Trouble analysis support method, trouble analysis support device, and program

Abstract

To provide a trouble analysis support method, etc., capable of reproducing a trouble state of a production facility more faithfully and easily.SOLUTION: A trouble analysis support method includes: a step (S12) of acquiring a first command response, which is a response to a first command issued to one or more units from a first operation log including an operation history in trouble occurrence in a production facility; and steps (S13-S17) of simulating operation of the production facility based on the first command response. The simulation step includes: a step (S13) of issuing a second command corresponding to the first command to one or more virtual units on the simulation corresponding to the one or more units; a step (S15) of executing the second command in one or more virtual units; and a step (S17) of issuing the acquired first command response as a second command response which is a response of each of the one or more virtual units to the second command.SELECTED DRAWING: Figure 5

Description

[Technical Field]

[0001] The present disclosure relates to a trouble analysis support method, a trouble analysis support device, and a program. [Background technology]

[0002] When a problem occurs in production equipment such as a component mounting device, the production data used to operate the production equipment and the operating conditions such as various setting conditions are used to reproduce the problem state of the production equipment, and then verification and response are considered (see Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-018830 Summary of the Invention [Problem to be solved by the invention]

[0004] However, while the technology of Patent Document 1 focuses on reproducing the flow of commands issued to the production equipment up until the time of the occurrence of a problem, simply reproducing the flow of commands issued may not faithfully reproduce the trouble state of the production equipment. Also, it is desirable to be able to easily reproduce the trouble state.

[0005] Therefore, the present disclosure provides a trouble analysis support method, a trouble analysis support device, and a program that can more faithfully and more easily reproduce a trouble state of a production facility. [Means for solving the problem]

[0006] A trouble analysis support method according to one embodiment of the present disclosure is a trouble analysis support method that supports trouble analysis of a production facility consisting of one or more units by simulating the operation of the production facility, and includes: a command response acquisition step of acquiring a first command response, which is a response of the one or more units to a first command issued to the one or more units, from a first operation log including an operation history at the time of a trouble occurrence in the production facility; and a simulation step of simulating the operation of the production facility based on the acquired first command response, wherein the simulation step includes: a command issuing step of issuing a second command corresponding to the first command to one or more virtual units in the simulation corresponding to the one or more units; a command execution step of executing the second command in the one or more virtual units; and a command response issuing step of issuing a second command response, which is a response of the one or more virtual units to the second command, wherein the acquired first command response is issued as the second command response in the command response issuing step.

[0007] A trouble analysis support device according to one embodiment of the present disclosure supports trouble analysis of production equipment consisting of one or more units by simulating the operation of the production equipment, and includes: an acquisition unit that acquires a first command response, which is the response of the one or more units to a first command issued to the one or more units, from a first operation log including an operation history at the time of a trouble occurrence in the production equipment; and a simulation processing unit that simulates the operation of the production equipment based on the acquired first command response, wherein the simulation processing unit issues a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units, executes the second command in the one or more virtual units, and issues a second command response, which is the response of the one or more virtual units to the second command, and in issuing the second command response, issues the acquired first command response as the second command response.

[0008] A program according to one aspect of the present disclosure is a program for causing a computer to execute the above-described trouble analysis support method. [Effects of the Invention]

[0009] According to one aspect of the present disclosure, it is possible to realize a trouble analysis support method and the like that can more faithfully and easily reproduce the trouble state of production equipment. [Brief explanation of the drawings]

[0010] [Figure 1] FIG. 1 is a diagram showing the overall configuration of a trouble analysis support system according to an embodiment. [Figure 2] FIG. 2 is a block diagram showing the functional configuration of an actual manufacturing system according to an embodiment. [Figure 3] FIG. 3 is a diagram illustrating an example of a first operation log according to the embodiment. [Figure 4] FIG. 4 is a block diagram showing the functional configuration of a manufacturing system on a software simulator in the analysis support device according to the embodiment. [Figure 5] FIG. 5 is a sequence diagram illustrating the operation of the analysis support device according to the embodiment. [Figure 6] FIG. 6 is a flowchart showing the operation of each unit of the analysis support device according to the embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0011] (Background to this application) Patent Document 1 discloses that a component mounting device (component mounter) is provided with a production mode and an operation reproduction mode, and the operation at the time of the trouble is reproduced in the operation reproduction mode using the operating conditions at the time of the trouble that were saved in the production mode. In other words, Patent Document 1 reproduces the trouble state using the component mounting device itself in which the trouble occurred. Patent Document 1 also generates commands to be used when reproducing the trouble state in the operation reproduction mode based on the operating conditions at the time of the trouble in the production mode, and uses the generated commands to reproduce the operation at the time of the trouble.

[0012] However, even if the flow of issuing commands when a problem occurs is reproduced using the same component mounting device, it is not possible to completely reproduce the command responses of each unit in response to the issued commands.

[0013] Furthermore, with the technology of Patent Document 1, the problem is reproduced using the component mounting device in which the problem occurred, so production cannot be carried out while the problem is being reproduced using that component mounting device. In other words, with the technology of Patent Document 1, the problem cannot be reproduced without affecting production.

[0014] Therefore, in this disclosure, we have conducted extensive research into a trouble analysis support method, a trouble analysis support device, and a program that can more faithfully and easily reproduce trouble conditions in production equipment, and have devised the trouble analysis support method, the trouble analysis support device, and the program described below.

