Coordination support system, coordination support program, and coordination support method

Abstract

To support adjustment targeting any one of a production line model in a virtual space, an actual machine, and both the production line model in the virtual space and the actual machine.SOLUTION: An adjustment support system has a control unit and a storage unit. The storage unit holds production line model data related to models of one or more production facilities in a virtual space of a production line and actual machine data obtained by actually measuring the one or more production facilities arranged in an actual space of the production line. The control unit calculates a difference between the production line model data and the actual machine data and, if it is determined that the difference exists on the basis of a result of calculating the difference, creates one or more adjustment plans targeting at least one of the models of the one or more production facilities in the virtual space and the one or more production facilities arranged in the actual space, and outputs the created one or more adjustment plants.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a technology for assisting in the adjustment of production lines and models when constructing production lines.

Background Art

[0002] When constructing a production line, the robot and the surrounding environment are modeled in a virtual space, and after performing layout design, motion design, performance evaluation, etc., the actual machine is manufactured, introduced, and started up based on the design results for construction.

[0003] At this time, it is common for a difference to occur between the design value based on the model in the virtual space and the measured value of the actual machine.

[0004] In Patent Document 1, regarding the difference between the design value based on the model in the virtual space and the measured value of the actual machine, it is described that "virtual model acquisition means for acquiring a virtual model that virtually shows the shape of the surrounding structures of the robot, movement path acquisition means for acquiring data regarding the movement path of the robot, measured model acquisition means for acquiring a measured model showing the shape of the surrounding structures of the robot in the actual machine, and correction means for correcting the data regarding the movement path when a movement path shorter than the movement path can be generated based on the difference between the virtual model and the measured model, or when interference occurs between the robot and the surrounding structures due to the movement of the robot along the movement path."

Prior Art Documents

Patent Documents

[0005] [[ID=三十一]]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0006] When the actual machine is started up, if the environment simulated in the virtual space beforehand differs from the actual machine's state, adjustments will be necessary to the results of the deployment design, operational design, and performance evaluation conducted in the virtual space. Therefore, it is necessary to match the state of the virtual space model with the actual machine by either adjusting the actual machine or modifying the virtual space model, or by at least one of these methods.

[0007] Patent Document 1 describes a method for avoiding interference in the actual environment by correcting the robot's movement path based on the difference between the design value and the actual measured value of the actual machine. However, since this only adjusts the movement path to match the actual environment and does not consider adjusting the actual environment to match the virtual space, it may not be possible to realize the highly productive operating methods and movements obtained from prior performance evaluations in the virtual space.

[0008] The present invention has been made in view of the above problems, and aims to provide a production line and model adjustment support system that allows users to select a highly productive adjustment plan by presenting candidate adjustment plans, with at least one of a virtual production line model, an actual machine, or a virtual manufacturing line model and an actual machine as the adjustment target. [Means for solving the problem]

[0009] To solve at least one of the above problems, the present invention provides an adjustment support system comprising a control unit and a storage unit, wherein the storage unit holds production line model data relating to models of one or more production equipment in a virtual space of a production line, and actual machine data obtained by actually measuring one or more production equipment placed in the actual space of a production line, and the control unit calculates the difference between the production line model data and the actual machine data, and if it is determined that there is a difference based on the result of calculating the difference, each targets at least one of the models of one or more production equipment in the virtual space and one or more production equipment placed in the actual space, multiple We will create a proposal for adjustments. For each of the above-mentioned adjustment proposals, the value of a predetermined evaluation indicator that would be obtained if the adjustment were made is calculated. The above created multiple Adjustment proposal and the value of the evaluation indexIt is characterized by outputting an output. [Effects of the Invention]

[0010] According to one aspect of the present invention, a production line and model adjustment support system presents candidate adjustment options for either a virtual production line model, an actual machine, or both, allowing the user to select the most productive adjustment option.

[0011] Furthermore, issues, configurations, and effects other than those mentioned above will be clarified by the following description of the embodiments. [Brief explanation of the drawing]

[0012] [Figure 1] This is a functional block diagram showing an example of the functional configuration of the production line and model adjustment support system according to this embodiment. [Figure 2A] This is an explanatory diagram showing an example of production line model data in a virtual space according to this embodiment. [Figure 2B] This is an explanatory diagram showing an example of virtual space data according to this embodiment. [Figure 2C] This is an explanatory diagram showing an example of actual sensor data according to this embodiment. [Figure 2D] This is an explanatory diagram showing an example of actual sensor data according to this embodiment. [Figure 3] This is an explanatory diagram showing an example of the result display screen of the production line and model adjustment support system according to this embodiment. [Figure 4] This block diagram shows an example of the hardware configuration of the production line and model adjustment support system according to this embodiment. [Figure 5] This is a functional block diagram showing another example of the functional configuration of the production line and model adjustment support system according to this embodiment. [Figure 6] This is an explanatory diagram showing an example of a proposed adjustment by the production line and model adjustment support system according to this embodiment. [Figure 7]It is a flowchart showing an example of production line and model adjustment plan calculation processing executed in the production line and model adjustment support system according to the present embodiment. [Figure 8] It is an explanatory diagram showing an example of past adjustment history data held by the production line and model adjustment support system according to the present embodiment. [Figure 9] It is a flowchart showing an example of evaluation value calculation processing executed in the production line and model adjustment support system according to the present embodiment.

Mode for Carrying Out the Invention

[0013] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0014] FIG. 1 is a functional block diagram showing an example of the functional configuration of a production line and model adjustment support system 1 according to the present embodiment.

