Visualization system

Abstract

To provide a visualization system for visualizing factors useful for improvement of a manufacturing site.SOLUTION: A visualization system according to the present invention has a plurality of kinds of sensors installed in a manufacturing site and a computer terminal for displaying content corresponding to an output from the sensors. The sensors include, for example, a power meter, a temperature sensor, a humidity sensor, an atmospheric pressure sensor, an image sensor or an RFID reader. The computer terminal creates a graph corresponding to outputs from these sensors to display them on a client terminal or a monitor.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a visualization system.

Background Art

[0002] For example, Patent Document 1 has a standard work time database 46 that stores the standard work time for each work process, gives a work instruction to an operator by an output device 50, measures the actual work time for each work process of the operator, records it in a work time database 42, and compares the total standard work time until the end of a plurality of work processes recorded in the standard work time database with the total actual work time, which is the total of the actual work times of the operator recorded in the work time database 42. When the total actual work time exceeds the total standard work time, it detects the work processes in which the actual work time exceeds the standard work time in each work process to evaluate the work proficiency of the operator and records the evaluation result in a proficiency database 48. A work proficiency support device 10 is disclosed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] An object of the present invention is to provide a visualization system that visualizes elements leading to improvement in a manufacturing site.

Means for Solving the Problems

[0005] The visualization system according to the present invention includes a plurality of types of sensors installed in a manufacturing site and a display unit that displays content corresponding to the output from the sensors.

Effects of the Invention

[0006] According to this invention, it is possible to visualize elements that can lead to improvements in the manufacturing site. [Brief explanation of the drawing]

[0007] [Figure 1] This figure illustrates an overview of the visualization system in the embodiment. [Figure 2] This is an example diagram visualizing the operating status of a manufacturing line in a manufacturing site. [Figure 3] Figure 2 illustrates the components involved in visualizing the operating status of the manufacturing line. [Figure 4] Figure 2 illustrates a roadmap for visualizing the operating status of the manufacturing line. [Figure 5] This is an example diagram visualizing electricity consumption and electricity costs in a manufacturing site. [Figure 6] Figure 5 illustrates a roadmap for visualizing electricity consumption and electricity charges. [Figure 7] This is an example diagram that visualizes the temperature environment of the manufacturing site and the location of the workers by overlaying them. [Figure 8] Figure 7 illustrates the components and roadmap for the superimposed visualization of the temperature environment and worker positions in the manufacturing site. [Figure 9] This diagram illustrates the connection between multiple types of sensors and cloud services. [Figure 10] This diagram illustrates a roadmap for a visualization system initiative. [Figure 11] This diagram illustrates centralized remote monitoring of a manufacturing floor from multiple viewpoints. [Figure 12] Figure 11 illustrates the components and roadmap of the unified remote monitoring system. [Figure 13] This diagram illustrates anomaly detection and predictive maintenance on a manufacturing line. [Figure 14] This diagram illustrates a more specific overall configuration of the visualization system. [Figure 15] This diagram illustrates the hardware configuration of the visualization device 2. [Figure 16]This diagram provides a more detailed explanation of the PLC4 and the sensor control device 6. [Figure 17] This diagram illustrates the visualization of the operating and maintenance status of manufacturing equipment installed on a manufacturing site. [Modes for carrying out the invention]

[0008] As illustrated in Figures 1 to 13, the visualization system includes multiple types of sensors installed on the manufacturing site and a computer terminal, which displays content corresponding to the output from the sensors to visualize each element of the manufacturing site. More specifically, the visualization system has multiple types of sensors installed on the manufacturing site (e.g., power meters, temperature sensors, humidity sensors, pressure sensors, image sensors, or RFID readers) and a computer terminal that displays content corresponding to the output from the sensors, and the computer terminal creates graphs corresponding to the output from these sensors and displays them on client terminals or monitors.

[0009] The visualization system can, for example, visualize productivity and the manufacturing site environment. As illustrated in Figures 2 to 4, the visualization system visualizes "manufacturing rods," "manufacturing results," "progress rate," "scheduled operating time of the manufacturing line," "cycle time," "hourly utilization rate," "operating time," and "line operating status" based on the output from multiple types of wireless sensors installed on the manufacturing site, and displays them on client terminals and monitors. The visualization system can visualize each manufacturing line.

[0010] As illustrated in Figures 5 and 6, the visualization system visualizes "electricity costs," "production volume," "electricity cost ratio," "production volume ratio," "production volume," and "unit cost" based on the output from multiple types of wireless sensors, and displays them on client terminals and monitors. The visualization system can visualize each manufacturing line.