[0015] A trouble analysis support method according to one embodiment of the present disclosure is a trouble analysis support method that supports trouble analysis of a production facility consisting of one or more units by simulating the operation of the production facility, and includes: a command response acquisition step of acquiring a first command response, which is a response of the one or more units to a first command issued to the one or more units, from a first operation log including an operation history at the time of a trouble occurrence in the production facility; and a simulation step of simulating the operation of the production facility based on the acquired first command response, wherein the simulation step includes: a command issuing step of issuing a second command corresponding to the first command to one or more virtual units in the simulation corresponding to the one or more units; a command execution step of executing the second command in the one or more virtual units; and a command response issuing step of issuing a second command response, which is a response of the one or more virtual units to the second command, wherein the acquired first command response is issued as the second command response in the command response issuing step.

[0016] As a result, by using the first operation log, which has not been used in the past, the behavior of each virtual unit in the simulation can be made closer to the behavior of each unit in reality. In other words, the trouble state of the production equipment can be reproduced more faithfully in the simulation. This contributes to, for example, efficiently performing cause analysis of the trouble, data analysis, and countermeasure consideration when a trouble occurs in the production equipment. Furthermore, since the production equipment in which the trouble occurred is not used to reproduce the trouble state, the trouble state can be reproduced without affecting production. Therefore, a trouble analysis support method can be realized that can reproduce the trouble state of the production equipment more faithfully and more easily.

[0017] Furthermore, for example, the method may further include an operation log generation step of generating a second operation log including the second command response for each of the one or more virtual units, and a first determination step of determining whether the first operation log and the second operation log match.

[0018] This allows a determination to be made as to whether the first operation log and the second operation log match, thereby informing the user whether the behavior of each real unit has been perfectly reproduced on each virtual unit.

[0019] Also, for example, if it is determined in the first determination step that the first operation log and the second operation log do not match, the first operation log may be edited and the simulation step may be executed again based on the edited first operation log.

[0020] This allows the degree of agreement between the first operation log and the second operation log to be increased if the first operation log and the second operation log do not match, thereby making it possible to more faithfully reproduce the trouble state of the production equipment in the simulation.

[0021] Also, for example, the one or more virtual units may have a first virtual unit and a second virtual unit, the first operation log may include a first command response corresponding to only one of the first virtual unit and the second virtual unit, and the edited first operation log may include an additionally obtained first command response that corresponds to the other virtual unit of the first virtual unit and the second virtual unit.

[0022] This allows the first command responses issued by the real units to be added to the first operation log, making it possible to more accurately reproduce the behavior of each real unit on each virtual unit.

[0023] Also, for example, the one or more virtual units may include a first virtual unit and a second virtual unit, the first operation log may include a first command response of only one of the first virtual unit and the second virtual unit, and the edited first operation log may include a dummy value of the first command response of the other virtual unit of the first virtual unit and the second virtual unit.

[0024] This allows a dummy value to be added to the first operation log as the first command response of a unit that has not received the first command response issued by a real unit, making it possible to easily reproduce the behavior of each real unit on each virtual unit.

[0025] Also, for example, the method may further include a second determination step of determining the type of the acquired second command, and in the command response issuing step, a first command response corresponding to the unit is extracted from the first operation log according to the determined type of the second command, and the extracted first command response is issued as the second command response.

[0026] As a result, each virtual unit automatically obtains the first command response corresponding to that virtual unit from the first operation log, and therefore the processes from obtaining the first command response to issuing the second command response can be performed automatically.

[0027] Furthermore, for example, the first command and the second command may be commands generated based on production data relating to production when a problem occurs in the production equipment and setting conditions of the one or more units.

[0028] As a result, the first command and the second command become the same command, and therefore the trouble state of the production equipment can be reproduced more faithfully.

[0029] A trouble analysis support device according to one embodiment of the present disclosure supports trouble analysis of a production facility consisting of one or more units by simulating the operation of the production facility, the trouble analysis support device including: an acquisition unit that acquires, from a first operation log including an operation history at the time of a trouble occurring in the production facility, a first command response that is a response of the one or more units to a first command issued to the one or more units; and a simulation processing unit that simulates the operation of the production facility based on the acquired first command response, wherein the simulation processing unit issues a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units, executes the second command in the one or more virtual units, and issues a second command response that is a response of the one or more virtual units to the second command, and in issuing the second command response, issues the acquired first command response as the second command response. A program according to one embodiment of the present disclosure is a program for causing a computer to execute the trouble analysis support method described above.

[0030] This provides the same effect as the above-mentioned trouble analysis support method.

[0031] Hereinafter, the embodiments will be specifically described with reference to the drawings.

[0032] The embodiments described below are all comprehensive or specific examples. The numerical values, shapes, components, component placement and connection configurations, steps, and step order shown in the following embodiments are merely examples and are not intended to limit the present disclosure. Furthermore, among the components in the following embodiments, components not described in independent claims are described as optional components.

[0033] Furthermore, each figure is a schematic diagram and is not necessarily an exact illustration. Therefore, for example, the scales of the figures do not necessarily match. Furthermore, in each figure, substantially the same components are given the same reference numerals, and redundant explanations are omitted or simplified.

[0034] Furthermore, in this specification, "part" or "device" is not limited to a physical configuration that is mechanically realized by hardware, but also includes a configuration in which at least a portion of the functions of the configuration are realized by software such as a program.

[0035] Furthermore, in this specification, terms indicating relationships between elements such as coincidence, as well as numerical values ​​and numerical ranges, are not expressions that express only the strict meaning, but also expressions that include a substantially equivalent range, for example, a difference of a few percent (e.g., about 10%).

[0036] (Embodiment) A trouble analysis support system including an analysis support device according to this embodiment will be described below with reference to FIGS.