[0015] The production line and model adjustment support system 1 includes an input / output interface control unit 10, a control unit 20, a storage unit 30, a communication unit 40, and a bus 50 that connects these to each other. Note that a user (for example, a person in charge of line construction) uses the functions of the production line and model adjustment support system 1 via an input device 401 and an output device 402 connected to the input / output interface control unit 10.

[0016] The input / output interface control unit 10 is a functional unit that controls communication between the input device 401 and the output device 402 connected to the production line and model adjustment support system 1.

[0017] The control unit 20 is a functional unit that controls overall processing of the production line and model adjustment support system 1. The control unit 20 includes an input reception unit 21, a difference detection unit 22, an adjustment plan creation unit 23, and an output processing unit 25. [[ID=​The input receiving unit 21 is a functional unit that receives various types of information from input devices 401 of the production line and model adjustment support system 1, or from external devices (not shown) connected via the communication unit 40. For example, the input receiving unit 21 receives information such as information related to evaluation indicators and instructions for executing the production line and model adjustment plan calculation process from input devices 401 such as keyboards, mice, and touch panels, or from external devices connected via a predetermined communication network N such as the internet. The input receiving unit 21 also passes the received information to the corresponding predetermined functional unit.

[0019] The difference detection unit 22 is a functional unit that calculates the difference between the measured values ​​of the actual machine and the design values ​​of the virtual space.

[0020] The adjustment plan formulation unit 23 is a functional unit that selects an adjustment target from either a manufacturing line model in a virtual space, an actual machine, or both a manufacturing line model in a virtual space and an actual machine, and calculates the adjustment amount.

[0021] The output processing unit 25 generates screen information to be displayed on the output device 402 of the production line and model adjustment support system 1 or an external device. For example, the output processing unit 25 creates input screen information for receiving evaluation indicator input from the user, as well as screen information showing the calculation results of the adjustment target and adjustment amount, and displays them on the output device 402.

[0022] The memory unit 30 is a functional unit that stores predetermined information. Specifically, the memory unit 30 contains actual machine sensor data 100, virtual space data 130, and virtual space production line model data 150.

[0023] Figure 2A is an explanatory diagram showing an example of the production line model data 150 in the virtual space according to this embodiment.

[0024] The virtual space production line model data 150 is data relating to the representation of a line in a virtual space. Specifically, it is a model in which production equipment, such as a conveyor belt 203 and robots 202A-202C, are placed in a space 201 that simulates a production line. This model may be a 2D drawing or a 3D model such as a 3D CAD.

[0025] Figure 2B is an explanatory diagram showing an example of virtual space data 130 according to this embodiment.

[0026] The virtual space data 130 is data obtained in the virtual space. Specifically, the virtual space data 130 may include position 131 and force sensor values ​​132, etc.

[0027] Here, as an example, we will explain the case where actual robots A and B are already installed, and a new actual robot C is to be installed. The three robots 202A, 202B, and 202C shown in Figure 2A are models of robots A, B, and C placed in virtual space 201. In this example, position 131 includes the position of robot C measured from robot A and the position of robot C measured from robot B, and these are all data obtained in virtual space. Similarly, the force sensor value 132 is a hypothetical value that would be obtained if a force sensor were attached to robot C when each robot is placed and operated as described above.

[0028] Figures 2C and 2D are explanatory diagrams showing an example of actual sensor data 100 according to this embodiment.

[0029] The actual machine sensor data 100 is information about the entire line, which consists of the robot, peripheral measuring instruments, and multiple pieces of equipment. Specifically, the actual machine sensor data 100 may include position 101 and force sensor values ​​102, etc.

[0030] The three robots 212A to 212C shown in Figure 2C represent actual robots A to C installed in a real space according to the virtual space production line model data 150 shown in Figure 2A. For example, cameras (not shown) are attached to the end-effectors of actual robots A and B, and the position of robot C acquired from these cameras is stored as position 101. In addition, a force sensor (not shown) is attached to actual robot C, and the value obtained from this force sensor (i.e., the measured value) is stored as force sensor value 102.

[0031] Ideally, position 101 should coincide with position 131, and force sensor value 102 should coincide with force sensor value 132. However, in reality, differences can occur between the two due to errors between the placement of each robot model in virtual space and the placement of each actual robot in real space. Such errors can arise from various factors, such as insufficient precision in the installation of each robot, errors in the dimensions of each robot, or unevenness of the floor surface on which they are installed.

[0032] Figure 3 is an explanatory diagram showing an example of the result display screen 300 of the production line and model adjustment support system 1 according to this embodiment.

[0033] The results display screen 300 displays the results of the processing by the adjustment plan formulation unit 23. For example, when the difference detection unit 22 detects the difference between the measured values ​​of the actual machine and the design values ​​of the virtual space, and the adjustment plan formulation unit 23 calculates an adjustment plan, or when the output processing unit 25 receives a display instruction from the user via the input reception unit 21 for the results display screen 300 of the production line and model adjustment support system, it generates screen information and displays it on the output device 402.

[0034] As shown in Figure 3, the results display screen 300 of the production line and model adjustment support system has a data comparison area 301 and an adjustment proposal display area 306.

[0035] The data comparison area 301 displays the actual device data 302 and the virtual space data 304. These may be the same as those shown in Figures 2C and 2A. Furthermore, the data resulting from the difference detection by the difference detection unit 22 for the actual device data 302 and the virtual space data 304 are displayed as the actual device difference data 303 and the virtual space difference data 305, respectively. These may be the same as those shown in Figures 2D and 2B. In Figure 4, positions 101 and 131 are displayed as examples.

