Production Management Device for Machine Tool Substitution
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Solution Overview
Problem
In production systems with multiple machine tools of different types and varying operation conditions, maintaining an overall operating rate is challenging due to differences in machine types and conditions, which can lead to reduced efficiency when one machine tool stops and cannot be substituted by another with the same machining program.
Innovation Solution
A production management device communicably connected to slave control devices and a master control device, which acquires data on machine types and operation conditions, selects alternative machine tools of the same type with lower operating rates, and provides machining instructions and programs to ensure seamless substitution and maintain overall operating rates, including automatic adjustments of electric motor mechanisms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If machine tools of different types are used in the production system, then the versatility and flexibility of the system is improved, but the difficulty of maintaining overall operating rate increases due to incompatible machining programs and operation conditions
Solution Approach 1:
The patent transforms machining programs into different parameter representations (first parameter set for original machine, second parameter set for alternative machine) and uses conversion tables to translate between them. This allows machine tools of different types to execute the same machining process by converting program parameters to match the alternative machine's specifications, thereby maintaining system versatility while ensuring reliable operation substitution.
2Reliability
If alternative machine tools are selected based on same machine type, then the compatibility of machining programs is improved, but the ability to maintain overall operating rate deteriorates when the alternative machine is also unavailable or unsuitable
Solution Approach 1:
The patent creates a universal machine substitution system where any machine tool in the system can potentially substitute for another by converting machining programs between different machine types. The conversion table stores parameter relationships across multiple machine types, enabling a single alternative machine to handle multiple different machining program types, thus improving both compatibility and overall operating rate maintenance capability.
3Ease of manufacture
If a machine tool stops due to maintenance or alarm, then the availability of that specific machine is reduced, but the overall operating rate can be maintained through substitution if proper machine selection and program conversion is implemented
Solution Approach 1:
The patent introduces a production management device as an intermediary between the master control device and slave control devices. This intermediary automatically detects machine stoppages, selects alternative machines, converts machining programs between different machine types using stored conversion tables, and redistributes workloads. This mediation enables seamless substitution during maintenance or alarms, maintaining overall productivity while allowing individual machines to be taken offline for upkeep.
Data Source
AI summary
A production management device is communicably connected to a plurality of slave control devices respectively connected to a plurality of machine tools, and also communicably connected to a master control device for preparing an overall operation plan of the plurality of machine tools. The production management device acquires data on a machine type and an operation condition of each of the plurality of machine tools from the slave control device. The production management device selects, on the basis of the data, an alternative machine tool to be substituted for a specific machine tool from among the plurality of machine tools. Furthermore, the production management device substitutes the alternative machine tool for the specific machine tool.