[0037] [1. Configuration of the trouble analysis support system] First, the configuration of a trouble analysis support system according to this embodiment will be described with reference to Figures 1 to 4. Figure 1 is a diagram showing the overall configuration of a trouble analysis support system 1 according to this embodiment.

[0038] 1, the trouble analysis support system 1 includes a manufacturing system 10, an analysis support device 100, and a display device 200. The trouble analysis support system 1 is an information processing system for reproducing a trouble that occurs in the manufacturing system 10 by a simulation using the analysis support device 100. The manufacturing system 10 (e.g., a control device 20) and the analysis support device 100 are connected to each other so that they can communicate with each other. The communication method may be wired communication or wireless communication.

[0039] The manufacturing system 10 is an actual manufacturing system that is placed in a factory or the like, and includes a control device 20 and one or more component mounting devices 30. The one or more component mounting devices 30 form a manufacturing line.

[0040] The control device 20 manages production in the manufacturing system 10. The control device 20 controls one or more component mounting devices 30 in the production line, for example, based on production data and setting conditions. The control device 20 generates commands for controlling each unit based on production data input from outside and setting conditions of each unit that makes up the component mounting device 30, and issues the generated commands to each unit. In other words, the control device 20 outputs commands to each unit. The control device 20 also obtains command responses, which are responses to the commands, from each unit. The commands that the control device 20 issues to each unit of the component mounting device 30 are an example of a first command.

[0041] The production data is data related to production, and includes information on the boards to be produced and the components to be mounted, the number of productions, the production time, and the like.

[0042] The setting conditions are the setting conditions of each unit of the component mounting apparatus 30, and include information such as the conditions of the components of each unit (for example, the conditions of the suction nozzle), the mounting position of the component, and the like.

[0043] The command is an instruction regarding the operation or processing content for controlling each unit, and may, for example, cause each unit to perform a predetermined operation, obtain a measurement value using a sensor or the like, or output a determination result as to whether the measurement value is normal. If the unit is the component mounting head unit 32, the predetermined operation may be, for example, a pickup operation, a correction operation, a mounting operation, etc., and the measurement value may be a flow rate value, a position correction value, etc. Furthermore, the determination result may be whether the flow rate value or the mounting position is normal.

[0044] The command response is a response from each unit to a command, and if the unit is the component mounting head unit 32, includes a flow rate value or status information such as a pickup error or a mounting error.

[0045] A trouble occurs when a unit does not operate normally in response to a command issued by the control device 20, and, for example, when production cannot be performed as intended. When the unit is the component mounting head unit 32, the trouble may be, for example, a flow rate error, a mounting error, etc. The trouble may also be an error that causes the operation of the component mounting device 30 to stop.

[0046] In addition, information summarizing the command responses of each unit is also recorded as an operation log.

[0047] The control device 20 outputs production data, setting conditions, and an operation log before and after the occurrence of the trouble to the analysis support device 100. The production data, setting conditions, and operation log are information for reproducing the operation of the component mounting device 30 in the analysis support device 100. In this embodiment, the control device 20 outputs an operation log (first operation log 50 described later) to the analysis support device 100 as information for reproducing the operation of the component mounting device 30.

[0048] The component mounting apparatus 30 is an example of production equipment that constitutes a production line, and is a mounting equipment that mounts components on an object (workpiece) such as a board etc. The configuration of the component mounting apparatus 30 will be described later with reference to FIG.

[0049] The components are electronic components, such as, but not limited to, resistors, capacitors, etc. The target object is not limited to a substrate, and may be any workpiece that can be subjected to a predetermined processing.

[0050] The analysis support device 100 reproduces in a simulation the operation of the component mounting device 30 based on the production data, the setting conditions, and the operation log. The analysis support device 100 simulates the operation (processing) of the component mounting device 30. In this embodiment, the analysis support device 100 reproduces in a simulation the operation of the component mounting device 30 when a problem occurs in the component mounting device 30.

[0051] The analysis support device 100 is realized by a personal computer or the like, but may also be realized by a mobile terminal such as a tablet terminal.

[0052] The display device 200 displays an image output from the analysis support device 100. The display device 200 displays information relating to the operation of the component mounting device 30 reproduced in the simulation. The display device 200 is realized by, for example, a liquid crystal display or the like, but is not limited to this.

[0053] The trouble analysis support system 1 may also include a reception device (not shown) that receives input from a user. The trouble analysis support system 1 may receive instructions for the analysis support device 100 via the reception device. The reception device may include a keyboard, buttons, a touch panel, etc., or may include a microphone that receives voice.

[0054] At least one of the analysis support device 100 and the display device 200 may be provided outside the factory where the manufacturing system 10 is installed.

[0055] The configuration of the manufacturing system 10 will now be described further with reference to Fig. 2 and Fig. 3. Fig. 2 is a block diagram showing the functional configuration of the actual manufacturing system 10 according to this embodiment. In Fig. 2, solid arrows indicate commands issued by the control device 20 to each unit of the component mounting device 30, and dashed arrows indicate command responses issued from each unit to the control device 20.

[0056] As shown in Fig. 2, the manufacturing system 10 includes a control device 20, a component mounting device 30, and a storage unit 40. In Fig. 2, for convenience, the control device 20 controls one component mounting device 30, but there may be multiple component mounting devices 30. The number of component mounting devices 30 controlled by the control device 20 is not particularly limited.

[0057] Based on the production data D1 and setting conditions D2 acquired from the outside, the control device 20 issues commands to each unit of the component mounting device 30. For example, when the control device 20 causes the component mounting head unit 32 to pick up a component, the control device 20 issues a flow rate value check command to the component mounting head unit 32.