[0036] The adjustment proposal display area 306 displays the adjustment proposal 600 calculated by the adjustment proposal planning unit 23. Details of the adjustment proposal 600 will be described later (see Figure 6). The user can select one of the multiple adjustment proposals included in the adjustment proposal 600 displayed in the adjustment proposal display area 306. The user can also rearrange the order of the adjustment proposals by specifying the adjustment target and other columns. The output processing unit 25 may highlight the selected adjustment proposal.

[0037] Figure 4 is a block diagram showing an example of the hardware configuration of the production line and model adjustment support system 1 according to this embodiment.

[0038] The production line and model adjustment support system 1 can be configured using, for example, a general-purpose computer (e.g., a personal computer), and its characteristic processing functions (e.g., the control unit 20 of the production line and model adjustment support system 1) are realized by, for example, software program processing.

[0039] As shown in the figure, the production line and model adjustment support system 1 includes an input device 401, an output device 402, an external storage device 403, an arithmetic unit 404, a main memory device 405, a communication device 406, and a bus 407 that electrically interconnects these.

[0040] The input device 401 may be a keyboard, a mouse, a pointing device such as a touch panel, or a voice input device such as a microphone.

[0041] The output device 402 is a display, printer, or an audio output device such as a speaker.

[0042] The external storage device 403 is a non-volatile storage device such as a so-called hard disk drive, solid state drive (SSD), or flash memory, which is capable of storing digital information.

[0043] The arithmetic unit 404 is, for example, a CPU (Central Processing Unit). The main memory 405 is a memory device such as RAM (Random Access Memory) and ROM (Read Only Memory).

[0044] The communication device 406 is a device for communicating information with an external device (not shown), and is either a wired communication device that performs wired communication via a network cable or a wireless communication device that performs wireless communication via an antenna.

[0045] Each functional unit included in the control unit 20 is implemented by a program that causes the arithmetic unit 404 to perform processing. This program is stored in the main memory 405 or external memory 403, loaded onto the main memory 405 for program execution, and executed by the arithmetic unit 404. The storage unit 30 is implemented by the main memory 405, the external memory 403, or a combination thereof. The communication unit 40 is implemented by the communication device 406.

[0046] Furthermore, each of the above configurations, functions, processing units, and processing means may be implemented in hardware, either partially or entirely, by designing them as integrated circuits, for example. Alternatively, the above configurations and functions may be implemented in software by having the processor interpret and execute programs that implement each function. Information such as programs, tables, and files that implement each function can be stored in memory, hard disks, SSDs, or other storage devices, or in recording media such as IC cards, SD cards, and DVDs.

[0047] The hardware configuration of the production line and model adjustment support system 1 has been described above.

[0048] Figure 5 is a functional block diagram showing another example of the functional configuration of the production line and model adjustment support system 1 according to this embodiment.

[0049] The memory unit 30 contains past adjustment history data 160 and evaluation index candidate data 180. The control unit 20 also has an adjustment proposal evaluation unit 24. The other configurations are the same as those of the production line and model adjustment support system 1 shown in Figure 1.

[0050] Figure 6 is an explanatory diagram showing an example of an adjustment plan 600 calculated by the production line and model adjustment support system 1 according to this embodiment.

[0051] The adjustment plan 600 includes information such as the adjustment plan number 601, the adjustment target 602, the name of the equipment to be adjusted 603, the adjustment amount 604, the adjustment method 605, and the line throughput 606, which is the evaluation value of the adjustment plan.

[0052] Adjustment proposal number 601 is a number that identifies the calculated adjustment proposal. Adjustment target 602 indicates whether the adjustment target is a physical machine or a virtual space model. Equipment name 603 indicates the equipment to be adjusted. Adjustment method 605 and adjustment amount 604 are the method and amount of adjustment performed in the adjustment proposal, respectively, for example, equipment movement and the amount of movement. Line throughput 606 is the value of the evaluation index calculated for each adjustment proposal. Figure 6 shows the case where line throughput is selected as the evaluation index, but if other evaluation indexes are selected, the value of those evaluation indexes will be included in the adjustment proposal 600.

[0053] The adjustment plan 600 shown in Figure 6 includes three examples of adjustment plans that are calculated when the data exemplified in Figures 2A to 2D is obtained. The adjustment target for adjustment plan 601, where adjustment plan number is "1" (hereinafter also referred to as adjustment plan No. 1; the same applies to other adjustment plans), is the actual robot C (i.e., the newly installed robot). According to this plan, the installation position of the actual robot C is moved by -50 units in the X-axis direction, -20 units in the Y-axis direction, and 0 units in the Z-axis direction relative to robot A. As a result, the position of the actual robot C becomes the same as the position 131 in the virtual space shown in Figure 2B, and the difference between the two is eliminated.

[0054] Adjustment proposal No. 2 targets robot A in the virtual space. According to this proposal, the position coordinates of the 3D model of robot A in the virtual space will be modified by 50 in the X-axis direction, 20 in the Y-axis direction, and 0 in the Z-axis direction. As a result, the position of the 3D model of robot C in the virtual space will be the same as the position 101 of the actual robot shown in Figure 2D (i.e., the difference will be eliminated).

[0055] In this case, the positional relationship between the actual robots A and B and the adjusted actual robot C will differ from the positional relationship in the initial virtual space production line model data 150. Therefore, the production line and model adjustment support system 1 needs to regenerate the robot paths using the positional coordinates of each robot in the adjusted virtual space. This process will be described later (see Figure 9).

