Method for operating a manufacturing chain

Abstract

A system architecture for operating a manufacturing chain is provided, in which items of operating status information concerning individual functional elements of the manufacturing chain are compared with one another.

Description

[0001] Title: Method for operating a production chain

[0002] Description

[0003] The invention relates to a method for operating a production chain for manufacturing products and to a system with such a production chain.

[0004] A production chain comprises numerous steps, stations, and cells. A product, in the form of a raw part, is fed into the production chain and manufactured into a finished product, in the form of a finished part, through several production steps. These steps include processing, transporting, and measuring the product.

[0005] The product runs sequentially in a specific order.

[0006] The production program varies depending on the product and product variant. The sequence of production programs and the interaction between individual steps are regularly programmed individually and extensively. The complexity of the program increases with the number of steps.

[0007] Such a system is known, for example, from DE 10 2021 133 852 Al .

[0008] The invention is based on the objective of providing a simple system architecture for operating a production chain.

[0009] The problem underlying the invention is solved by the method for operating a production chain for manufacturing products with the features of claim 1. The production chain comprises at least one handling device, in particular a robot, feeder or conveyor belt, for handling the product and at least one first production station upstream of the handling device and / or at least one second production station downstream of the handling device. The at least one handling device and the at least one first production station and / or the at least one second production station each provide status information characterizing their operating status.The at least one handling device then removes a product from the at least one first production station and / or then moves a product to the at least one second production station when the status information of the at least one handling device and the status information of the at least one first production station and / or the status information of the at least one second production station is available.

[0010] The production stations are designed to be complementary to each other.

[0011] This approach follows a bottom-up strategy, incorporating diligent field components. A handling device only executes an action if the surrounding, adjacent, or related components match the handling device's status. This allows a complex manufacturing chain to be divided into smaller, dynamic subsystems. The result is a simple, manageable, and easy-to-maintain system architecture. Furthermore, it improves the overall system's clarity, simplifies troubleshooting, and automatically makes parallel structures, such as buffers or machine tools, resilient to idle time or malfunctions.

[0012] As the product progresses through the production chain, it goes through numerous stages. Initially, the product is fed into the production chain as a raw material. Within the production chain, the product is processed as a semi-finished part until it ultimately becomes a finished product. For the sake of simplicity, the invention refers to the "product" throughout, even though it goes through several stages.

[0013] For the purposes of the invention, "production station" is understood to mean any station that does not handle or transport the product, or does not do so exclusively. Accordingly, image processing or measuring stations are to be understood as production stations. For the purposes of the invention, "processing station" is understood to mean any station that actually processes, i.e., modifies, the product. A higher-level production control system is preferably configured to receive status information and to check whether adjacent or related status information is complementary to each other. If the production control system recognizes that the status information is complementary to each other, then a production program corresponding to the production task is assigned to the at least one handling device and / or the at least one production station.

[0014] The at least one first production station and / or the at least one second production station can each be configured as one of the following stations or as different stations from the following:

[0015] Processing station for processing the product, buffer station for storing the product, measuring station for recording product characteristics, temperature control station for temperature control of the product, staging station for providing a product to be manufactured, and / or finished goods station for storing the finished product.

[0016] The categorization of the aforementioned stations into production stations enables an abstract approach to control and thus a simplification of the system architecture.

[0017] The status information of at least one

[0018] The handling device and / or the status information of at least one production station can assume one, several or all of the following operating statuses:

[0019] Ready to unload, Ready to load, Ready to finish, and / or fault.

[0020] The following examples illustrate when status information is complementary. One or more of the following rules or patterns can be sequentially checked for different areas of a production chain. These patterns can be defined during the control system setup of the production chain. Preferably, the following rules or patterns cover a large number, in particular all, of the possible control processes in a production chain. This ensures that a storage location is free before a handling device, such as a robot or feeder, even picks up a product. By checking according to patterns, it is easy to prevent a handling device from stopping in a loaded state and blocking the system because it cannot find a storage location for the product.Furthermore, this allows the handling device to anticipate when the appropriate moment for the next action is. Such a procedure would have to be laboriously programmed manually in the prior art.