[0058] The control device 20 also acquires a command response from each unit, which is a response to the issued command. For example, the control device 20 acquires a command response including a flow rate value or a determination result of the flow rate value from the component mounting head unit 32 as a response to a flow rate value check command. The control device 20 may store the command responses acquired from each unit in the storage unit 40 as a first operation log 50. The first operation log 50 is information summarizing the command responses of each unit of the component mounting device 30, and is a log recording the operation history of the component mounting device 30. The first operation log 50 includes information summarizing the command responses of each unit of the component mounting device 30 when a problem occurs in the component mounting device 30.

[0059] Component mounting apparatus 30 is made up of multiple units. In this embodiment, component mounting apparatus 30 is made up of a component supply unit 31, a component mounting head unit 32, a component recognition unit 33, an axis control unit 34, and a board transport control unit 35. Each unit is made up of a processing unit (software processing unit) that processes commands such as a CPU, and a physical configuration (hardware) that operates based on the commands.

[0060] The component supply unit 31 has one or more feeders arranged side by side, and supplies components to a pick-up position by the component mounting head unit 32. The feeders are, for example, tape feeders, but may also be, for example, bulk feeders. A command to the component supply unit 31 is to supply a component to the pick-up position, and the command response is, but is not limited to, information identifying the feeder that supplied the component, or information indicating whether the component supply has been completed successfully.

[0061] The component mounting head unit 32 mounts (mounts) components placed at the pick-up position of the component supply unit 31 onto the board. The component mounting head unit 32 includes a mounting head (head) equipped with component suction nozzles (nozzles) that can pick up components from a feeder and move up and down individually. The head may be equipped with, for example, multiple nozzles. The component mounting head unit 32 may also have a sensor such as a flow sensor that measures the flow rate of air flowing through the nozzle. Commands sent to the component mounting head unit 32 include commands to pick up components from the component supply unit 31 (component pickup command), mount the component on the board, check the flow rate value, etc., and command responses include, but are not limited to, information indicating whether component pickup or component mounting was completed successfully, the measured flow rate value, etc.

[0062] The component recognition unit 33 includes an imaging device such as a camera, and recognizes components by capturing an image of the component. When the mounting head picks up a component from a feeder arranged in the component supply unit 31 and moves above the camera, the component recognition unit 33 captures an image of the component held by the mounting head. The component recognition unit 33 identifies and detects the position of the component by processing the captured image using image recognition by a processing unit (not shown). The component recognition unit 33 may function as a sensor to determine whether the nozzle has picked up a component and to detect the amount of deviation in the pickup position of the picked-up component, for example. A command to the component recognition unit 33 is to recognize the component, and a command response includes, but is not limited to, the recognition result of the component (e.g., positional deviation), etc.

[0063] The axis control unit 34 controls the drive of the servo motors to move the component mounting head unit 32. This controls the position of the nozzle mounted on the component mounting head unit 32. A command to the axis control unit 34 is to move the nozzle to a predetermined position, and the command response includes, but is not limited to, information indicating whether the nozzle movement was completed successfully, the block number supporting the nozzle, etc.

[0064] The board transport control unit 35 transports the board carried in from the upstream side in a direction along the manufacturing system 10, and positions and holds the board on a mounting stage set for performing component mounting work. The board transport control unit 35 is configured to include, for example, one or more transport lanes. A command to the board transport control unit 35 is to transport the board, etc., and the command response is, but is not limited to, information indicating whether the board transport has been completed successfully or a positional deviation, etc.

[0065] Each unit is also provided with various sensors that detect the operation of that unit and that can detect problems with that unit.

[0066] The number of units included in the component mounting apparatus 30 is not particularly limited as long as it is equal to or greater than 1. The configuration of the component mounting apparatus 30 is not limited to the above, and is determined appropriately depending on the type, shape, processing method, etc. of the object and component.

[0067] The storage unit 40 is a storage device that stores various information for manufacturing in the manufacturing system 10, as well as measurement values ​​measured during manufacturing. In this embodiment, the storage unit 40 stores a first operation log 50. The first operation log 50 contains the same information as the command responses issued from each unit. The first operation log 50 may be, for example, time-series data of the command responses of each unit.

[0068] Furthermore, the storage unit 40 may store, for example, commands issued by the control device 20 to each unit, or may store the production data D1 and the setting conditions D2.

[0069] 3 is a diagram showing an example of the first operation log 50 according to this embodiment. The first operation log 50 shown in FIG. 3 is, for example, a command response based on common production data D1 and setting conditions D2.

[0070] 3, the first operation log 50 includes axis control unit data values, component supply unit data values, component mounting head unit data values, status information data values, and component recognition unit data values. The axis control unit data values ​​are values ​​based on command responses from the axis control unit 34, and in the example of FIG. 3, include block numbers, coordinate ID numbers, turn numbers, mounting order, and pickup order. The component supply unit data values ​​are values ​​based on command responses from the component supply section unit 31, and in the example of FIG. 3, include physical feeder address numbers and feeder serial numbers.

[0071] The component placement head unit data value and the status information data value are values ​​based on the command response of the component placement head unit 32. In the example of FIG. 3, the component placement head unit data value includes the nozzle holder address number and the nozzle serial number, and the status information data value includes the placement status and the flow rate value. The placement status indicates whether a placement error has occurred, and the flow rate value indicates the measurement value of the flow rate sensor. The component recognition unit data value is a value based on the command response of the component recognition unit 33. In the example of FIG. 3, the data value includes the recognition correction amounts X1, Y1, and A, the pickup correction amounts X2 and Y2, and the pickup learning amounts X3 and Y3. The recognition correction amounts X1, Y1, and A indicate the positional deviation of the component from the reference at the component supply position (the amount of correction to the pickup position when the nozzle picks up the component), and indicate the deviation of the component in the X-axis direction, Y-axis direction, and rotational direction. The pickup correction amounts X2 and Y2 respectively indicate the positional deviation of the pickup position from the reference when the nozzle picks up a component (the correction amount of the nozzle position relative to the component mounting position), and indicate the nozzle positional deviation in the X-axis and Y-axis directions.