[0056] Adjustment proposal No. 3 targets the following robots: the physical robot A, the physical robot B, the virtual robot A, the virtual robot B, and the virtual robot C. According to this proposal, the position of the physical robot A will be adjusted by -50 in the X-axis direction, -20 in the Y-axis direction, and 0 in the Z-axis direction. When adjusted in this way, the difference will be eliminated. The position of the physical robot B will also be adjusted by 50 in the X-axis direction, 20 in the Y-axis direction, and 0 in the Z-axis direction. Furthermore, the position coordinates of the 3D models of robots A through C in the virtual space will be adjusted by -50 in the X-axis direction, -20 in the Y-axis direction, and 0 in the Z-axis direction. In this case as well, as with adjustment proposal No. 2 above, it is necessary to regenerate the robot paths using the adjusted position coordinates of each robot in the virtual space.

[0057] The above is an example of an adjustment plan when there is a difference between the actual position of the machine and the placement of the model in virtual space. However, if there is a difference in sensor values ​​other than position, an adjustment plan will be created to bring that difference closer to zero. For example, if there is a difference in force sensor values ​​132 and 102, an adjustment plan for the control information of the equipment, such as the robot path, may be created to resolve the difference.

[0058] [Explanation of operation] Figure 7 is a flowchart showing an example of the production line and model adjustment plan calculation process performed by the production line and model adjustment support system 1 according to this embodiment.

[0059] The process shown in Figure 7 is initiated, for example, when the input receiving unit 21 receives an instruction from the user to execute the production line and model adjustment plan calculation process via the input device 401. For example, after virtual space production line model data 150 as shown in Figure 2A and corresponding virtual space data 130 as shown in Figure 2B are generated, and the actual robot C is installed according to this data, the user may input an instruction to execute the production line and model adjustment plan calculation process before actually starting production using the robot C.

[0060] When processing begins, the output device 402 displays the evaluation indicator candidate data 180 stored in the storage unit 30. The input receiving unit 21 accepts input for the evaluation indicator candidate data 180 (step S101). The evaluation indicator candidate data 180 are indicators for evaluating the adjustment plan, such as the man-hours required for adjustment, the cost required for adjustment, the expected equipment yield after adjustment, the operating time of the equipment after adjustment, and the expected throughput and lead time of the production line after adjustment. The user selects the evaluation indicator they want to evaluate from the evaluation indicator candidate data 180 shown on the output device 402 and inputs it to the input receiving unit 21. Note that the evaluation indicator may also be input from an external source.

[0061] Next, the difference detection unit 22 acquires the actual machine sensor data 100 (step S102). The actual machine sensor data 100 is data acquired from sensors placed in a line consisting of a robot, peripheral measuring equipment, and multiple pieces of equipment, and includes many types such as position sensors, force sensors, current sensors, microphones, weight sensors, and cameras. In the example in Figure 2D, the position 101 of robot C and the force sensor value 102 are acquired as the actual machine sensor data 100.

[0062] Next, the difference detection unit 22 acquires virtual space data corresponding to the detection items of the actual sensor (step S103). For example, if position and force sensor values ​​are acquired by the actual sensor, data corresponding to the position and force sensor values ​​is acquired in the virtual space data. In the example in Figure 2B, the position 131 and force sensor value 132 of robot C are acquired.

[0063] The difference detection unit 22 then calculates the difference between the measured values ​​of the actual robot and the design values ​​of the virtual space (step S104). In the examples of Figures 2B and 2D, there is a difference of (-50, -20, 0) between the measured values ​​of the actual robot and the design values ​​of the virtual space for the position of robot C, relative to robot A of the actual robot. The parameter with the difference is the position, and the adjustment amount is detected as (-50, -20, 0) relative to robot A of the actual robot, or (50, 20, 0) relative to robot A of the virtual space model. The adjustment target is any one or more of robots A, B, and C, which were used to calculate the position of robot C.

[0064] The difference detection unit 22 calculates the difference wp and then determines whether there are any parameters with differences (step S105). If there are no parameters with differences, the process is terminated.

[0065] If there are differences in parameters, the adjustment plan formulation unit 23 searches for adjustment history for the same parameters as the differences (step S106). At this time, it refers to past adjustment history data 160, which is the history of adjustments made to the actual machine or production line model in other cases.

[0066] Figure 8 is an explanatory diagram showing an example of past adjustment history data 160 held by the production line and model adjustment support system 1 according to this embodiment.

[0067] The past adjustment history data 160 contains information such as No. 161, implementation date and time 162, project name 163, detected parameter with difference 164, equipment to be adjusted 165, equipment to be adjusted 166, adjustment method 167, adjustment amount 168, evaluation value of the adjustment result (in this case, throughput of the adjustment result 169), and actual adjustment man-hours 170.

[0068] No. 161 is the identification number of the data registered in the past adjustment history data 160. The date and time of implementation 162 indicates the date and time when the actual adjustment was performed in the past. The case name 163 is the name that identifies the case of the adjustment performed in the past. The detected parameter with a difference 164 indicates the parameter in which a difference was detected during the adjustment performed in the past. For example, if a difference is detected in the installation position, installation angle, or measured value of a sensor attached to equipment such as a robot or conveyor, the value that identifies these differences is stored as the detected parameter with a difference 164.

[0069] The equipment to be adjusted 165 indicates equipment such as robots or conveyors that have been subject to adjustment in the past. The adjustment target 166 indicates whether the subject of past adjustments was a physical machine or data in a virtual space. The adjustment method 167 indicates the method of adjustment that has been performed in the past. For example, if the installation position of a physical machine is moved, the physical machine is re-taught, or the placement coordinates or placement angle of a three-dimensional model in a virtual space are modified, the values ​​indicating these actions are stored as the adjustment method 167.

