diagram showing the relationship between a control unit (PLC) and each device in the equipment operation debugging method of the present invention. The equipment has many devices (jigs 14, robots 16, equipment 18, etc.), and all the devices are sequence-controlled by a control unit (PLC) 12. Here, there may be multiple jigs, robots, and equipment.

[0019] Sequence control is a control in which each step of control is carried out sequentially according to a predetermined order or procedure. For example, the control unit (PLC) 12 sends an OUT signal to a specific device, and when the specific device completes a predetermined operation, the device sends an IN signal to the control unit (PLC) 12. That is, the control unit 12 receives the IN signal from the device. In FIG. 1, the sending of an OUT signal is described as "OUT signal output" and the receiving of an IN signal is described as "IN signal return." For all devices, the sending (output) of an OUT signal and the receiving (return) of an IN signal are performed. The control unit 12 has operating procedure information regarding the order and chronological order in which multiple devices are operated. That is, it has information that arranges the OUT signal and IN signal for each device in chronological order.

[0020] This operating procedure information is software for performing sequence control, a so-called ladder diagram. That is, the ladder diagram controls a specific device to start a specific operation in response to an OUT signal from the control unit 12, and to return an IN signal to the control unit 12 when the operation is completed. Note that sequence control is usually performed for each cycle, which is a convenient division of work.

[0021] The control unit 12 may send an OUT signal to multiple devices at the same time, or may send an OUT signal to one device multiple times. However, an IN signal is always returned each time an OUT signal is sent to a device and the device completes a specified operation. If the control unit 12 cannot properly receive the IN signal, the control unit 12 stops control.

[0022] When a device is modified, the associated ladder diagram is also modified (modified). Debugging the operation involves checking whether the control by the control unit 12 for one cycle (or more cycles), including the ladder diagram, operates correctly. If there is a malfunction, the control unit 12 will stop, and in that case, for example, the ladder diagram will need to be modified.

[0023] 2 is a flow diagram of the operations of the equipment operation debugging method of the present invention. First, virtual operation data for the unmodified equipment is created (virtual operation data creation process: step S1). Next, an operation program is created that, when the control unit is operating, acquires OUT signals and IN signals for the unmodified equipment from the virtual operation data and sends them to the control unit (operation program creation process: step S2). Next, only the modified equipment is operated and operation debugging work is performed (operation debugging process: step S3). Then, if the control unit stops (step S5: Yes), the ladder diagram for the modified equipment is checked and corrected (ladder diagram correction process: step S5).

[0024] Finally, the time interval between the OUT signal to the modified device and the IN signal from the modified device is determined (time interval determination step: step S6). If the time interval between the OUT signal and the IN signal becomes longer due to the modification of the device, the control unit issues a warning and requests that the modified device be readjusted.

[0025] As described above, for unmodified equipment, only virtual signals are sent and received without actually operating, so there is no need for the person in charge of operating each device to be on standby; it is possible to debug the operation of the equipment if only the person in charge of operating the modified device is present.

[0026] Each step will be described in more detail below.

[0027] Virtual operation data creation process (Step S1) Figure 3 shows an example of virtual operating data for unmodified equipment. It shows the OUT signals from the control unit of each unmodified piece of equipment and the IN signals to the control unit in a time series during mass production. For example, an OUT4 signal is sent to a robot at time t1, and an IN4 signal is returned from the robot at time t2. An OUT7 signal is sent to the equipment at time t3, and an IN7 signal is returned from the equipment at time t6. This is how the equipment always operates during mass production, and information on the OUT and IN signals on this time axis always exists for all equipment. In this process, this type of time series information is created only for equipment that has not been modified.

[0028] Such information on the time axis of virtual OUT signals and IN signals that do not actually prompt the operation of the device, that is, virtual operation data, can be created by the control unit.

[0029] Operation program creation process (step S2) An operating program is created that enables the modified equipment to be operated, an OUT signal to be sent from the control unit to the modified equipment, and the control unit to receive an IN signal from the modified equipment, and enables the virtual operating data during mass production operation shown in Figure 3 to be sent to the control unit.