[0072] The first operation log 50 may be, for example, time-series data for a predetermined period of time. The predetermined period is a period including the time when a problem occurred in the component mounting apparatus 30, and may be a period before or after that time, or a period in the past including that time. For example, using flow rate values ​​as an example, the first operation log 50 may include changes in flow rate values ​​over time. The first operation log 50 can also be said to include detailed information on behavior during command responses (e.g., changes in flow rate values ​​over time). The behavior refers to the state or change in state of each unit based on actual measured values. For example, if the unit is the component mounting head unit 32, it may be the flow rate value or changes in flow rate values ​​over time, but is not limited to this.

[0073] In the example of Figure 3, the first operation log 50 does not include values ​​based on the command response of the substrate transport control unit 35, but this is not limited to this and values ​​based on the command response of the substrate transport control unit 35 may also be included.

[0074] 2, an example has been described in which the first operation log 50 is generated by the control device 20 and stored in the storage unit 40, but this is not limiting and the first operation log 50 may be obtained directly from each unit, for example. The first operation log 50 may also be created based on command responses obtained directly from each unit without going through the control device 20.

[0075] Next, the configuration of analysis support device 100 will be described with reference to Fig. 4. Fig. 4 is a block diagram showing the functional configuration of manufacturing system 10 on a software simulator in analysis support device 100 according to this embodiment.

[0076] 4, the analysis support device 100 includes a control unit 120 and a component mounting device 130. The control unit 120 and the component mounting device 130 represent functional configurations on a software simulator.

[0077] The control unit 120 performs processing on the simulator that corresponds to that of the control device 20 of the manufacturing system 10. Specifically, the control unit 120 issues commands to each unit of the component mounting device 130 based on production data D1 and setting conditions D2 acquired from an external device. The control unit 120 is configured to issue the same commands as the control device 20 when the same production data D1 and setting conditions D2 as those of the control device 20 are input. The control unit 120 may be configured to issue the same commands as the control device 20 to each unit in the same order and timing as the control device 20, for example. The production data D1 and setting conditions D2 input to the control unit 120 are the production data D1 and setting conditions D2 actually used to operate the component mounting device 30, and are, for example, the same as the production data D1 and setting conditions D2 when a problem occurs in the manufacturing system 10, but are not limited to this.

[0078] Component mounting apparatus 130 is a simulation model corresponding to component mounting apparatus 30 for simulating the operation of component mounting apparatus 30. Component mounting apparatus 130 includes one or more units (virtual units, which are modeled units). In the example of FIG. 4, component mounting apparatus 130 includes component supply unit 131, component mounting head unit 132, component recognition unit 133, axis control unit 134, and board transport control unit 135. One of component supply unit 131, component mounting head unit 132, component recognition unit 133, axis control unit 134, and board transport control unit 135 is an example of a first virtual unit, and the other unit is an example of a second virtual unit.

[0079] The component supply unit 131 is a modeled unit corresponding to the component supply unit 31 and has a function corresponding to the software processing unit of the component supply unit 31. The component mounting head unit 132 is a modeled unit corresponding to the component mounting head unit 32 and has a function corresponding to the software processing unit of the component mounting head unit 32. The component recognition unit 133 is a modeled unit corresponding to the component recognition unit 33 and has a function corresponding to the software processing unit of the component recognition unit 33. The axis control unit 134 is a modeled unit corresponding to the axis control unit 34 and has a function corresponding to the software processing unit of the axis control unit 34. The board transport control unit 135 is a modeled unit corresponding to the board transport control unit 35 and has a function corresponding to the software processing unit of the board transport control unit 35. A first operation log 50 is input to the component mounting apparatus 130. The first operation log 50 includes command responses corresponding to the production data D1 and setting conditions D2 input to the control unit 120.

[0080] Conventionally, each unit in a simulation is configured to operate in a steady state. For example, when a command is input, each unit issues a command response indicating normal operation. For example, even if a command based on production data D1 and setting conditions D2 is input when a problem occurs in component mounting device 30, each unit issues a command response indicating normal operation. Thus, conventionally, it is possible to match the commands issued by control unit 120 with the commands issued by control device 20, but it is not possible to match the command responses issued by each unit. In other words, conventionally, it is not possible to reproduce the behavior of each unit in a simulation. For example, it is not possible to reproduce the pickup state and mounting state during an error in a simulation.

[0081] However, from the viewpoint of easily analyzing the cause of troubles that occur in the component mounting device 30, it is desirable to make the behavior of each unit or sensor in the simulation consistent with the behavior of each unit or sensor of the actual component mounting device 30.

[0082] Therefore, in this embodiment, when a command is input to each unit in the simulation, the unit extracts a command response corresponding to the command from the first operation log 50 and issues the extracted command response to the control unit 120. When a command from the control unit 120 is input to each unit, the unit replaces the command response with a command response indicating normality and issues the command response extracted from the first operation log 50 to the control unit 120. This allows the behavior of each unit in the simulation to match the behavior of each unit in the actual component mounting apparatus 30. For example, the behavior of each unit or sensor in the actual component mounting apparatus 30 when a problem occurs can be matched with the behavior of each unit or sensor in the simulation. For example, taking the flow rate value as an example, the change over time in the flow rate value, which is the command response of the component mounting head unit 132 in the simulation, can be matched with the change over time in the flow rate value, which is the command response of the actual component mounting head unit 32, until the problem occurs.