[0070] The adjustment amount 168 indicates the amount of adjustments made in the past. Examples of adjustment amounts 168 include the amount of movement of the equipment's installation position, the amount of correction of the installation angle, and the allowable amount of deviation in sensor values ​​during reteaching. The throughput of the adjustment result 169 indicates the throughput value measured after the adjustments made in the past. For example, the throughput of the adjustment result 169 may include information showing the difference between the throughput measured after the adjustment and the calculated value from the prior simulation (i.e., based on the original virtual space production line model data 150). If an indicator other than throughput is used as an evaluation indicator, the value of that indicator is also stored.

[0071] The actual adjustment man-hours of 170 represent the man-hours required for adjustments that have been made in the past. For example, if adjustments requiring a large amount of man-hours were made, such as moving large pieces of equipment, that will be reflected in the actual adjustment man-hours of 170.

[0072] In the example in Figure 8, the history data of the five adjustments performed in the past is stored as past adjustment history data 160. The adjustment history data where No. 161 is "1" (hereinafter also referred to as adjustment history data No. 1; the same applies to other adjustment history data) is the data for the adjustment performed on December 1, 2021. This example shows an adjustment that was performed when a difference was detected in the position parameters, indicating that the installation position of the newly installed robot was moved by 100 units in the Z-axis direction relative to the existing robot, that the throughput after the adjustment was the same as the result of the prior simulation, and that the man-hours required for the adjustment were 30 hours.

[0073] Similarly, adjustment history data No. 3 and No. 5 both indicate adjustments made when differences were detected in the position parameters. Of these, adjustment history data No. 3 shows that the placement coordinates of the 3D model of the newly installed conveyor in virtual space were adjusted, and the man-hours required were 10 hours. Adjustment history data No. 5 shows that the installation position of the existing robot, the placement coordinates of the 3D model of that robot in virtual space, and the placement coordinates of the 3D model of the newly installed robot in virtual space were adjusted, and the man-hours required were 32 hours.

[0074] When searching the adjustment history, the detected difference in parameter 164 is referenced to identify the parameter that matches the one being adjusted in the line where the difference was detected. In the examples in Figures 2B and 2D, since there is a difference in the position of robot C, the adjustment history data where the value of the detected difference in parameter 164 is "position" is searched. As a result, from the past adjustment history data 160 shown in Figure 8, adjustment history data No. 1, which is the history of adjusting the actual machine, adjustment history data No. 3, which is the history of adjusting the model in the virtual space, and adjustment history data No. 5, which is the history of adjusting both the actual machine and the model in the virtual space.

[0075] The adjustment plan planning unit 23 then extracts the data for the equipment to be adjusted 165 and the adjustment method 167 from the adjustment history data Nos. 1, 3, and 5 as an adjustment plan (step S107). This corresponds to the equipment to be adjusted 602 and the adjustment method 605 in the adjustment plan 600 in Figure 6. The equipment name 603 and the adjustment amount 604 to be adjusted are associated with the equipment to be adjusted and the adjustment amount extracted in step S104, respectively. This creates the adjustment plan.

[0076] Furthermore, if the memory unit 30 holds information specifying equipment or model data to be excluded from the adjustment, the adjustment plan planning unit 23 will create an adjustment plan that does not include the specified equipment or model data. For example, if there is equipment whose position should not be changed for any reason, the user may input information into the production line and model adjustment support system 1 in advance indicating that the equipment should be excluded from the adjustment. This information is held in the memory unit 30, and in step S107, an adjustment plan is created that does not include the position of the specified equipment in the adjustment.

[0077] Furthermore, the adjustment plan evaluation unit 24 calculates the evaluation value of the evaluation indicators for each adjustment plan based on past adjustment history or simulations (step S108). This step will be described later using the flow chart in Figure 9. The evaluation value obtained in this step corresponds to the line throughput 606 in adjustment plan 600 in Figure 6.

[0078] Subsequently, the output processing unit 25 presents the user with adjustment suggestions in order of evaluation values ​​for the evaluation indicators (step S109).

[0079] Figure 9 is a flowchart showing an example of the evaluation value calculation process performed in the production line and model adjustment support system 1 according to this embodiment.

[0080] Specifically, Figure 9 shows an example of the calculation process for the evaluation value in step S107 of Figure 7. Here, we will explain an example where the adjusted line throughput is selected as the evaluation indicator. The adjustment proposal extracted in step S106 is processed.

[0081] First, the adjustment proposal evaluation unit 24 selects one of the multiple adjustment proposals extracted in step S106 and determines whether that adjustment proposal includes adjustments to the virtual space (step S201).

[0082] If the proposed adjustment is for the virtual space, or if it is a proposal to adjust both the actual machine and the virtual space model (Step S201: Yes), then adjusting the virtual space model will change the evaluation values ​​obtained in the prior simulation verification, so it is necessary to perform the evaluation again. Therefore, the adjustment proposal evaluation unit 24 first creates a model with the position adjusted in the virtual space (Step S202).

[0083] Next, the adjustment plan evaluation unit 24 regenerates the robot path using the adjusted virtual space model (step S203).

[0084] Next, the adjustment plan evaluation unit 24 performs a line simulation of operating the robot using the generated robot path and calculates the line throughput (step S204).

[0085] Note that the robot path is an example of control information when the equipment to be adjusted is a robot. If the equipment to be adjusted is not a robot, the control information for that equipment is regenerated in step S203, and a line simulation is performed in step S204 using the regenerated control information.

[0086] Next, the output processing unit 25 displays the throughput obtained from the simulation as the line throughput for the adjustment plan in the virtual space (step S205).

[0087] On the other hand, if the selected adjustment plan is the adjustment plan for the actual machine (step S201: No), the evaluation value obtained in the prior simulation verification remains unchanged, so the output processing unit 25 displays the throughput of the original simulation line (step S206).