[0030] Figure 4 is a conceptual diagram of the operating program. The left side shows the OUT signal from the control unit to the operating modified equipment, and the IN signal from the modified equipment to the control unit on the time axis. The right side shows the OUT signal from the control unit to the operating and unmodified equipment, and the IN signal from the operating and unmodified equipment to the control unit on the time axis. The transmission and reception of signals to the control unit on the right side is virtual; that is, the program is written to send the OUT signal and IN signal during mass production operation to the control unit based on the virtual operation data shown in Figure 3. The actual program is written in, for example, C language.

[0031] Operation debugging process (step S3) The modified device and the above operating program are actually run to debug the equipment. For the device being operated (a jig in Figure 4), an OUT1 signal is sent from the control unit to the jig at a predetermined time, for example, time T1, and when the jig completes its predetermined operation, an IN1 signal is returned to the control unit. Because the jig has been modified, the return time is not fixed. Then, at time t1, the control unit sends an OUT4 signal to the robot, and at time t2, an IN4 signal is returned from the robot. This signal from the robot is the virtual operating data shown in Figure 3.

[0032] In this way, when the operating program is run, actual signal transmission and reception information is obtained from the modified device, and virtual signal transmission and reception information shown in Figure 3 is obtained from other unmodified devices.

[0033] The control unit controls each device, and if the software that operates the control unit, i.e., the ladder diagram, is correct, the control unit will continue to send and receive signals without stopping until the end of the specified cycle (usually one cycle, as control is performed cycle by cycle). If there is no problem with the ladder diagram, the control unit will not stop (Step S4: No), but if there is a problem with the ladder diagram (Step S4: Yes), the control unit will stop, so the following ladder diagram correction process must be carried out.

[0034] Ladder diagram correction process (Step S5) As mentioned above, if there is a problem with the ladder diagram related to the modified device, the control unit will stop. For example, if the IN signal does not return within the specified time, or a different IN signal returns, and an OUT signal cannot be sent to the next device. In this case, there is a problem with the ladder diagram related to the modified device, so check and correct the ladder diagram. After the correction is complete, turn it back on and operate the control unit. If the ladder diagram is corrected correctly, the control unit will operate without stopping until the end of the specified cycle.

[0035] Time interval determination step (step S6) After the control unit runs one cycle, the interval between the OUT signal and the IN signal becomes clear for both the modified and unmodified devices, i.e., the time interval between the time the OUT signal is sent from the control unit and the time the IN signal is received from each device. This time interval is determined by the time interval determination unit in the control unit. For unmodified devices, virtual operating data from mass production is used, as described above. Figure 5 shows the OUT and IN signal data for each device during mass production before modification and after modification.

[0036] In Figure 5, "Signal Relationships During Operation" shows the interval between the OUT signal and the IN signal for each piece of equipment during mass production operation. In other words, this is information before the equipment was modified. "Actual Machine Debugging" shows the interval between the OUT signal and the IN signal for the modified equipment (here, the jig). Comparing the signal intervals between "Signal Relationships During Operation" and "Actual Machine Debugging," the time interval shown in (1) becomes shorter after the modification, as shown in (1)'. On the other hand, the time interval shown in (2) becomes longer after the modification, as shown in (2)'. The time interval shown in (3) remains the same even after the modification.

[0037] When equipment is modified, the problem is that the interval between cycles becomes longer, as shown in (2)'. This means that the operating time required for one cycle becomes longer, and ultimately the manufacturing time for the product becomes longer than before. If this situation is confirmed, the modified equipment must be readjusted.

[0038] Figure 6 shows an example of a warning issued by the control unit when the operating time of a device becomes longer after modification. For example, with regard to (2)' above, if the operating time becomes longer after modification, a warning will be displayed indicating the target signal relationship, the previous operating time, and the operating time after modification, stating, "The operating time after modification is longer than before. Please check and adjust the actual device." If the operating time is the same as before or shorter, there is no particular problem.