[0021] Generic route:

[0022] The status information of a handling device and the status information of a production station immediately downstream of the handling device are complementary to each other if the following pattern is used.

[0023] Status information available: upstream handling device: ready for unloading, downstream production station: ready for loading.

[0024] The status information of a production station and the status information of a handling device immediately downstream of the production station are complementary to each other if the following pattern of status information is present: upstream production station: Ready to unload, downstream handling device: Ready to load.

[0025] Static route:

[0026] The status information of a handling device, at least one production station immediately upstream of the handling device, and at least one production station immediately downstream of the handling device are complementary to each other if the following pattern of status information is present: the at least one upstream production station: Ready to unload, handling device: Ready to load, the at least one downstream production station: Ready to load.

[0027] Transit route: The status information of a production station, at least one handling device immediately upstream of the production station, and at least one handling device immediately downstream of the production station, wherein the upstream handling device and the downstream handling device are formed by a common handling device, and wherein the product continues to be handled by the common handling device during production by the production station, are complementary to each other if the following pattern of status information is present: common handling device: Ready to load, production station: Ready to load.

[0028] In this case, the production station does not have its own storage area where the product can be placed by the handling device. Therefore, the handling device keeps the product available even while the production station is manufacturing it.

[0029] Preferably, an additional production station is located directly upstream of the common handling device: Ready for unloading.

[0030] Route with lifting device / double grab (Case 1):

[0031] The status information of a primary production station, a primary handling device immediately downstream of the primary production station, a secondary production station immediately downstream of the primary handling device (the secondary production station having at least two storage locations for receiving and dispensing a product), and a secondary handling device immediately downstream of the secondary production station (in particular, the primary handling device and the secondary handling device being formed by a common handling device) is complementary to each other if the following pattern of status information is present: primary production station: Ready to unload, primary handling device: Ready to load, secondary production station: Ready to unload, secondary handling device: Ready to load.

[0032] Accordingly, production stations are depicted which, due to the large number of storage locations, can simultaneously be "ready for loading" and "ready for unloading". This functionality can also be implemented with a double grabber, which, unlike a production station, provides the two storage locations via two grab positions.

[0033] Route with lifting device / double grab (Case 2):

[0034] The status information of a primary handling device, a primary production station immediately downstream of the primary handling device (the primary production station having at least two storage locations for receiving and dispensing a product), a secondary handling device immediately downstream of the primary production station (in particular, the primary handling device and the secondary handling device being formed by a common handling device), and a secondary production station immediately downstream of the secondary handling device are complementary to each other if the following pattern of status information is present: primary handling device: Ready to unload, primary production station: Ready to unload, secondary handling device: Ready to unload, secondary production station: Ready to load.

[0035] Pattern matching allows at least one handling device to achieve high utilization of the production stations. Furthermore, the handling device gains an intelligence that allows it to anticipate when a product can be picked up in anticipation of a storage location. The system is also resilient because, if one substation fails (arranged in parallel in the production chain), it continues to operate using the remaining substation(s). The failed substation no longer transmits status information, thus preventing the detection of a complementary pattern.

[0036] It is advantageous if the product moves through the production chain along a production direction, while a check is performed against the production direction to see if a pattern of complementary status information exists. This ensures that a product always has a next station or storage location and prevents blockages ("clogging") of the production chain.

[0037] Furthermore, it is advantageous if, particularly through production control, a sequential check is performed to determine whether a pattern of complementary status information exists. This ensures that tasks are assigned to the available stations and equipment at regular intervals.

[0038] Preferably, at least one production station is formed from at least two substations arranged parallel to each other in the production chain. This enables a higher production speed. If two parallel substations form a pattern with the surrounding stations and devices, then the substations can have different priorities.