[0083] Note that the match here is not limited to a perfect match, and at least some behavior may differ. For example, since the first operation log 50 does not include the command response of the board transport control unit 35, the command response of the board transport control unit 135 in the simulation may not match the command response of the board transport control unit 35. Furthermore, there may be units (not shown) other than the units shown in Figures 2 and 4, and the command response in the simulation may not match the command response of the actual component mounting apparatus 30 due to the influence of these units.

[0084] Furthermore, information summarizing command responses issued from each unit (virtual unit) of the component mounting apparatus 130 is referred to as the second operation log 150. The second operation log 150 is a log equivalent to the first operation log 50 acquired by the manufacturing system 10 in the trouble analysis support system 1, and is a log that records the operation history of the component mounting apparatus 130. The second operation log 150 includes information summarizing command responses from each unit (each virtual unit) of the component mounting apparatus 130 when a problem occurs in the component mounting apparatus 130. From the viewpoint of easily analyzing the cause of the problem, it is preferable that the second operation log 150 matches the first operation log 50.

[0085] [2. Operation of the analysis support device] Next, the operation of the analysis support device 100 configured as above will be described with reference to Fig. 5 and Fig. 6. Fig. 5 is a sequence diagram showing the operation of the analysis support device 100 according to this embodiment. Steps S13 to S17 shown in Fig. 5 are an example of a simulation step that simulates the operation of the component mounting device 30 based on the command response (an example of the first command response) acquired from the first operation log 50.

[0086] As shown in FIG. 5, when a problem occurs in the actual component mounting apparatus 30, the control device 20 outputs a first operation log 50 to the component mounting apparatus 130, and the component mounting apparatus 130 acquires the first operation log 50 (S11).

[0087] Next, the component mounting device 130 extracts a command response from the first operation log 50 (S12). Each unit of the component mounting device 130 extracts a command response corresponding to the command issued to that unit from the first operation log 50. Furthermore, each unit of the component mounting device 130 extracts a command response corresponding to that unit from the first operation log 50. It can also be said that each unit of the component mounting device 130 acquires a command response (an example of a second command response) that is the response of each unit to the command (an example of a second command) issued to that unit from the first operation log 50. Step S12 is an example of a command response acquisition step.

[0088] Next, the control unit 120 generates a command to control each unit (each virtual unit) of the component mounting device 130 based on the production data D1 and setting conditions D2 when a problem occurs in the component mounting device 30 (S13), and the generated command is issued from each unit (each virtual unit). In other words, in step S13, a second command corresponding to the first command is issued to each unit (each virtual unit) in the simulation. The first command and the second command may be commands generated based on the production data D1 and setting conditions D2 when a problem occurs in the component mounting device 30. The first command and the second command may be the same command. Step S13 is an example of a command issuing step.

[0089] Next, the control unit 120 issues the generated command to each unit, and each unit receives the issued command (S14).

[0090] Next, the component mounting device 130 executes the acquired command (S15). Specifically, each unit of the component mounting device 130 executes a command corresponding to that unit. Each unit of the component mounting device 130 executes, for example, a process of simulating the operation of hardware. Step S15 is an example of a command execution step.

[0091] Next, the component mounting apparatus 130 sets the command response extracted in step S12 as the command response to the command executed in step S15 (S16). It can also be said that the component mounting apparatus 130 sets the command response extracted in step S12 as the second command response. This allows the component mounting apparatus 130 to reproduce the trouble that occurred in the component mounting apparatus 130.

[0092] Next, the component mounting apparatus 130 issues a command response, and the control unit 120 acquires the command response (S17). In step S17, it can be said that a first command response is issued as a second command response, which is a response from each unit (each virtual unit) to the second command. Step S17 is an example of a command response issuing step.

[0093] Next, the control unit 120 generates a second operation log 150 (S18). The control unit 120 generates the second operation log 150 including the command responses issued by each unit to the control unit 120 in step S17. Step S18 is an example of an operation log generation step.

[0094] Next, the control unit 120 outputs the second operation log 150 to the component mounting device 130, and the component mounting device 130 acquires the second operation log 150 (S19).

[0095] Next, the component mounting apparatus 130 determines whether the first operation log 50 and the second operation log 150 match (S20). Step S20 is an example of a first determination step.

[0096] If the first operation log 50 and the second operation log 150 match (Yes in S20), the component mounting device 130 continues analyzing the cause of the trouble. If the first operation log 50 and the second operation log 150 do not match (No in S20), the component mounting device 130 edits the first operation log 50 (S21), returns to step S12, and continues processing using the edited first operation log 50. In step S21, the component mounting device 130 may add to the first operation log 50 a first command response corresponding to the other virtual unit of the first virtual unit and the second virtual unit, which first command response was additionally acquired after step S20. Furthermore, in step S21, the component mounting device 130 may acquire a dummy value of the first command response of the other virtual unit of the first virtual unit and the second virtual unit, and add the dummy value to the first operation log 50. The dummy value is not a command response issued by the component mounting device 30, but a value set by a user or the like. The dummy value may be a value that is set in advance, or may be a value that is acquired by input by the user or the like.

[0097] Although an example in which the second operation log 150 is generated by the control unit 120 has been described with reference to FIG. 5, the second operation log 150 may be generated by the component mounting apparatus 130 instead.