[0088] Continue this procedure until all adjustments extracted in step S106 have been processed (step S207).

[0089] This process allows us to examine how production-related evaluation metrics change if the virtual space model is adjusted, and then select an adjustment plan.

[0090] The adjustment plan 600 in Figure 6 is calculated according to the flows in Figures 7 and 9. The adjustment plan 600 calculated in this example includes adjustment plan No. 1, which is an adjustment plan for the actual machine; adjustment plan No. 2, which is an adjustment plan for the virtual space model; and adjustment plan No. 3, which is an adjustment plan for both the actual machine and the virtual space model. The user can select an adjustment plan by looking at the evaluation value, the line throughput 606. For example, the production line and model adjustment support system 1 may display the result display screen 300 on the output device 402, and the user may input information to select one of the adjustment plans into the input device, in which case the user may select that adjustment plan.

[0091] Alternatively, the production line and model adjustment support system 1 may automatically select the adjustment plan with the highest evaluation (for example, the adjustment plan that maximizes throughput) based on the evaluation value, without user selection.

[0092] The adjustment plan 600 shows the adjustment amount 604 calculated in step S104 from the difference between the actual measured values ​​of the actual machine and the design values ​​in the virtual space, and the adjustment method 605 extracted from past adjustment history data 160. For example, if plan No. 3, which adjusts both the actual machine and the virtual space model, is selected, the on-site worker will move and reinstall the installation positions of robots A and B by the amount indicated by the adjustment amount 604, and the production line and model adjustment support system 1 will update the virtual space model by moving the placement coordinates of the 3D models of robots A, B, and C by the amount indicated by the adjustment amount 604.

[0093] Furthermore, after adjustment, the difference between the measured values ​​of the actual machine and the design values ​​in the virtual space can be calculated again using the production line and model adjustment support system. If there is a difference, adjustment should be performed again.

[0094] The production line and model adjustment support system 1 according to this embodiment have been described above.

[0095] According to this production line and model adjustment support system 1, it is possible to devise a method that allows the user to select a highly productive adjustment plan by presenting candidate adjustment plans, with either a virtual space manufacturing line model, an actual machine, or both a virtual space manufacturing line model and an actual machine as the adjustment target.

[0096] The system of the embodiment of the present invention may be configured as follows, for example.

[0097] (1) An adjustment support system comprising a control unit (e.g., a control unit 20 or a computing device 404 that implements it) and a storage unit (e.g., a storage unit 30 or a main memory device 405 or external storage device 403 that implements it), wherein the storage unit holds production line model data relating to models of one or more production equipment in a virtual space of the production line (e.g., at least one of virtual space production line model data 150 and virtual space data 130) and actual machine data obtained by actually measuring one or more production equipment placed in the actual production line space (e.g., actual machine sensor data 100), and the control unit calculates the difference between the production line model data and the actual machine data (e.g., step S104), and if it is determined that there is a difference based on the result of calculating the difference (e.g., step S105: Yes), it creates one or more adjustment proposals (e.g., adjustment proposals No. 1 to 3 in Figure 6) each targeting one or more models of production equipment in a virtual space and one or more production equipment placed in the actual space (e.g., step S107), and outputs the one or more adjustment proposals created (e.g., step S109).

[0098] This allows the user to select from several proposed adjustments, either for a virtual production line model, actual equipment, or both.

[0099] (2) In (1) above, the control unit creates a plurality of adjustment proposals (for example, step S107), calculates a predetermined value of an evaluation index when the adjustment is made for each of the created plurality of adjustment proposals (for example, step S108), and outputs the plurality of adjustment proposals and the value of the evaluation index (for example, step S109).

[0100] This allows users to select the most productive option from among the multiple adjustment proposals presented.

[0101] (3) In (2) above, the evaluation indicators include at least one of the time required for the adjustment work based on each adjustment plan, the cost of the adjustment work, the operating time of the production equipment after adjustment, the yield of the production equipment after adjustment, and the throughput of the production equipment after adjustment. When information specifying the evaluation indicators is input (for example, in step S101), the control unit calculates the value of the specified evaluation indicators.

[0102] This allows for the selection of adjustment proposals based on the evaluation metrics requested by the user.

[0103] (4) In (2) above, the control unit selects the adjustment proposal with the highest evaluation from among several adjustment proposals based on the value of the evaluation index.

[0104] This allows for the selection of the most productive adjustment plan based on predetermined criteria.

[0105] (5) The control unit further comprises an input device and an output device, and the output device displays a plurality of adjustment options and evaluation index values, and when information indicating one of the plurality of adjustment options is input to the input device, the control unit selects the indicated adjustment option.

[0106] This allows users to select their desired adjustment plan based on productivity evaluation values.

[0107] (6) In (2) above, if one or more adjustment proposals include adjustment proposals targeting one or more production equipment models in a virtual space (for example, adjustment proposal No. 2 or 3 in Figure 6), the adjustment proposal includes information to adjust the data of one or more production equipment models in a virtual space so that the difference becomes small, and the control unit creates control information for the production equipment using the data of one or more production equipment models in a virtual space adjusted based on the adjustment proposal (for example, step S203), and calculates a predetermined evaluation index value by performing a simulation based on the adjusted data and the created control information (for example, step S204).

[0108] This allows us to calculate the value of the evaluation index when data in the virtual space is adjusted.

[0109] (7) In (1) above, the storage unit further stores adjustment history data (for example, past adjustment history data 160) that shows the difference detected in the past and the history of adjustments made in the past corresponding to that difference, and the control unit creates one or more adjustment proposals based on the result of comparing the calculated difference with the difference detected in the past (for example, steps S106, S107).

[0110] This allows for the creation of adjustment plans that are expected to be effective.