[0039] In an advantageous embodiment of the invention, a production control system superior to the production chain is provided, wherein the production control system sequentially checks whether one of the following tasks:

[0040] Unloading,

[0041] Loading, manufacturing, and / or fault handling matches a complementary pattern of status information, and if a match exists, then the production control assigns the corresponding production program to the respective handling device and / or production station. The production programs can be stored in the handling device and / or the production station, and the production control only transmits the corresponding program name or program ID.

[0042] The problem underlying the invention is also solved by a computer program having the features of claim 13. The problem underlying the invention is also solved by a computer-readable storage medium having the features of claim 14.

[0043] The problem underlying the invention is also solved by a data carrier signal with the features of claim 15.

[0044] The problem underlying the invention is also solved by a system with a production chain for manufacturing products with the features of claim 16. The production chain comprises at least one handling device for handling the product and at least one first production station upstream of the handling device and / or at least one second production station downstream of the handling device. The at least one handling device and the at least one first production station and / or the at least one second production station are each configured such that they provide status information characterizing their operating status to a production control system superior to the production chain.The production control system is set up to assign a production program belonging to the production task, depending on the status information provided by the at least one handling device and / or the at least one production station.

[0045] The production control system is preferably configured to carry out the previously described procedure. Figures show:

[0046] Fig. 1 shows a schematic view of a system with a manufacturing chain comprising a generic route;

[0047] Fig. 2 shows a schematic view of a system with a manufacturing chain comprising another generic route;

[0048] Fig. 3 shows a schematic view of a system with a production chain comprising a static route;

[0049] Fig. 4 shows a schematic view of a system with a manufacturing chain comprising a transit route;

[0050] Fig. 5 shows a schematic view of a system with a manufacturing chain comprising a route with a lifting device (case 1);

[0051] Fig. 6 shows a schematic view of a system with a production chain comprising a route with a lifting device (case 2); and

[0052] Fig. 7 shows a schematic view of a system with a manufacturing chain comprising a transit route and a route lifting device (case 2).

[0053] Figures 1 to 7 each show a system according to the invention.

[0054] Figure 10 shows a production chain 12, which is traversed by a product 14 along a production direction 16. Figures 1 to 6 show exemplary, complementary status information. Figure 7 shows an example of a composite production chain 12, which includes several, in this case two, samples.

[0055] Each system 10 has at least one manufacturing station 18 and at least one handling device 20. Manufacturing steps, such as processing or measuring the product 14, are carried out at the manufacturing stations 18. The handling devices 20 are used for handling, in particular holding or transporting, the product 14.

[0056] Figure 1 shows a production chain 12 with an upstream production station 18, in particular a staging station for providing products 14, and with a downstream handling device 20 for removing a product 14 from the production station 18. The production station and the handling device each provide their status information to a higher-level production control system 22.

[0057] If the staging station has one or more bays and these are occupied, then the staging station has the status "Ready to unload". If the bay(s) are free, then it has the status "Ready to load". If some, but not all, bays are occupied, then it has both the status "Ready to load" and "Ready to unload". If the handling device 20 is carrying a product 14, then it is "Ready to unload". If it is not carrying a product 14, then it is "Ready to load".

[0058] Figure 1 shows a complementary pattern (generic route) where the production station 18 is "Ready to unload" and the handling device 20 is "Ready to load". The production controller 22 checks the provided status information and recognizes a complementary pattern. The production controller 22 then initiates the handling device 20 to pick up the product 14 from the production station 18. Since the individual motion functions are stored in or on the handling device 20, the production controller 22 only transmits the corresponding program reference, in particular the program name, to the handling device 20.

[0059] Figure 2 also shows a generic route, where the handling device 20 is located upstream of the production station 18, here a machining center. The handling device 20 has the status "Ready to unload" and the production station 18 has the complementary status "Ready to load".