[0098] Fig. 6 is a flowchart showing the operation of each unit (trouble analysis support method) of analysis support device 100 according to this embodiment. Fig. 6 can also be said to show a trouble analysis support method that supports the analysis of trouble in component mounting device 30 by simulating the operation of component mounting device 30 made up of one or more units. Note that the following description will be given using component mounting head unit 132 as an example. It is assumed that production data D1 and setting conditions D2 when a trouble occurs in actual component mounting device 30 are input to control unit 120.

[0099] As shown in FIG. 6, the component mounting head unit 132 determines whether or not a command has been received from the control unit 120 (S101).

[0100] If it is determined that a command has been acquired (Yes in S101), the component mounting head unit 132 determines the type of the command (S102), and if it is determined that a command has not been received (No in S101), it waits until a command is received. Step S102 is an example of a second determination step.

[0101] Next, the component mounting head unit 132 extracts a corresponding command response from the first operation log 50 based on the type of command determined in step S102 (S103). The component mounting head unit 132 may, for example, extract a command response (first command response) corresponding to the unit from the first operation log 50 in accordance with the determined type of command, and issue the extracted command response as a second command response. Step S103 corresponds to step S12 shown in FIG. 5.

[0102] Next, the component mounting head unit 132 executes the command acquired in step S101 (S104). Step S104 corresponds to step S15 shown in FIG.

[0103] Next, the component mounting head unit 132 generates a command response to the acquired command from the extracted command response (S105). The component mounting head unit 132 generates the command response by replacing the command response in the steady state with the command response extracted in step S103.

[0104] Next, the component mounting head unit 132 issues the command response generated in step S105 to the control unit 120 (S106).

[0105] The above describes the operation of the component mounting head unit 132, but the other units also execute the process shown in FIG.

[0106] The analysis support device 100 described above can simulate commands issued in the manufacturing system 10 when a problem occurs in the component mounting device 30, and can also simulate command responses issued in response to the commands. If an error is found in the second command response of any unit, the user can easily confirm whether the problem in the component mounting device 30 is due to a software bug by checking the commands issued to each unit around the time the second command response was issued. Furthermore, the analysis support device 100 can simulate whether a countermeasure against the problem is effective, allowing for efficient consideration of the countermeasure. In other words, the analysis support device 100 can assist the user in analyzing the cause of the problem.

[0107] (Other embodiments) Although the trouble analysis support method and the like according to one or more aspects have been described above based on the embodiments, the present disclosure is not limited to these embodiments, etc. As long as they do not deviate from the spirit of the present disclosure, various modifications conceivable by a person skilled in the art to the present embodiments and forms constructed by combining components of different embodiments may also be included in the present disclosure.

[0108] For example, in the above embodiments, a component mounting device is used as an example of production equipment, but the production equipment is not limited to a component mounting device. The production equipment may be any device that performs predetermined processing or predetermined work on an object. The production equipment may be, for example, a solder application device, an inspection device, or other device.

[0109] In the above embodiments, each component may be configured with dedicated hardware, or may be realized by executing a software program suitable for each component. Each component may be realized by a program execution unit such as a CPU or processor reading and executing a software program recorded on a recording medium such as a hard disk or semiconductor memory.

[0110] The order in which the steps in the flowchart are executed is merely an example for specifically explaining the present disclosure, and an order other than the above may be used. Also, some of the steps may be executed simultaneously (in parallel) with other steps, or some of the steps may not be executed.

[0111] The division of functional blocks in the block diagram is an example, and multiple functional blocks may be realized as a single functional block, one functional block may be divided into multiple blocks, or some functions may be moved to another functional block.Furthermore, the functions of multiple functional blocks having similar functions may be processed in parallel or in time-sharing by a single piece of hardware or software.

[0112] Furthermore, the trouble analysis support device according to the above-described embodiments may be realized as a single device or may be realized by multiple devices. When the trouble analysis support device is realized by multiple devices, the components of the trouble analysis support device may be distributed in any manner among the multiple devices. When the trouble analysis support device is realized by multiple devices, the communication method between the multiple devices is not particularly limited, and may be wireless communication or wired communication. Furthermore, wireless communication and wired communication may be combined between the devices.

[0113] Furthermore, these general or specific aspects may be realized as a system, a method, an integrated circuit, a computer program, or a non-transitory recording medium such as a computer-readable CD-ROM, or as any combination of the system, method, integrated circuit, computer program, or recording medium. The program may be pre-stored in the recording medium, or may be supplied to the recording medium via a wide area communication network including the Internet.

[0114] Furthermore, each component described in the above embodiments may be implemented as software or, typically, as an LSI, an integrated circuit. These components may be integrated individually on a single chip, or some or all of them may be integrated on a single chip. While LSI is used here, it may also be referred to as an IC, system LSI, super LSI, or ultra LSI depending on the level of integration. Furthermore, the integration method is not limited to LSI; it may be implemented using a dedicated circuit (a general-purpose circuit that executes a dedicated program) or a general-purpose processor. It is also possible to use a field programmable gate array (FPGA), which can be programmed after LSI fabrication, or a reconfigurable processor, which allows the connection or settings of circuit cells within an LSI to be reconfigured. Furthermore, if an integrated circuit technology that can replace LSI emerges due to advances in semiconductor technology or a derivative technology, that technology may naturally be used to integrate the components.

[0115] A system LSI is an ultra-multifunctional LSI manufactured by integrating multiple processing units on a single chip, and is specifically a computer system consisting of a microprocessor, ROM (Read Only Memory), RAM (Random Access Memory), etc. Computer programs are stored in the ROM. The system LSI achieves its functions when the microprocessor operates in accordance with the computer program.

[0116] Another aspect of the present disclosure may be a computer program that causes a computer to execute each of the characteristic steps included in the trouble analysis support method shown in either FIG. 5 or FIG.