[0111] (8) In (7) above, the control unit identifies the history of adjustments made in the past that include the calculated difference in the parameter (for example, if a difference in the position parameter is calculated in step S104, it identifies the history Nos. 1, 3, and 5 in Figure 8, which are the history of adjustments made when the difference in position was detected), and creates one or more adjustment proposals based on the identified history of adjustments.

[0112] This allows for the creation of adjustment proposals that are expected to be effective, based on the parameters in which differences have been detected.

[0113] (9) In (1) above, the memory unit further holds information indicating that at least one of the models of one or more production facilities in the virtual space and one or more production facilities located in the actual space is excluded from the adjustment, and the control unit creates one or more adjustment proposals that apply to the models of one or more production facilities in the virtual space and one or more production facilities located in the actual space that are not excluded from the adjustment.

[0114] This allows for the creation of appropriate adjustment plans tailored to the specific circumstances of the production line.

[0115] (10) In the above (9), if the control unit receives information specifying which of the models of one or more production facilities in the virtual space and one or more production facilities located in the actual space should be excluded from the adjustment, it stores information in the storage unit indicating that the specified items should be excluded from the adjustment.

[0116] This allows for the creation of appropriate adjustment plans tailored to the specific circumstances of the production line.

[0117] (11) In the above (1), if one of the one or more adjustment proposals is an adjustment proposal that targets one or more production equipment models in the virtual space, and the adjustment proposal is selected, the control unit will create one or more production equipment models in the virtual space that have been adjusted based on the selected adjustment proposal.

[0118] This allows the selected adjustment plan to be quickly implemented in the production line system.

[0119] (12) In (1) above, if one of the one or more adjustment proposals is an adjustment proposal targeting one or more production equipment models in a virtual space (for example, adjustment proposal No. 2 in Figure 6), the adjustment proposal includes information to adjust the data of one or more production equipment models in a virtual space so as to reduce the difference; if one of the one or more adjustment proposals is an adjustment proposal targeting one or more production equipment placed in an actual space (for example, adjustment proposal No. 1 in Figure 6), the adjustment proposal includes information to adjust the arrangement of one or more production equipment in an actual space so as to reduce the difference; if one of the one or more adjustment proposals is an adjustment proposal targeting both one or more production equipment models in a virtual space and one or more production equipment placed in an actual space (for example, adjustment proposal No. 3 in Figure 6), the adjustment proposal includes information to adjust the data of one or more production equipment models in a virtual space and the arrangement of one or more production equipment in an actual space so as to reduce the difference.

[0120] This allows for the creation of appropriate adjustment proposals depending on the specific issue being addressed.

[0121] It should be noted that the present invention is not limited to the embodiments described above. The embodiments described above can be modified in various ways within the scope of the technical concept of the present invention.

[0122] For example, in the embodiment described above, line throughput was selected as the evaluation metric, but multiple evaluation metrics, such as line throughput and adjustment man-hours, may be selected, and the user may select an adjustment plan based on multiple evaluation metrics on the results display screen.

[0123] Furthermore, if the calculated adjustment plan is selected for the virtual space model, the virtual space model may be automatically edited and adjusted.

[0124] The above-described embodiments are explained in detail for the purpose of clearly illustrating the present invention, and are not necessarily limited to those comprising all the described configurations. Furthermore, it is possible to replace parts of the configuration of one embodiment with those of another embodiment, and it is also possible to add configurations from other embodiments to the configuration of one embodiment. In addition, it is possible to add, delete, or replace parts of the configuration of each embodiment with those of other embodiments.

[0125] Furthermore, each of the above configurations, functions, processing units, and processing means may be implemented in hardware, either partially or entirely, by designing them as integrated circuits, for example. Alternatively, each of the above configurations and functions may be implemented in software by a processor interpreting and executing programs that implement each function. Information such as programs, tables, and files that implement each function can be stored in storage devices such as non-volatile semiconductor memory, hard disk drives, and SSDs (Solid State Drives), or in computer-readable non-temporary data storage media such as IC cards, SD cards, and DVDs.

[0126] Furthermore, the control lines and information lines shown above are those deemed necessary for the explanation, and do not necessarily represent all control lines and information lines present in the actual product. In reality, it is safe to assume that almost all components are interconnected. [Explanation of Symbols]

[0127] 1...Production line and model adjustment support system, 10...Input / output interface control unit, 20...Control unit, 21...Input reception unit, 22...Difference detection unit, 23...Adjustment plan formulation unit, 25...Output processing unit, 30...Storage unit, 40...Communication unit, 50...Bus, 100...Actual machine sensor data, 130...Virtual space data, 150...Virtual space production line model data, 401...Input device, 402...Output device, 403...External storage device, 404...Arithmetic unit, 405...Main memory, 406...Communication device, N...Network

Claims

1. It is an adjustment support system, It has a control unit and a storage unit, The storage unit holds production line model data relating to models of one or more production equipment in a virtual space of the production line, and actual equipment data obtained by actually measuring one or more production equipment placed in the space of the actual production line. The control unit, The difference between the production line model data and the actual machine data is calculated. Based on the results of calculating the difference, if it is determined that there is a difference, each will create multiple adjustment plans targeting at least one of the models of one or more production facilities in the virtual space and at least one of the one or more production facilities located in the actual space. For each of the above-mentioned adjustment proposals, the value of a predetermined evaluation indicator that would be obtained if the adjustment were made is calculated. An adjustment support system characterized by outputting the values ​​of the multiple adjustment proposals and the evaluation indicators that have been created.