[0060] The processing machine has, for example, a loading station for receiving a product 14. Furthermore, the processing machine has the status "Busy" compared to the staging station when it is processing product 14.

[0061] Figure 3 shows a static route which extends over two production stations 18 and a

[0062] The handling device 20 extends. If, for safety reasons, a handling device 20 is not to carry a product 20, then a storage location must already be known or available when picking it up. In this case, the handling device 20 only picks up a product 14 from the upstream production station 18, in particular the staging station, if the downstream production station 18, in particular the processing station, is "Ready to load". Accordingly, the following pattern results for the static route: "Ready to unload" (staging station), "Ready to load" (handling device), "Ready to load" (processing station). If this pattern is present, the production control 22 initiates the handling of the product 14 by the handling device 20.

[0063] Figure 4 shows a transit route characterized by the fact that the production station 18, here an image acquisition system, does not have its own storage area for receiving the product 14. Therefore, the handling device 20 handles the product 14 even during production by the production station 18. This means that the handling device holds and moves the product 14 before, during, and after the production step. The pattern of the transit route corresponds to the pattern of the static route. When this pattern is present, the production control system 22 initiates the handling of the product 14 by the handling device 20 as well as the production by the image acquisition system.

[0064] Figures 5 and 6 each show a production station 18, in particular a processing station, with a lifting device. A lifting device provides at least two loading positions in a production station 18, so that the station can be both "ready for unloading" and "ready for loading." Accordingly, a handling device 20 can transport a product 14 to the production station 18 in one step, deposit it, and then pick up and remove a processed product 14. Therefore, the handling device 20 is a common handling device located upstream and downstream of the production station 18 along the production direction 16.

[0065] Figure 5 shows the first case of the route with a lifting device, where a static route is provided after the lifting device. Accordingly, the complementary pattern is as follows: "Ready to unload" (upstream production station), "Ready to load" (upstream handling device), "Ready to unload" (downstream production station), "Ready to load" (downstream handling device). In this case, the upstream production station 18 is a staging station and the downstream production station 18 is a finished parts station for storing the completed products 14. Therefore, the handling device 20 can remove a product 14 from the staging station when the downstream processing station also provides a product 14. Thus, a new product 14 can be loaded in one step, followed by the removal of the previously completed product 14.If the pattern is not followed, the production chain 12 will be blocked. This would be the case, for example, if the handling device 20 were not "Ready to Load". Furthermore, the utilization will be reduced if a product 14 is removed from the processing station without a new one being taken in.

[0066] Product 14 is being loaded.

[0067] Figure 6 shows the second case of the route with a lifting device, where a static route is provided upstream of the lifting device. Accordingly, the complementary pattern is as follows: "Ready to unload" (upstream handling device), "Ready to unload" (upstream production station), "Ready to unload" (downstream handling device), "Ready to load" (downstream production station). In this case, the upstream production station 18 is a staging station, and the downstream production station 18 is a finished goods station for storing the finished products 14. If the pattern were not followed, the production chain 12 would be blocked. This would be the case, for example, if the finished goods station were not "Ready to load".Then the handling device 20 would load a new product 14 into the processing station and remove the finished product 14, but there would be no storage location.

[0068] The lifting device can alternatively be implemented by having the handling device 20 have two or more gripping positions. In this case, the finished product can be gripped in an empty gripping position, and the product to be manufactured can be placed from a full gripping position into the production station 18.

[0069] All production stations 18 and handling devices 20 can also have the status "fault". In addition, the production control system 22 can assign the task of troubleshooting / maintenance to each individual production station 18 and handling device 20.

[0070] Figure 7 shows a production chain 12 with five production stations 18 and two handling devices 20. This example is intended to demonstrate that the inspection according to samples must be carried out against the direction of production 16 in order to prevent blockages in the production chain 12.