[0039] When a warning is issued, the person who modified the equipment should check and adjust the equipment (actual machine) to make the operating time the same as or shorter than the previous time. In this way, the equipment as a whole is maintained in the best condition.

[0040] According to the equipment operation debugging method of this embodiment, when a modified device is present, debugging of the equipment is possible with only the person in charge of operating the modified device. That is, the control unit sends an OUT signal to the modified device to actually operate it, and receives an IN signal from the modified device once the specified operation of the modified device is complete. On the other hand, for unmodified devices, the control unit receives OUT and IN signals as virtual operation data based on the mass-production operation data stored in the control unit, i.e., the OUT and IN signals arranged in chronological order. Therefore, in a procedure where modified and unmodified devices coexist, equipment operation debugging is possible without operating the unmodified device. This allows equipment operation debugging to be performed with only the presence of the person in charge of operating the modified device.

[0041] Furthermore, if there is an error in the ladder diagram related to the modified device, the IN signal from the modified device cannot be received properly, so the operation manager must immediately correct the operation procedure information again at this stage. This allows for quick checking and adjustment of only the modified device in question. This not only makes it possible for the operation manager to perform operation debugging alone, but also achieves debugging with smooth operation.

[0042] Furthermore, if the time interval between the OUT signal and the IN signal becomes longer after the modification, a warning is issued, prompting the operator of the modified equipment to make the necessary adjustments. This not only enables the operator to debug the operation alone, but also effectively prevents the modification from extending the operating time of the entire facility.

[0043] The present invention is not limited to the above-described embodiment, and various modifications are possible within the scope of the present invention. For example, although jigs, robots, equipment, etc. related to product manufacturing are exemplified as devices controlled by the control panel, measuring instruments may also be used.

[0044] Furthermore, when there are multiple modified devices and two people are involved, one person may first perform the equipment operation debugging method of the present invention on the devices modified by the other person, assuming that the devices modified by the other person are not modified.Then, the other person may take over the results of the equipment debugging method performed by the first person and perform the equipment operation debugging method of the present invention.Of course, two people can also each operate their own modified devices and perform the equipment operation debugging method of the present invention. [Explanation of symbols]

[0045] 10 Mass production equipment 12 Control unit (PLC) 14 Jig 16. Robot 18 Equipment

Claims

1. An automobile mass production facility has a plurality of devices, and a control unit performs sequence control of the plurality of devices to perform a set of operations, and a method for debugging the operation of the mass production facility is performed when some of the plurality of devices are modified, comprising: The control unit The order in which the plurality of devices are to be operated and operation procedure information for operating each device are included; Sequentially transmitting OUT signals to the plurality of devices to cause them to start a predetermined operation, and receiving IN signals indicating that the operation has been completed from each device after the device has completed the predetermined operation; In addition, information on the OUT signal and the IN signal during mass production operation, which is the collective operation of all of the plurality of devices, is stored in advance, The sequence control uses the stored information on the OUT signal and IN signal during mass production operation of a device other than the modified device that is the target of operational debugging, sends the OUT signal that will actually be operated to the modified device that is the target of operational debugging, receives the IN signal emitted from the device, and confirms the appropriateness of the operation of the modified device based on the time interval between sending the OUT signal and receiving the IN signal. This is a method for debugging the operation of mass production equipment, characterized in that

2. 2. The method for debugging the operation of mass production equipment according to claim 1, wherein the control unit corrects the operating procedure information when the IN signal emitted by the modified device cannot be properly received.

3. The control unit 3. The method for debugging the operation of mass production equipment according to claim 1, further comprising a time interval determination unit that determines the time interval between the OUT signal and the IN signal related to the modified equipment, and the propriety of operation of the modified equipment is determined based on whether the pre-stored time interval between the OUT signal and the IN signal before the modification has become longer, and if it has become longer, a warning is issued.

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