[0011] As illustrated in FIGS. 7 and 8, the visualization system superimposes and visualizes the positions of workers and the temperature map of the manufacturing site based on the outputs from multiple types of wireless sensors, and displays them on a client terminal or a monitor. The position of a worker is visualized, for example, based on the output of a wireless-tagged card carried by each worker. The temperature map of the manufacturing site is visualized, for example, based on the outputs of mesh-arranged temperature sensors, humidity sensors, and pressure sensors.

[0012] As illustrated in FIG. 9, the visualization system serves as a composite system and a controller that connects multiple types of wireless sensors, performs temporary data processing (edge processing), and directly uploads the data to a cloud service.

[0013] As illustrated in FIGS. 10 to 12, the visualization system performs unified remote monitoring of the manufacturing floor from multiple viewpoints based on the outputs from multiple types of wireless sensors and the captured images taken by cameras.

[0014] As illustrated in FIGS. 10 and 13, the visualization system performs anomaly detection and predictive maintenance of the production line based on the outputs from multiple types of wireless sensors, the captured images taken by cameras, and AI analysis.

[0015] FIG. 14 is a diagram illustrating a more specific overall configuration of the above visualization system. As illustrated in FIG. 14, the visualization system includes a visualization device 2, a plurality of PLCs 4, and a plurality of sensor control devices 6. The visualization device 2 is an example of the above computer terminal. It aggregates the detection results of various sensors via the PLCs 4 and the sensor control devices 6, and visualizes the information of the manufacturing site based on the aggregated detection results. The PLC 4 is a programmable logic controller, and outputs the detection results of sensors received wirelessly from the sensor control device 6 to the visualization device 2. The sensor control device 6 has ports for connecting sensors, acquires the detection results of the sensors, and wirelessly transmits the acquired detection results to the PLC 4.

[0016] Figure 15 is a diagram illustrating the hardware configuration of the visualization device 2. As illustrated in Figure 15, the visualization device 2 includes a CPU 200, memory 202, HDD 204, network interface 206 (network IF 206), display device 208, and input device 210, and these components are connected to each other via a bus 212. CPU200 is, for example, the central processing unit. Memory 202 is, for example, volatile memory and functions as main memory. HDD204 is, for example, a hard disk drive, which stores computer programs and other data files as a non-volatile recording device. Network IF206 is an interface for wired or wireless communication, and for example, it enables communication with user terminal 4. The display device 208 is, for example, a liquid crystal display. The input device 210 is, for example, a keyboard and a mouse.

[0017] Figure 16 is a diagram illustrating the PLC4 and sensor control device 6 in more detail. As illustrated in Figure 16, for example, the MELSEC communication protocol (MC protocol) is used for wireless communication between the PLC4 and the sensor control device 6. The sensor control device 6 is, for example, a microcontroller module such as M5Stack, and has ports to which multiple types of sensors can be connected. The sensor control device 6 has multiple ports, and can simultaneously transmit the detection results of sensors connected to these ports to the PLC4. For example, by connecting a temperature sensor to the sensor control device 6, the visualization device 2 can create the temperature maps shown in Figures 7 and 8.

[0018] Figure 17 illustrates the visualization of the operating and maintenance status of manufacturing equipment installed on a manufacturing site. The sensor control device 6, to which the optical sensor is connected, detects light emitted from warning lamps, etc., of the manufacturing equipment and outputs the detection result to the visualization device 2 via the PLC 4. The visualization device 2h then detects the operating status of the manufacturing equipment (operating / off / operator call) based on the detection result of the optical sensor. Furthermore, the sensor control device 6, installed near the manufacturing equipment, has a touch panel. When a maintenance worker notices an operator call, they touch this touch panel (touch sensor) before starting maintenance work on the manufacturing equipment. The visualization device 2 can then detect the timing of the maintenance worker's start and end of maintenance work based on the touch operation on the sensor control device 6. As a result, the visualization device 2 can visualize the time spent on maintenance and the time until the start of maintenance work, based on the operating status of the manufacturing equipment, the start timing of maintenance work, and the end timing of maintenance work, as illustrated in Figure 17. As a result, improvement measures to increase the operating rate can be considered. [Explanation of Symbols]

[0019] 2…Visualization device 4…PLC 6…Sensor control device

Claims

1. Multiple types of sensors installed in the manufacturing site, A display unit that displays content corresponding to the output of the aforementioned sensor. It has, The sensor includes a light sensor that detects the light of a warning lamp on the manufacturing equipment and a touch sensor located near the manufacturing equipment. The display unit displays content that visualizes the operating status of the manufacturing equipment, the time required for maintenance of the manufacturing equipment, and the time taken until the maintenance was performed. Visualization system.

2. A sensor control device connected to a sensor installed on the manufacturing site, A PLC that communicates wirelessly with the aforementioned sensor control device and acquires the detection results from the aforementioned sensor. It further possesses, The display unit displays content corresponding to the detection results acquired by the PLC. The visualization system according to claim 1.

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