[0071] Initially, a staging station 18A is provided, in which products 14 are provided. This production station 18 therefore has the status "Ready for unloading". Staging station 18A is linked to the subsequent handling device 20 and an image recognition system 18B as a transit route. The products 14 manufactured with the image recognition system 18B are then placed in a buffer 18C. From the buffer 18C, products 14 can be removed by the second handling device 20 and fed to the processing station 18D. This station has a lifting device, so that in the same step a manufactured product 14 can be removed by the second handling device 20 and placed in a finished parts station 18E. Therefore, the second handling device 20 is subsequently described as being upstream and downstream of the processing station 18D.

[0072] In the following example, a pattern is present at the first handling device 20. However, the production control 22 will still not initiate the handling and production, as this would otherwise block the production chain 12.

[0073] If the first handling device 20 now starts production in

[0074] After image recognition system 18B performs its operation, a storage location is subsequently lacking. Buffer 18C is not ready to be loaded.

[0075] This leads to a blockage of the production chain 12.

[0076] Therefore, it is not enough that somewhere in the production chain

[0077] 12. A pattern is recognized. It is advantageous if the production chain 12 follows the pattern against the direction of production.

[0078] 16 will be examined.

[0079] Fig. 7 shows such a complementary pattern which does not lead to the blocking of the production chain 12. Accordingly, the first handling device 20, downstream of the image recognition system 18B, can place the product 14 in the buffer 18C. Consequently, the production control 22 is configured such that, in the first example, no handling of the first handling device 20 is initiated, and in the second example (as shown in Fig. 7), handling of the product 14 by the first handling device 20 is initiated. This is the result of a check for the presence of the sample transit route and / or route with lifting device / double gripper (case 2).

Claims

Patent claims 1. A method for operating a production chain (12) for manufacturing products (14), wherein the production chain (12) comprises at least one handling device (20) for handling the product (14) and at least one first production station (18) upstream of the handling device (20) and / or at least one second production station (18) downstream of the handling device (20), wherein the at least one handling device (20) and the at least one first production station (18) and / or the at least one second production station (18) each provide status information characterizing their operating status, wherein the at least one handling device (20) then removes a product (14) from the at least one first production station (18) and / or moves it to the at least one second production station (18),if the status information of the at least one handling device (20) and the status information of the at least one first production station (18) and / or the status information of the at least one second production station (18) are complementary to each other.

2. The method according to claim 1, wherein the at least one first production station (18) and / or the at least one second production station (18) are each configured as one of the following stations: - Processing station (18D) for processing the product - Buffer station (18C) for storing the product (14) , - Measuring station (18B) for recording product characteristics, - Temperature control station for temperature control of the product (14) , - Staging station (18A) for staging a product to be manufactured (14) , and / or - Finished parts station (18E) for storing the finished product (14) .

3. Method according to claim 1 or 2, wherein the status information of the at least one handling device (20) and / or the status information of the at least one manufacturing station (18) can assume one, several or all of the following operating statuses: - Ready to unload, - Ready for loading, - Ready to be finished, and / or - Disturbance.

4. Method according to claim 3, wherein the status information of a handling device (20) and the status information of a manufacturing station (18) immediately downstream of the handling device (20) are complementary to each other if the following pattern of status information is present: - Upstream handling device (20): Ready for unloading, - downstream manufacturing station (18): Ready for loading, and / or wherein the status information of a manufacturing station (18) and the status information of a manufacturing station (18) immediately downstream The handling device (20) are then designed to be complementary to each other if the following pattern of status information is present: - Upstream manufacturing station (18): Ready for unloading, - downstream handling device (20): Ready for loading.

5. Method according to claim 3 or 4, wherein the status information of a handling device (20), at least one production station (18) immediately upstream of the handling device (20) and at least one production station (18) immediately downstream of the handling device (20) are complementary to each other if the following pattern of status information is present: - at least one upstream manufacturing station (18): Ready for unloading, - Handling device (20): Ready for loading, - at least one downstream manufacturing station (18): Ready for loading.