2. The adjustment support system according to Claim 1, The evaluation indicators include at least one of the time required for the adjustment work based on each adjustment plan, the cost of the adjustment work, the operating time of the production equipment after adjustment, the yield of the production equipment after adjustment, and the throughput of the production equipment after adjustment. The control unit is characterized by calculating the value of the specified evaluation index when information specifying the evaluation index is input.

3. The adjustment support system according to Claim 1, The control unit is characterized by selecting the adjustment proposal with the highest evaluation among the multiple adjustment proposals based on the value of the evaluation index.

4. The adjustment support system according to Claim 1, It further includes an input device and an output device, The control unit, The output device is made to display the values ​​of the multiple adjustment proposals and the evaluation indicators. An adjustment support system characterized in that, when information indicating one of the multiple adjustment options is input to the input device, the system selects the indicated adjustment option.

5. The adjustment support system according to Claim 1, If the aforementioned multiple adjustment proposals include adjustment proposals that target one or more production equipment models in the virtual space, the adjustment proposals include information that adjusts the data of one or more production equipment models in the virtual space so that the difference becomes smaller. The control unit, Using the data of one or more production equipment models in the virtual space adjusted based on the adjustment proposal, control information for the production equipment is created. An adjustment support system characterized by calculating the value of a predetermined evaluation index by performing a simulation based on the adjusted data and the created control information.

6. An adjustment support system, It has a control unit and a storage unit, The storage unit holds production line model data relating to the model of one or more production equipment in the virtual space of the production line, actual equipment data obtained by actually measuring one or more production equipment placed in the actual space of the production line, and adjustment history data showing the difference detected in the past and the history of adjustments made in the past corresponding to that difference. The control unit, The difference between the production line model data and the actual machine data is calculated. If it is determined that there is a difference based on the result of calculating the difference, then, based on the result of comparing the calculated difference with the previously detected difference, each will create one or more adjustment proposals targeting at least one of the models of one or more production facilities in the virtual space and one or more production facilities located in the actual space. An adjustment support system characterized by outputting one or more adjustment proposals that have been created.

7. The adjustment support system according to claim 6, The control unit identifies the history of adjustments made to parameters that include the calculated difference from the history of adjustments made in the past, and creates one or more adjustment proposals based on the identified history of adjustments.

8. The adjustment support system according to Claim 1, The memory unit further stores information indicating that at least one of the models of one or more production facilities in the virtual space and one or more production facilities located in the actual space are excluded from the adjustment process. The control unit is characterized by creating multiple adjustment proposals that target one or more production equipment models in the virtual space and one or more production equipment placed in the actual space that have not been excluded from the adjustment process.

9. The adjustment support system according to claim 8, The adjustment support system is characterized in that, when the control unit receives information specifying which of the models of one or more production facilities in the virtual space and one or more production facilities located in the actual space should be excluded from the adjustment, it stores information indicating that the specified items should be excluded from the adjustment in the storage unit.

10. The adjustment support system according to Claim 1, The control unit is an adjustment support system characterized in that one of the plurality of adjustment proposals is an adjustment proposal targeting one or more production equipment models in the virtual space, and when such adjustment proposal is selected, it creates one or more production equipment models in the virtual space adjusted based on the selected adjustment proposal.

11. The adjustment support system according to Claim 1, If one of the aforementioned adjustment proposals is an adjustment proposal that targets one or more production equipment models in the virtual space, the adjustment proposal includes information to adjust the data of one or more production equipment models in the virtual space so that the difference becomes smaller. If one of the aforementioned adjustment proposals is an adjustment proposal that targets one or more production facilities located in the actual space, the adjustment proposal includes information to adjust the arrangement of one or more production facilities in the actual space so as to reduce the difference. An adjustment support system characterized in that, if one of the aforementioned adjustment proposals is an adjustment proposal that targets both the model of one or more production facilities in the virtual space and the one or more production facilities placed in the actual space, the adjustment proposal includes information to adjust the data of the model of one or more production facilities in the virtual space and the arrangement of one or more production facilities in the actual space so as to reduce the difference.

12. An adjustment support program to be executed by an adjustment support system, The adjustment support system comprises a control unit and a storage unit. The storage unit holds production line model data relating to models of one or more production equipment in a virtual space of the production line, and actual equipment data obtained by actually measuring one or more production equipment placed in the space of the actual production line. The aforementioned adjustment support program, A procedure for calculating the difference between the production line model data and the actual machine data, If it is determined that there is a difference based on the results of calculating the difference, each of them will create multiple adjustment proposals targeting at least one of the models of one or more production facilities in the virtual space and one or more production facilities located in the actual space, A procedure for calculating the value of a predetermined evaluation indicator when the adjustment is made for each of the multiple adjustment proposals created, An adjustment support program characterized by causing the control unit to execute a procedure for outputting the multiple adjustment proposals and the values ​​of the evaluation indicators that have been created.

13. An adjustment support method performed by an adjustment support system, The adjustment support system comprises a control unit and a storage unit. The storage unit holds production line model data relating to models of one or more production equipment in a virtual space of the production line, and actual equipment data obtained by actually measuring one or more production equipment placed in the space of the actual production line. The aforementioned adjustment support method is: The control unit performs a procedure for calculating the difference between the production line model data and the actual machine data, If the control unit determines that there is a difference based on the result of calculating the difference, each unit creates a set of adjustment proposals targeting at least one of the models of one or more production facilities in the virtual space and at least one of the one or more production facilities located in the actual space. The control unit provides a procedure for calculating a predetermined evaluation index value for each of the multiple adjustment proposals created, when the adjustment is made. A method for supporting adjustments, characterized in that the control unit provides a procedure for outputting the created set of adjustment proposals and the values ​​of the evaluation indicators.

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