[0117] Furthermore, for example, the program may be a program to be executed by a computer. Another aspect of the present disclosure may be a computer-readable non-transitory recording medium on which such a program is recorded. For example, such a program may be recorded on a recording medium and distributed or circulated. For example, the distributed program may be installed in a device having another processor, and the program may be executed by the processor, thereby causing the device to perform each of the above processes. [Industrial Applicability]

[0118] The present disclosure is useful for an analysis device that analyzes problems in production equipment. [Explanation of symbols]

[0119] 1. Troubleshooting support system 10 Manufacturing Systems 20 Control device 30, 130 Component mounting equipment 31, 131 Parts supply unit 32, 132 Component mounting head unit 33, 133 Parts Recognition Unit 34, 134 axis control unit 35, 135 Substrate transport control unit 40 Storage section 50 First Operation Log 100 Analysis support equipment 120 control section 150 Second Operation Log 200 Display device D1 Production Data D2 Setting conditions

Claims

1. A trouble analysis support method for supporting trouble analysis of a production facility by simulating the operation of the production facility composed of one or more units, comprising: a command response acquisition step of acquiring, from a first operation log including an operation history at the time of occurrence of a trouble in the production equipment, a first command response which is a response from the one or more units to a first command issued to the one or more units; a simulation step of simulating an operation of the production equipment based on the acquired first command response, The simulation step includes: a command issuing step of issuing a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units; a command execution step of executing the second command in the one or more virtual units; a command response issuing step of issuing a second command response, which is a response from the one or more virtual units to the second command; the command response issuing step issues the acquired first command response as the second command response; moreover, an operation log generation step of generating a second operation log including the second command response of each of the one or more virtual units; a first determination step of determining whether the first operation log and the second operation log match, If it is determined in the first determination step that the first operation log and the second operation log do not match, the first operation log is edited, and the simulation step is executed again based on the edited first operation log. Troubleshooting support method.

2. the one or more virtual units include a first virtual unit and a second virtual unit; the first operation log includes a first command response corresponding to only one of the first virtual unit and the second virtual unit; the edited first operation log includes an additionally acquired first command response that corresponds to the other virtual unit of the first virtual unit and the second virtual unit; The trouble analysis support method according to claim 1.

3. the one or more virtual units include a first virtual unit and a second virtual unit; the first operation log includes a first command response of only one of the first virtual unit and the second virtual unit; the edited first operation log includes a dummy value of a first command response of the other virtual unit of the first virtual unit and the second virtual unit; The trouble analysis support method according to claim 1.

4. Further, a second determination step of determining a type of the acquired second command is included, In the command response issuing step, a first command response corresponding to the unit is extracted from the first operation log according to the determined type of the second command, and the extracted first command response is issued as the second command response. The trouble analysis support method according to any one of claims 1 to 3.

5. the first command and the second command are commands generated based on production data related to production when a problem occurs in the production equipment and setting conditions of the one or more units. The trouble analysis support method according to any one of claims 1 to 4.

6. A trouble analysis support method for supporting trouble analysis of a production facility by simulating the operation of the production facility composed of one or more units, comprising: a command response acquisition step of acquiring, from a first operation log including an operation history at the time of occurrence of a trouble in the production equipment, a first command response which is a response from the one or more units to a first command issued to the one or more units; a simulation step of simulating an operation of the production equipment based on the acquired first command response, The simulation step includes: a command issuing step of issuing a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units; a command execution step of executing the second command in the one or more virtual units; a command response issuing step of issuing a second command response, which is a response from the one or more virtual units to the second command; the command response issuing step issues the acquired first command response as the second command response; Further, a second determination step of determining a type of the acquired second command is included, In the command response issuing step, a first command response corresponding to the unit is extracted from the first operation log according to the determined type of the second command, and the extracted first command response is issued as the second command response. Troubleshooting support method.

7. A trouble analysis support device that supports trouble analysis of a production facility by simulating the operation of the production facility, the trouble analysis support device comprising one or more units, an acquisition unit that acquires, from a first operation log including an operation history at the time of occurrence of a trouble in the production equipment, a first command response that is a response from the one or more units to a first command issued to the one or more units; a simulation processing unit that simulates an operation of the production equipment based on the acquired first command response, The simulation processing unit issuing a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units; Executing the second command in the one or more virtual units; issuing a second command response, the second command response being the one or more virtual units' response to the second command; In issuing the second command response, the acquired first command response is issued as the second command response; moreover, generating a second operation log including the second command response for each of the one or more virtual units; determining whether the first operation log and the second operation log match; If it is determined that the first operation log and the second operation log do not match, the first operation log is edited, and a simulation is performed again based on the edited first operation log. Troubleshooting support device.

8. A trouble analysis support device that supports trouble analysis of production equipment by simulating the operation of the production equipment composed of one or more units, an acquisition unit that acquires, from a first operation log including an operation history at the time of occurrence of a trouble in the production equipment, a first command response that is a response from the one or more units to a first command issued to the one or more units; a simulation processing unit that simulates an operation of the production equipment based on the acquired first command response, The simulation processing unit issuing a second command corresponding to the first command to one or more virtual units in a simulation corresponding to the one or more units; Executing the second command in the one or more virtual units; issuing a second command response, the second command response being the one or more virtual units' response to the second command; In issuing the second command response, the acquired first command response is issued as the second command response; Furthermore, a type of the acquired second command is determined; extracting a first command response corresponding to the unit from the first operation log according to the determined type of the second command, and issuing the extracted first command response as the second command response; Troubleshooting support device.

9. A program for causing a computer to execute the trouble analysis support method according to any one of claims 1 to 6.

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