6. A method according to any one of claims 3 to 5, wherein the status information of a production station (18), at least one handling device (20) immediately upstream of the production station (18) and at least one handling device (20) immediately downstream of the production station (18), wherein the upstream handling device (20) and the downstream handling device (20) are formed by a common handling device (20), wherein the product (14) is further handled during production by the production station (18) by the common The handling device (20) remains handled, and are designed to be complementary to each other if the following pattern of status information is present: - common handling device (20): Ready for loading, - Production station (18): Ready for loading.

7. A method according to any one of claims 3 to 6, wherein the status information of a primary manufacturing station (18), a primary handling device (20) immediately downstream of the primary manufacturing station (18), a secondary manufacturing station (18) immediately downstream of the primary handling device (20), wherein the secondary manufacturing station (18) has at least two storage locations for receiving and dispensing a product (14), and a secondary handling device (20) immediately downstream of the secondary manufacturing station (18), wherein the primary handling device (20) and the secondary handling device (20) are formed by a common handling device (20), are then complementary to each other if the following pattern of status information is present: - Primary manufacturing station (18): Ready for unloading, - Primary handling device (20): Ready for loading, - Secondary manufacturing station (18): Ready to unload, - secondary handling device (20): Ready for loading .

8. Method according to any one of claims 3 to 7, wherein the status information of a primary handling device (20) , one of the primary handling devices (20) a primary manufacturing station (18) immediately downstream, wherein the primary manufacturing station (18) has at least two storage locations for receiving and issuing a product (14), a secondary handling device (20) immediately downstream of the primary manufacturing station (18), wherein the primary handling device (20) and the secondary handling device (20) are formed by a common handling device (20), and a secondary manufacturing station (18) immediately downstream of the secondary handling device (20) are then designed to be complementary to each other if the following pattern of status information is present: - Primary handling device (20): Ready for unloading, - Primary manufacturing station (18): Ready for unloading, - secondary handling device (20): Ready for unloading, - Secondary manufacturing station (18): Ready for loading.

9. Method according to any one of claims 4 to 8, wherein the product (14) moves along a manufacturing direction through the manufacturing chain (12), checking against the manufacturing direction whether a pattern of complementary status information is present.

10. Method according to any one of claims 4 to 9, wherein it is sequentially checked whether a pattern of complementary status information is present.

11. Method according to any of the preceding claims, wherein at least one manufacturing station (18) is made of at least two substations arranged parallel to each other in the production chain (12) are formed.

12. Method according to one of the preceding claims, wherein a production control system superior to the production chain (12) is provided, and wherein the production control system (22) sequentially checks whether one of the following tasks: - Unloading, - Loaded, - Finished, and / or - Fault handling matches a complementary pattern of status information, and if a match is found, then the production control (22) assigns the appropriate production program to the respective handling device (20) and / or production station (18).

13. Computer program comprising instructions which, when executed by a computer, cause the computer to execute the method according to any one of claims 1 to 12.

14. Computer-readable storage medium comprising instructions which, when executed by a computer, cause it to execute the method according to any one of claims 1 to 12.

15. Data carrier signal that transmits the computer program according to claim 13.

16. System (10) with a production chain (12) for manufacturing products (14), wherein the production chain (12) comprises at least one handling device (20) for handling the product (14) and at least one first production station (18) upstream of the handling device (20) and / or at least one second production station (18) downstream of the handling device (20), wherein the at least one handling device (20) and the at least one first production station (18) and / or the at least one second production station (18) are each configured such that they provide status information characterizing their operating status to a production control system (22) superior to the production chain (12), wherein the production control system (22) is configured such thatto assign a production program to a production task depending on the status information provided by the at least one handling device (20) and / or the at least one production station (18).

17. System (10) according to claim 16, wherein the production control (22) is further configured to execute a method according to any one of claims 1 to 12.

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